Intelligent control system for dustproof baffle of ship unloader hopper

Abstract

The application relates to the technical field of bulk material dust suppression control, and discloses an intelligent control system for a dust suppression baffle of a ship unloader hopper. The system comprises a triggering module, a distribution module and a release module. The triggering module is used for calculating a wedge-shaped opening area and a pump gas dust emission flow according to feedback signals of two-side hydraulic valve group oil cylinder stroke switches, and obtaining a pump gas effect triggering signal. The distribution module is used for dividing two-side cast steel wind baffles into a driving side and a driven side according to a wind direction angle, and obtaining a master-slave side distribution result. The release module comprises a calculation unit, a locking unit and a closing unit, and is used for calculating a pre-locking angle, forming a V-shaped flow guide groove and obtaining a double-side closed state. The locking module is used for correcting a correlation model of the pre-locking angle and a sealing efficiency by using a least square method, obtaining a corrected pre-locking angle and executing locking by a superimposed hydraulic lock. The application improves the closing reliability of the dust suppression baffle of the hopper in the whole ship unloading process and the self-adaptive response capability of the pre-locking angle to different wind load working conditions.

Description

Technical Field

[0001] This application relates to the field of bulk material dust suppression control technology, and in particular to an intelligent control system for a dust suppression baffle in a ship unloader hopper. Background Technology

[0002] Bridge-type grab unloaders are equipment used for bulk cargo transfer at ports. During operation, the grab buckets grab bulk materials such as coal and ore from the ship's hold and dump them into the hopper. The materials fall freely under gravity and impact the bottom of the hopper at high speed, generating a large amount of dust particles. To suppress dust escape, existing technology installs tiltable cast steel baffles on both sides of the hopper. The baffles are opened and closed by a hydraulic control system, and a dust sensor and PLC form the basic control loop. When the dust concentration exceeds a preset threshold, the baffles are triggered to close, thus blocking the openings on both sides of the hopper. At the same time, a stacked throttle valve is installed in the hydraulic system to regulate the movement speed of the cylinders on both sides, and a stacked hydraulic lock is installed to maintain the locked position after the baffles are in place, preventing displacement drift caused by wind pressure or vibration.

[0003] However, the existing technology has the following shortcomings: The existing control system simultaneously sends reversing commands to the hydraulic valve groups on both sides of the hopper. Because the two valve groups are physically installed independently, have different pipeline lengths, and have manufacturing tolerances in the throttle valve settings, and because a single cast steel lower baffle weighs approximately 400 kg and a single cast steel middle baffle weighs approximately 200 kg, the load difference between the two baffles objectively exists, causing a deviation in the angular velocity of the baffles' rotation. The compensation accuracy is only ±5%. During the baffle opening and closing transition, the rotation angles of the two baffles are inconsistent, creating a potential hazard in front of the hopper. The momentary opening of the wedge shape changes with the pressure difference between the inside and outside. At the same time, the baffle flips and disturbs the local low-pressure zone inside the hopper. Driven by the pressure difference between the inside and outside, the external dust-laden airflow rushes in at high speed from the wedge opening and then rebounds and escapes, generating a pumping effect. This actively pumps the dust out of the wedge opening, and its harmfulness far exceeds the passive dispersion when the baffle is statically open. The existing control strategy treats the valve groups on both sides as a whole and drives them synchronously. It neither quantifies the area of ​​the wedge opening in real time nor establishes a differentiated scheduling mechanism for the opening and closing sequence of the baffles on both sides. It cannot fundamentally eliminate the root cause of the pumping effect. Summary of the Invention

[0004] This application provides an intelligent control system for the dust suppression baffle of the unloading machine hopper. It solves the problems of the existing synchronous control mode of the unloading machine hopper baffle, which causes the wedge-shaped instantaneous opening due to the asynchronous flipping of the baffles on both sides, thus triggering the pumping effect to actively pump out dust, and the problem that the pre-locking angle in the sequential closing strategy cannot simultaneously meet the hydraulic safety boundary and dynamic sealing efficiency constraints. It improves the sealing reliability of the dust suppression baffle of the hopper throughout the unloading operation and the adaptive response capability of the pre-locking angle to different wind load conditions.

[0005] This application provides an intelligent control system for a dust suppression baffle in a ship unloader hopper, the intelligent control system comprising:

[0006] The trigger module is used to calculate the wedge opening area and pump air dust discharge flow rate formed by the deviation of the flipping angular velocity of the two side baffles based on the feedback signals of the oil cylinder stroke switches driven by the hydraulic valve groups on the left and right sides respectively, and obtain the pump air effect trigger signal.

[0007] The allocation module is used to divide the cast steel wind baffles on both sides of the hopper into an active side and a passive side according to the wind direction angle based on the pumping effect trigger signal, and obtain the main and passive side allocation result;

[0008] The release module includes a calculation unit, a locking unit, and a closing unit. The calculation unit is used to substitute the master-slave side allocation result and the maximum locking torque of the superimposed hydraulic lock into the safety margin constraint to calculate the pre-locking angle of the active side cast steel baffle. The locking unit is used to drive the active side hydraulic valve group to move the active side cast steel baffle to the pre-locking angle and lock it by the superimposed hydraulic lock, so that a V-shaped guide groove is formed in front of the hopper. The closing unit is used to drive the passive side hydraulic valve group to follow and close the passive side cast steel baffle until the extension position is triggered by the limit switch. After the superimposed hydraulic lock is released, the active side cast steel baffle is driven to be completely closed, resulting in a double-sided closed state.

[0009] The locking module is used to correct the correlation model between the pre-locking angle and the sealing efficiency using the least squares method based on the dust concentration change rate output by the dust sensor under the double-sided closed state, so as to obtain the corrected pre-locking angle. The superimposed hydraulic lock then locks the active side cast steel windshield according to the corrected pre-locking angle.

[0010] The technical solution provided in this application introduces a real-time calculation mechanism for the wedge opening area based on the feedback signal of the hydraulic cylinder limit switch into the PLC program. This transforms the deviation in the baffle rotation angular velocity caused by the independent drive of the two hydraulic valve groups into a quantifiable pump air dust discharge flow rate indicator. This allows the instantaneous wedge opening problem, which was previously ignored in existing synchronous control technology, to be accurately perceived and triggered at the control logic level, fundamentally changing the control paradigm of existing technologies that only rely on passive response after the dust sensor concentration exceeds the threshold. Furthermore, based on this, a master-slave allocation mechanism is established, which divides the cast steel baffles on both sides of the hopper into active and passive sides according to the wind direction angle and writes this information into the PLC data register. This integrates environmental wind load information with the hydraulic... The pressure-driven timing decision is directly related to the control command issuance sequence, which matches the actual force state of the two side baffles, rather than using the symmetrical synchronous drive method that is disconnected from the physical boundary. Furthermore, the master-slave side allocation result and the maximum locking torque of the superimposed hydraulic lock are substituted into the calculation path of the pre-locking angle in the 80% safety margin constraint inverse solution. This ensures that the active side cast steel baffle is always within the torque range that the hydraulic system can safely bear during the process of closing to the pre-locking angle and being locked by the superimposed hydraulic lock. The establishment of the V-shaped guide channel transforms the disturbed airflow that originally escaped due to the wedge-shaped opening into a directional airflow that is introduced into the hopper along the channel wall. This eliminates the conditions for the generation of the pumping effect from the perspective of the coordination between mechanical structure and control timing.

[0011] The least squares regression model uses the changes in pre-locking angle, wind speed, wind direction angle, and dust concentration in historical operations as inputs to establish a quantitative correlation between the pre-locking angle and sealing efficiency. This transforms the determination of the pre-locking angle from a static calculation relying on fixed parameters into a dynamic decision-making process that is continuously corrected according to actual working conditions. The core contribution of the algorithm lies in unifying the hydraulic safety boundary constraints and sealing efficiency threshold constraints into the same judgment logic that takes the larger value. This ensures that the corrected pre-locking angle satisfies both constraints simultaneously under any wind load conditions, rather than sacrificing one for the other. The substantial contribution of this algorithm feature to the solution is that it is not a simple optimization of existing control parameters, but rather a continuous correction of the regression coefficients of the correlation model through rolling accumulated historical data. This allows the locking position of the superimposed hydraulic lock on the active side cast steel windbreak to adaptively converge with the dynamic changes in the port operating environment. Thus, without adding any additional sensors or actuators, relying on the existing hardware configuration of hydraulic valve groups, limit switches, and dust sensors, the engineering effect of continuously improving dust suppression control accuracy over operating time is achieved. Attached Figure Description

[0012] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0013] Figure 1 This is a schematic diagram of an embodiment of the intelligent control system for the dust suppression baffle of the unloader hopper in this application.

[0014] Figure 2 This is a schematic diagram illustrating the change in relative dust concentration around the hopper at each stage of the sequential shutdown control in this embodiment of the application. Detailed Implementation

[0015] This application provides an intelligent control system for a dust suppression baffle in a ship unloader hopper. The terms "first," "second," "third," "fourth," etc. (if present) in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments described herein can be implemented in a sequence other than that illustrated or described herein. Furthermore, the terms "comprising" or "having" and any variations thereof are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or device that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or devices.

[0016] For ease of understanding, the specific process of the embodiments of this application is described below. Please refer to [link / reference]. Figure 1 One embodiment of the intelligent control system for the dust suppression baffle of the unloader hopper in this application includes:

[0017] The trigger module is used to calculate the wedge opening area and pump air dust discharge flow rate formed by the deviation of the flipping angular velocity of the two side baffles based on the feedback signals of the oil cylinder stroke switches driven by the hydraulic valve groups on the left and right sides respectively, and obtain the pump air effect trigger signal.

[0018] Specifically, the triggering module monitors the driving status of the independent hydraulic valve groups on both sides of the hopper in real time. The two valve groups control the extension and retraction of two actuator cylinders on the same side via a stacked throttle valve, a stacked hydraulic lock, a solenoid directional valve, and a one-way throttle valve. Each cylinder has two built-in mechanical limit switches, triggered at the fully open and fully closed positions of the baffle, respectively. Because the pipeline lengths, throttle valve settings, and baffle installation errors of the two valve groups are independent, when the PLC simultaneously sends reversal commands to both sides, there is an unavoidable deviation between the left and right baffle rotation angular velocities. This difference in rotation angle accumulates over time, resulting in a wedge-shaped opening in front of the hopper that varies with time. The triggering module calculates the pump air dust discharge flow rate based on the difference between the local low-pressure area generated inside the hopper by the baffle rotation disturbance and the external air pressure, combined with the area of ​​the wedge-shaped opening. When the pump air dust discharge flow rate exceeds the dust discharge flow rate alarm threshold determined based on the calibration data of the on-site dust sensors, the triggering module outputs a pump air effect trigger signal to the distribution module.

[0019] The allocation module is used to divide the cast steel wind baffles on both sides of the hopper into an active side and a passive side according to the wind direction angle based on the pumping effect trigger signal, and obtain the main and passive side allocation result;

[0020] Specifically, after receiving the pumping effect trigger signal, the distribution module reads the signal from the wind speed and direction sensor installed on the top of the hopper, and measures the wind direction angle clockwise with the front of the hopper as 0°. The reason for using the front of the hopper as the reference is that the hopper opening faces forward, and the lateral thrust of the wind coming from the front on the baffle is the greatest. Using this as the 0° reference can directly map the direction of the force on the baffle. When the wind direction angle falls within the 0° to 180° range, the distribution module marks the left cast steel wind deflector as the active side; when it falls within the 180° to 360° range, it marks the right cast steel wind deflector as the active side. For the case where the wind direction angle falls within the 45° to 135° oblique wind range, the distribution module uses the cosine of the difference between the wind direction angle and 90° as the oblique wind correction coefficient to correct the transverse wind load on the active side. The oblique wind correction coefficient is between 0.707 and 1.000 in this range, and its physical meaning is the effective component ratio of the oblique wind acting on the windward surface of the deflector. After correction, the transverse wind load on the active side and the transverse wind load on the driven side are compared. The side bearing the larger wind load is finally confirmed as the active side. The result is written into the PLC data register to obtain the master-slave side distribution result.

[0021] The release module includes a calculation unit, a locking unit, and a closing unit. The calculation unit is used to substitute the master-slave side allocation result and the maximum locking torque of the superimposed hydraulic lock into the safety margin constraint to calculate the pre-locking angle of the active side cast steel baffle. The locking unit is used to drive the active side hydraulic valve group to move the active side cast steel baffle to the pre-locking angle and lock it by the superimposed hydraulic lock, so that a V-shaped guide groove is formed in front of the hopper. The closing unit is used to drive the passive side hydraulic valve group to follow and close the passive side cast steel baffle until the extension position is triggered by the limit switch. After the superimposed hydraulic lock is released, the active side cast steel baffle is driven to be completely closed, resulting in a double-sided closed state.

[0022] Specifically, the calculation unit in the release module reads the master-slave side allocation results and the active side lateral wind load from the PLC data register. It calculates the active side wind load torque by multiplying the active side lateral wind load by the length of the lever arm from the center of gravity of the baffle to the axis of the rotating bearing seat. It calculates the maximum locking force of a single cylinder by multiplying the effective cylinder diameter of a single cylinder by the locking oil pressure of the superimposed hydraulic lock. It multiplies this by 2 to obtain the maximum locking force of both cylinders. It then multiplies this by the distance from the point of action of the cylinder to the axis of the rotating bearing seat to obtain the maximum locking torque of the superimposed hydraulic lock. The safety margin of 80% is to reserve sufficient safety margin when the equipment vibration, hydraulic system pressure fluctuation and other working conditions are superimposed. The pre-locking angle is obtained by solving the constraint inequality with inverse cosine. The locking unit calculates the time required for the active side baffle to move to the pre-locking angle based on the flow rate set by the superimposed throttle valve, sends a reversing command to the active side solenoid reversing valve to drive the two active side cylinders to extend. After the required time is reached, a holding command is issued, and the superimposed hydraulic lock automatically engages and locks. The active side cast steel baffle forms an oblique blocking barrier at the pre-locking angle, which together with the driven side cast steel baffle, which is still in the 90° open position, forms a V-shaped guide channel that opens into the hopper. After the V-shaped guide channel is established, the closing unit sends a reversing command to the driven side electromagnetic reversing valve, driving the two cylinders in the driven side hydraulic valve group to extend. When the two extended limit switches on the driven side are triggered simultaneously, the closing unit sends an unlocking command to the active side superimposed hydraulic lock, driving the two cylinders on the active side to continue extending until the two extended limit switches on the active side are triggered simultaneously. The two sets of superimposed hydraulic locks are simultaneously engaged and locked, and the cast steel lower baffle and the cast steel middle baffle completely seal both sides of the hopper. The industrial rubber upper baffle is attached to the edge of the top opening of the hopper, resulting in a double-sided closed state.

[0023] The locking module is used to correct the correlation model between the pre-locking angle and the sealing efficiency using the least squares method based on the dust concentration change rate output by the dust sensor under the double-sided closed state, so as to obtain the corrected pre-locking angle. The superimposed hydraulic lock then locks the active side cast steel windshield according to the corrected pre-locking angle.

[0024] Specifically, after confirming the double-sided closed state, the locking module reads the arithmetic mean of the output values ​​of the dust sensor for five consecutive scanning cycles before the baffle closes as the dust concentration baseline value. The difference between this baseline value and the measured dust concentration after the baffle closes is divided by the baseline value to obtain the dust concentration change rate, which is the quantitative expression of the sealing efficiency. The locking module writes a set of observation data—the pre-locking angle, wind speed, wind direction angle, and dust concentration change rate—into the PLC data register. When 10 sets are accumulated, a design matrix is ​​constructed. The dust concentration change rate is the dependent variable, and the cosine values ​​of the pre-locking angle, wind speed, and wind direction angle are the independent variables. The inverse matrix of the product of the transpose and the original matrix of the design matrix is ​​solved using the least squares method. This inverse matrix is ​​then multiplied by the dependent variable vector to obtain the regression coefficients of the correlation model. Accumulating 10 sets ensures that the regression equation has sufficient degrees of freedom and that the computational load is within the PLC's computing power. The locking module substitutes the current wind speed and wind direction angle into the regression coefficients to solve for the lower limit of the pre-locking angle that meets the sealing efficiency threshold of 75%. The larger value is taken between this pre-locking angle calculated with the safety margin constraint to obtain the corrected pre-locking angle. The sealing efficiency threshold of 75% is the lowest qualified line determined based on the on-site measured dust diffusion standard. The superimposed hydraulic lock locks the active side cast steel windbreak plate according to the corrected pre-locking angle.

[0025] In one specific embodiment, the triggering module is used to:

[0026] Based on the scan cycle count from the moment the switching command of the left hydraulic valve group and the right hydraulic valve group is issued, the feedback signals of the left cylinder limit switch and the right cylinder limit switch are integrated to obtain the left baffle flip angle and the right baffle flip angle.

[0027] Multiply the sine difference between the left and right baffle rotation angles by the sum of the width of the cast steel baffle along the hopper opening direction and the heights of the lower and middle cast steel baffles, and perform area conversion processing on the deviation of the rotation angles of the two baffles to obtain the wedge-shaped opening area.

[0028] Based on the average of the left and right baffle flip angles, the product of the average flip angle of both sides and the baffle rotation radius is squared and multiplied by the air density coefficient to calculate the pressure difference of the airflow disturbance inside the hopper, thus obtaining the pressure difference inside the hopper.

[0029] Substituting the wedge-shaped opening area and the internal pressure difference of the hopper into the dust discharge flow rate calculation formula, the pumping intensity is compared with the threshold. When the dust discharge flow rate exceeds the dust discharge flow rate alarm threshold, a pumping effect trigger signal is obtained.

[0030] Specifically, after the switching commands for the left and right hydraulic valve groups are issued, the trigger module performs integral processing on the feedback signals of the limit switches of the cylinders on both sides, using the PLC scan cycle as the timing unit. The meaning of integral processing is to accumulate the baffle rotation increment corresponding to the cylinder extension amount in each scan cycle. Since there is a fixed geometric conversion relationship between the cylinder stroke and the baffle flip angle (determined by the structural dimensions of the rotary bearing seat), the accumulated result is the real-time flip angle of the baffle on that side from the initial 90° opening position, thus obtaining the flip angle of the left baffle and the flip angle of the right baffle respectively. The calculation of the wedge-shaped opening area is based on the difference in the horizontal projection of the leading edges of the two baffles onto the hopper opening direction when the flipping angles of the two baffles are inconsistent. This actual opening width is equal to the width of the cast steel baffle along the hopper opening direction (9900mm) multiplied by the difference in the sine of the flipping angles of the two sides, and then multiplied by the sum of the heights of the lower cast steel baffle (1000mm) and the middle cast steel baffle (500mm) (1500mm). The reason for using the sine difference rather than the angle difference is that the horizontal displacement of the leading edge of the baffle and the flipping angle have a sinusoidal function relationship; directly using the angle difference would introduce geometric errors. The internal pressure difference of the hopper is calculated by multiplying the square of the product of the average flipping angular velocity of the two baffles and the baffle rotation radius (750mm) by the air density. The value is then halved. The baffle rotation radius of 750mm is taken from the distance from the axis of the rotary bearing housing to the center of gravity of the baffle. This distance is determined based on the geometric distance from the hydraulic cylinder hinge point to the axis of the bearing housing in the rotary bearing housing structure, and is taken as 600mm. The air density is taken as a constant value near sea level under standard atmospheric pressure. Since the port operation site is at a low altitude, the error of this value can be ignored under actual working conditions.

[0031] Substituting the wedge opening area and the internal pressure difference of the hopper into the dust discharge flow rate calculation formula, the structure of the dust discharge flow rate calculation formula is: wedge opening area multiplied by the pressure difference inside and outside the hopper divided by the air density, the square root is taken, and then multiplied by the correction coefficient. The physical meaning is the volume of dust-laden gas escaping through the wedge opening per unit time. The pumping effect trigger signal is determined by the comparison result of the dust discharge flow rate and the dust discharge flow rate alarm threshold. The dust discharge flow rate alarm threshold is determined based on the calibration data of the on-site dust sensor. The calibration method is to measure the correspondence between the sensor output voltage and the dust concentration in a standard air chamber with known dust concentration, convert it into volumetric flow rate, and take the exceeding critical value as the alarm threshold. When the dust discharge flow rate exceeds the threshold, the trigger module outputs the pumping effect trigger signal. This signal is a single-bit set signal in the PLC digital register. After being set, the distribution module immediately responds by reading the wind speed and wind direction sensor data and starting the master-slave side division process.

[0032] In one specific embodiment, the allocation module is used for:

[0033] Based on the pumping effect trigger signal, the wind direction angle output by the wind speed and wind direction sensor is divided into intervals. When the wind direction angle enters the interval from 0° directly in front of the hopper clockwise to 180°, the left cast steel wind baffle is marked as the active side and the right cast steel wind baffle is marked as the passive side. When the wind direction angle enters the interval from 180° to 360°, the right cast steel wind baffle is marked as the active side and the left cast steel wind baffle is marked as the passive side, thus obtaining the preliminary allocation result of the active and passive sides.

[0034] Based on the preliminary allocation results of the main and secondary sides, for the working condition where the wind direction angle enters the oblique wind range of 45° to 135°, the cosine value of the difference between the wind direction angle and 90° is used as the oblique wind correction coefficient. The product of the windward area of ​​the cast steel windbreak plate on the active side and the square of the wind speed is used to correct the oblique wind load, and the transverse wind load on the active side is obtained.

[0035] The active side lateral wind load and the passive side lateral wind load are compared in magnitude. The side bearing the larger wind load is identified as the active side and the side bearing the smaller wind load is identified as the passive side. The preliminary allocation result of the active and passive sides is verified and corrected to obtain the allocation result of the active and passive sides.

[0036] Based on the master-slave side allocation result, the active side identification signal and the active side lateral wind load are written into the PLC data register, and the master-slave side identification is stored to obtain the master-slave side allocation result and the active side lateral wind load for step S3.

[0037] Specifically, after receiving the pumping effect trigger signal, the allocation module reads the current wind direction angle from the wind speed and direction sensor. The wind direction angle is measured clockwise with the area directly in front of the hopper as the 0° reference. The reason for choosing the area directly in front of the hopper as the 0° reference is that the opening of the unloader's hopper faces directly forward, and the lateral thrust distribution of the wind on both sides of the baffles is most symmetrical. Using this as the reference zero point ensures that the boundary of the interval division corresponds precisely to the physical symmetry plane of the force on the baffles. When the wind direction angle enters the 0° to 180° interval, the left cast steel wind baffle is on the windward side, with a larger windward area, and is marked as the active side, while the right cast steel wind baffle is marked as the passive side; the opposite is true when the wind direction angle enters the 180° to 360° interval. The above interval division yields a preliminary allocation result of the active and passive sides. This result is only based on the geometric judgment of the wind direction angle and has not yet considered the actual difference in the force on both sides under the oblique wind condition, so further correction is needed. For the case where the wind direction angle falls within the 45° to 135° oblique wind range, the oblique wind correction factor is taken as the cosine of the difference between the wind direction angle and 90°. The geometric meaning of the cosine function is the projection ratio of the oblique wind velocity vector in the direction perpendicular to the baffle surface. When the wind direction angle is exactly 90°, the cosine value is 1, and the lateral force of the oblique wind on the baffle is the largest; when the wind direction angle is 45° or 135°, the cosine value is 0.707, and the lateral force is 70.7% of that of the frontal wind. The windward area of ​​the active side cast steel wind deflector is taken as the total area of ​​the lower cast steel wind deflector and the middle cast steel wind deflector, i.e., 9900mm multiplied by 1500mm equals 14.85 square meters. The product of this area and the square of the wind speed is multiplied by the oblique wind correction factor and the aerodynamic coefficient to obtain the active side lateral wind load. The aerodynamic coefficient is taken as 1.3, which is calculated from the wind load of 31576N in the simulation results of the three working conditions of the core material.

[0038] The allocation module compares the lateral wind loads on the active and passive sides numerically. The lateral wind load on the passive side is calculated using the same method but without applying a wind angle correction. The side bearing the larger wind load is ultimately identified as the active side. The significance of this verification and correction step is that the initial allocation result relies solely on the geometric range of the wind direction angle, which carries the risk of incorrectly allocating the active side when the force difference between the two sides is extremely small near the range boundary. By comparing the load values, this error can be eliminated, resulting in a master-slave allocation result consistent with the actual force state. The active side identification signal is written to the PLC data register as a single-bit Boolean value: 1 for the left side and 0 for the right side. The active side lateral wind load is written to the adjacent register address in floating-point format. Both are written within the same scan cycle, ensuring the time consistency between the active side identification and the lateral wind load data when the calculation unit reads them, and avoiding mismatches between the identification and load values ​​caused by multiple cycles of writing.

[0039] In one specific embodiment, the computing unit is used for:

[0040] Multiply the active side lateral wind load stored in the master-slave side allocation result by the lever arm length from the center of gravity of the active side baffle to the axis of the rotating bearing seat, and calculate the wind load moment borne by the active side cast steel wind baffle in the pre-locked position to obtain the active side wind load moment.

[0041] Based on the product of the effective cylinder diameter of a single cylinder in the active side hydraulic valve group and the locking oil pressure of the superimposed hydraulic lock, the total maximum locking force of the two active side cylinders is calculated and processed. Then, the total maximum locking force is multiplied by the distance from the cylinder action point to the axis of the rotating bearing seat to obtain the maximum locking torque of the superimposed hydraulic lock.

[0042] Substituting the active side wind load moment and the maximum locking moment of the superimposed hydraulic lock into the 80% safety margin constraint, the lower limit of the pre-locking angle that satisfies the requirement that the active side wind load moment does not exceed 80% of the maximum locking moment of the superimposed hydraulic lock is solved by inverse cosine calculation to obtain the pre-locking angle of the active side cast steel wind deflector.

[0043] Specifically, the calculation unit reads the floating-point number of the active side lateral wind load from the PLC data register, multiplies it by the lever arm length from the center of gravity of the active side baffle to the axis of the rotary bearing seat, and obtains the active side wind load torque. The lever arm length is 750mm. This value is determined based on the geometric distance from the center of gravity of the baffle to the axis in the structural diagram of the core material rotary bearing seat. The combined center of gravity of the cast steel lower baffle (9900mm×1000mm×5mm, mass about 400kg) and the cast steel middle baffle (9900mm×500mm×5mm, mass about 200kg) is calculated by the weighted average of their masses, and the lever arm length converted to the axis of the rotary bearing seat is fixed at 750mm. The calculation path for the maximum locking torque of the superimposed hydraulic lock is as follows: the effective cylinder diameter of a single cylinder is taken as 80mm, the locking oil pressure of the superimposed hydraulic lock is taken as 16MPa, and the maximum locking force of a single cylinder is obtained by the product of the cylinder diameter cross-sectional area and the locking oil pressure. The total maximum locking force of the two cylinders on the active side is twice the maximum locking force of a single cylinder. Then, multiply by the distance from the cylinder action point to the axis of the rotary bearing seat, which is 600mm, to obtain the maximum locking torque of the superimposed hydraulic lock. The distance from the cylinder action point, which is 600mm, is determined based on the geometric distance from the cylinder installation position to the axis of the rotary bearing seat in the design schematic diagram of the cylinder base of the core material.

[0044] The calculation unit substitutes the active side wind load moment and the maximum locking moment of the superimposed hydraulic lock into an 80% safety margin constraint. The mathematical form of the constraint is that the active side lateral wind load multiplied by the lever arm length and then multiplied by the cosine of the pre-locking angle shall not exceed 80% of the maximum locking moment of the superimposed hydraulic lock. In this inequality, the pre-locking angle appears as a cosine function because when the baffle is at the pre-locking angle position, the torque component generated by the wind load on the rotating bearing seat is proportional to the cosine value of the pre-locking angle. The smaller the pre-locking angle (the closer the baffle is to the vertical closed position), the smaller the cosine value, the smaller the wind load moment, and the easier it is for the superimposed hydraulic lock to maintain locking. The safety margin is taken as 80% instead of 100% to ensure that the superimposed hydraulic lock still has sufficient locking capability under conditions such as hydraulic system pressure fluctuations, wear of seals leading to a drop in locking oil pressure after long-term use of the equipment, and strong gusts in the port environment causing instantaneous loads to exceed the steady-state calculation value. After taking the equality sign of the above inequality, the inverse cosine solution is performed on the pre-locking angle to obtain the lower limit of the pre-locking angle that satisfies the safety margin constraint, namely the pre-locking angle of the active side cast steel wind deflector. This angle is the target position of the active side deflector when it moves and locks in the first stage of the sequential closing. The angle value is dynamically updated according to the active side lateral wind load read in real time before each action.

[0045] In one specific embodiment, the locking unit is used for:

[0046] Based on the difference between the pre-lock angle and the initial fully open angle of 90° of the active side cast steel baffle, the set flow rate of the superimposed throttle valve in the active side hydraulic valve group and the geometric parameters of the cylinder are converted to obtain the time required for the active side baffle to move to the pre-lock angle.

[0047] Based on the time required for the active side baffle to move to the pre-lock angle, a reversing command is sent to the active side electromagnetic reversing valve to drive the two active side cylinders to extend. The PLC scan cycle count is timed. When the time reaches the required time, a holding command is sent to the active side electromagnetic reversing valve to obtain the pre-lock position holding state of the active side cast steel baffle.

[0048] Based on the pre-locked position of the active side cast steel baffle, the superimposed hydraulic lock automatically engages and locks, hydraulically locking the active side cast steel baffle at the pre-locked angle. At this time, the active side cast steel baffle forms an oblique blocking barrier while the driven side cast steel baffle remains in a 90° open position, resulting in a V-shaped guide channel in front of the hopper.

[0049] Specifically, after the locking unit reads the pre-locking angle of the active side cast steel baffle from the PLC data register, it subtracts the pre-locking angle from 90° to obtain the angle difference that the active side baffle needs to flip from the fully open position. This angle difference is converted into the extension stroke required by the cylinder through the geometric conversion relationship of the rotary bearing seat. The extension stroke of the cylinder is determined by the product of the baffle flipping angle and the distance from the axis of the rotary bearing seat to the cylinder hinge point. Then, it is divided by the ratio of the set flow rate of the superimposed throttle valve to the effective cylinder diameter cross-sectional area to obtain the time required for the cylinder to extend, that is, the time required for the active side baffle to move to the pre-locking angle. The set flow rate of the superimposed throttle valve is determined according to the factory calibration value, and the unit is liters per minute. The effective cylinder diameter is taken as 80mm. All the above conversions are completed in the PLC floating point arithmetic unit, and the conversion results are stored in the data register in milliseconds. After the locking unit outputs a reversing command to the active side solenoid directional valve, it accumulates the number of scan cycles with the PLC scan cycle (set to 20ms) as the timing step. When the accumulated count multiplied by 20ms reaches the required time, the locking unit outputs a holding command to the active side solenoid directional valve, the solenoid directional valve switches to the neutral cut-off state, the cylinder stops extending, and the active side cast steel baffle plate is pre-locked and held in the position. The reason for using scan cycle counting instead of an external hardware timer is that the PLC scan cycle is fixed and the accuracy is controllable, avoiding the introduction of installation and calibration errors of additional hardware.

[0050] After the solenoid directional valve switches to the neutral cut-off state, the oil circuit pressure of the superimposed hydraulic lock is automatically balanced. The internal check valve of the hydraulic lock closes under the action of spring preload, locking the inlet and outlet ports of the two cylinders on the active side at the same time. The cast steel baffle on the active side is fixed at the pre-locking angle position. This process does not require the PLC to issue an additional locking command, which is a passive response mechanism of the hydraulic lock. After the active side cast steel baffle is locked at the pre-locking angle, its surface forms a certain tilt angle relative to the direction of the hopper opening, constituting an oblique blocking barrier. Meanwhile, the driven side cast steel baffle remains fully open at 90°. The spatial configuration of the two side baffles forms a V-shaped guide channel in front of the hopper. The opening of the V-shaped guide channel faces the inside of the hopper rather than the outside. Its physical function is to guide the airflow disturbance generated by the low-pressure area inside the hopper during the baffle flipping process along the V-shaped channel wall into the hopper, so that the dust-laden airflow is captured inside the hopper instead of escaping from the front opening. The opening angle of the V-shaped guide channel is determined by the pre-locking angle. The smaller the pre-locking angle, the narrower the channel and the more concentrated the guiding effect. The larger the pre-locking angle, the wider the channel and the more relaxed the time window for the driven side to close. The balance between the two is determined by the lower limit of the pre-locking angle calculated under the safety margin constraint.

[0051] In one specific embodiment, the closing unit is used for:

[0052] Based on the completion signal of the V-shaped guide groove, a reversing command is sent to the driven side electromagnetic reversing valve to drive the two oil cylinders in the driven side hydraulic valve group to extend, and the one-way throttle valve speed adjustment process is performed on the following closing process of the driven side cast steel baffle. When the two extended limit switches on the driven side are triggered at the same time, the driven side cast steel baffle is in a fully closed state.

[0053] Based on the fully closed state of the driven side cast steel wind baffle, an unlocking command is sent to the active side superimposed hydraulic lock to release the hydraulic lock of the active side cast steel wind baffle at the pre-locking angle. Then, a continuing reversing command is sent to the active side solenoid reversing valve to drive the two active side cylinders to continue extending until the two active side extension limit switches are triggered simultaneously. This drives the remaining stroke of the active side cast steel wind baffle from the pre-locking angle to full closure, resulting in the fully closed state of the active side cast steel wind baffle.

[0054] The fully closed state of the driven side cast steel wind baffle and the fully closed state of the active side cast steel wind baffle are combined and confirmed. The two sets of superimposed hydraulic locks are simultaneously engaged and locked. The lower cast steel wind baffle and the middle cast steel wind baffle completely seal both sides of the hopper. The upper industrial rubber wind baffle is attached to the edge of the top opening of the hopper, resulting in a double-sided closed state.

[0055] Specifically, after the closing unit reads the pre-lock position holding status flag of the active side cast steel baffle written by the locking unit into the PLC data register as valid, it determines that the V-shaped guide groove has been established. Then, it outputs a reversing command to the driven side solenoid reversing valve, driving the two cylinders in the driven side hydraulic valve group to extend synchronously. The extension speed of the driven side cylinder is determined by the opening degree of the one-way throttle valve in the driven side hydraulic valve group. The one-way throttle valve cuts off in the cylinder retraction direction and throttles in the extension direction. By adjusting the throttle opening, the angular velocity of the driven side baffle is controlled so that the closing speed of the driven side cast steel baffle matches the closing process of the V-shaped guide groove, avoiding the guide groove from disappearing too early due to the driven side closing speed being too fast, or the closing time being too long due to the slow closing speed being too slow. In the driven side hydraulic valve group, each cylinder has a built-in extension limit switch in the fully extended position. When the two PLC digital input points corresponding to the two extension limit switches on the driven side are simultaneously set to valid in the same scan cycle, the closing unit determines that the driven side cast steel baffle is fully closed. This judgment logic of simultaneous triggering of two points is to eliminate the erroneous judgment caused by the false triggering of the single cylinder limit switch, and to ensure that both cylinders are truly in position before proceeding to the next action.

[0056] After the driven-side cast steel baffle is fully closed, the closing unit outputs an unlocking command to the active-side superimposed hydraulic lock. This unlocking command, via the PLC digital output point, energizes the hydraulic lock control solenoid valve, opening the pilot oil circuit inside the hydraulic lock, releasing the check valve, and restoring communication between the inlet and outlet ports of the two active-side cylinders. This releases the hydraulic lock at the pre-lock angle of the active-side cast steel baffle. Upon unlocking, the closing unit immediately sends a continuing reversing command to the active-side solenoid directional valve, driving the two active-side cylinders to extend further from the corresponding stroke position at the pre-lock angle until both extension limit switches on the active side are simultaneously activated within the same scan cycle, resulting in a fully closed active-side cast steel baffle. The closing unit performs a logical AND operation on the fully closed status flags of the driven-side and active-side cast steel baffles. When both are simultaneously valid, it outputs a double-sided closure confirmation signal. This signal triggers both sets of superimposed hydraulic locks to simultaneously engage and lock. The locking mechanism is the same as in the pre-locking stage: the hydraulic lock passively closes the oil circuit after the solenoid directional valve reaches the neutral position. The cast steel lower baffle (9900mm×1000mm×5mm) and the cast steel middle baffle (9900mm×500mm×5mm) cover the main opening areas on both sides of the hopper in the fully closed position. The industrial rubber upper baffle (9900mm×500mm×4mm) relies on its own elastic deformation to fit the edge of the top opening of the hopper. The three baffles together form a complete closed protective ring, achieving a double-sided closed state.

[0057] Figure 2 This is a schematic diagram illustrating the changes in relative dust concentration around the hopper at each stage of the sequential shutdown control in this embodiment of the application. Figure 2As shown, during the sequential shutdown control process, the relative dust concentration around the hopper is based on an initial state of 100%. During the pumping effect triggering stage, the concentration briefly rises to 108% due to the wedge-shaped opening pumping effect generated by the synchronous movement of the baffles on both sides. After the active side cast steel baffle moves to the pre-locking angle and is locked by the superimposed hydraulic lock, the main channel for the transverse airflow into the hopper is partially blocked by the active side baffle, and the concentration drops back to 100%. After the V-shaped guide channel is established, the disturbed airflow is guided along the channel wall into the hopper, and the concentration drops to 82%. After the driven side cast steel baffle closes until the extension limit switch is triggered, the enclosed area on both sides of the hopper expands significantly, and the concentration further decreases. The dust concentration decreased to 63%; after the active side cast steel baffle plate released the superimposed hydraulic lock, it continued to drive to close completely, and the concentration decreased to 46%; finally, the double-sided superimposed hydraulic locks simultaneously engaged and locked, and the cast steel lower baffle plate, cast steel middle baffle plate, and industrial rubber upper baffle plate together formed a complete closed protective ring, reducing the relative dust concentration around the hopper to 26%, a decrease of 74 percentage points compared to the initial state. The dust concentration change rate met the qualified requirement of a sealing efficiency threshold of 75%.

[0058] In one specific embodiment, the locking module is used for:

[0059] Based on the aforementioned double-sided closed state, the difference between the dust concentration reference value output by the dust sensor before the baffle is closed and the measured dust concentration value output after the baffle is closed is divided by the dust concentration reference value. The sealing efficiency of this sequential closing action is calculated to obtain the dust concentration change rate.

[0060] The pre-lock angle, wind speed, wind direction angle and dust concentration change rate of this action are written into the PLC data register as a set of observation data. The historical action data is accumulated and stored in a rolling manner. When the number of accumulated observation data sets reaches 10 sets, the pre-lock angle associated dataset is obtained.

[0061] A design matrix is ​​constructed by taking 10 sets of observation data from the pre-locking angle association dataset. The dust concentration change rate is the dependent variable, and the pre-locking angle, wind speed, and wind direction cosine are the independent variables. The design matrix and the dependent variable vector are solved by the least squares method to obtain the regression coefficients of the association model between the pre-locking angle and the sealing efficiency.

[0062] Substitute the current wind speed and wind direction angle into the regression coefficients of the correlation model, perform inverse solution processing on the lower limit of the pre-locking angle corresponding to the sealing efficiency threshold, take the larger value of the inverse solution result and the pre-locking angle calculated under the safety margin constraint of the superimposed hydraulic lock, and obtain the corrected pre-locking angle. The superimposed hydraulic lock then locks the active side cast steel windbreak plate according to the corrected pre-locking angle.

[0063] Specifically, after confirming the signal is valid in the double-sided closed state, the locking module reads the output values ​​of the dust sensor over the five consecutive PLC scan cycles prior to the start of this baffle closing action and takes the arithmetic average to obtain the dust concentration baseline value. Taking the average over five scan cycles, rather than single-point sampling, is to eliminate the interference of instantaneous dust concentration fluctuations caused by wind speed disturbances in the port operating environment. After the baffle is fully closed, the dust sensor output value is collected again after a five-scan delay as the measured dust concentration value. This five-scan-cycle delay allows the airflow inside the hopper to stabilize after the baffle closes, avoiding overestimation of the measured value due to airflow disturbances at the moment of closure. The dust concentration change rate is obtained by subtracting the measured dust concentration value from the dust concentration baseline value and dividing by the baseline value. Its physical meaning is the proportion by which the dust concentration around the hopper decreases due to this sequential closing action, i.e., a quantitative expression of the sealing efficiency. The locking module writes four values—pre-lock angle, wind speed, wind direction angle, and dust concentration change rate—in floating-point format to a fixed address segment of the PLC data register for each action. One set is written for each action, and the register addresses are arranged in order of group number. When the number of stored groups exceeds 10, the address of the earliest written data set is overwritten by the address of the latest data set, achieving rolling cumulative storage. The cumulative number of groups is set to 10 to ensure that the least squares regression equation has sufficient degrees of freedom under the condition of 4 independent variables. There are 5 coefficients to be determined, including 4 independent variables and 1 intercept term. The 10 sets of data make the overdeterminacy of the equation system reach 2 times, and the stability of the regression results meets the engineering requirements.

[0064] After the number of accumulated data sets reaches 10, the locking module combines the three columns of data (pre-lock angle, wind speed, and wind direction cosine value) from the 10 sets of observation data with the entire column to construct a 10x4 design matrix. The 10 observation values ​​of dust concentration change rate constitute a 10-dimensional dependent variable vector. The least squares solution process is to calculate the product of the transpose of the design matrix and the original matrix to obtain a 4x4 square matrix. After inverting this square matrix, multiply it by the transpose of the design matrix and then multiply it by the dependent variable vector to obtain a 4-dimensional regression coefficient vector of the correlation model. The four components correspond to the pre-lock angle coefficient, wind speed coefficient, wind direction cosine value coefficient, and intercept term, respectively. The above matrix operations are performed step by step in the PLC floating-point arithmetic unit, and the operation results are stored in the data register. The locking module substitutes the current wind speed and the cosine of the wind direction angle into the regression coefficients, sets the dust concentration change rate to equal the sealing efficiency threshold of 75%, and performs an inverse solution on the pre-locking angle to obtain the lower limit of the pre-locking angle that meets the sealing efficiency threshold. The sealing efficiency threshold of 75% is determined based on the minimum qualification requirement for dust concentration reduction rate in the hopper area in the port bulk cargo operation dust emission standard. The larger value is taken between the inverse solution result and the pre-locking angle calculated under the superimposed hydraulic lock safety margin constraint. The logic for taking the larger value is that both constraints must be met simultaneously. The hydraulic safety constraint gives the lower limit that the pre-locking angle cannot be too small, and the sealing efficiency constraint gives the upper limit that the pre-locking angle cannot be too large. Taking the larger value means selecting the pre-locking angle with the optimal sealing efficiency within the hydraulic safety boundary, obtaining the corrected pre-locking angle. The superimposed hydraulic lock performs locking on the active side cast steel windbreak plate according to the corrected pre-locking angle.

[0065] In one specific embodiment, the dust concentration benchmark value is the arithmetic mean of the dust sensor output values ​​over five consecutive PLC scanning cycles before the baffle closes. If the cumulative number of observation data sets is less than 10, the corrected pre-locking angle is directly taken as the pre-locking angle calculated under the safety margin constraint of the superimposed hydraulic lock. The sealing efficiency threshold is 75%. When the dust concentration change rate is lower than 75%, a side curtain closing compensation command is triggered, and an alarm signal is output from the local control box.

[0066] Specifically, before each baffle closing action begins, the locking module traces back 5 scan cycles from the current PLC scan cycle, reads 5 output values ​​from the dust sensor within that time window, and takes the arithmetic average to obtain the dust concentration baseline value. The sampling window is set for 5 scan cycles (i.e., 5 × 20 ms = 100 ms) instead of single-point sampling. This is because the intermittent changes in wind speed in the port operating environment can cause large-amplitude discrete fluctuations in the dust sensor output within a short period of time. Single-point sampling is prone to mistaking the peak value of the fluctuation as the baseline value, resulting in an underestimation of the sealing efficiency calculation. The arithmetic average of 5 cycles can compress the influence of random fluctuations to one-fifth of that of single-point sampling, ensuring that the baseline value reflects the true steady-state level of dust concentration around the hopper before the baffle closes. When the number of accumulated observation data sets is less than 10, the regression coefficients of the correlation model cannot be effectively solved by the least squares method. At this stage, the locking module directly uses the pre-locking angle calculated under the safety margin constraint of the superimposed hydraulic lock as the corrected pre-locking angle to perform locking. The rationality of this cold start substitution strategy is that the safety margin constraint has ensured the mechanical safety of the baffle locking from the perspective of the hydraulic system's load-bearing capacity. When the historical data accumulation is insufficient, performing locking at this angle will not cause the hydraulic lock to overload. After the data accumulates to 10 sets, the regression model will automatically intervene to correct.

[0067] The sealing efficiency threshold is set at 75%. This value is determined based on the minimum acceptable requirement for dust concentration reduction rate in the unloading operation area in the dust emission management regulations for port bulk cargo terminals. A value below 75% means that there are residual leakage channels in the closed protective ring formed by the current sequential closing action, and the closure of the cast steel lower baffle and the cast steel middle baffle alone is insufficient to meet the dust suppression requirements. When the dust concentration change rate is below 75%, the locking module writes a side curtain closing compensation command to the PLC digital output module. This command drives the side curtain actuators on both sides of the hopper to open the side curtains to cover the residual gap area between the cast steel baffle and the hopper structure. The side curtains are made of flexible material and can adapt to the irregular gap shape after the baffle is closed. At the same time, the locking module outputs an alarm signal to the local control box, and the corresponding alarm indicator light on the local control box panel lights up and remains lit. The alarm signal is driven by the PLC digital output point, and the signal type is a continuous high level. The alarm signal will be automatically cleared by the locking module until the operator manually confirms the reset on the local control box panel or the dust concentration change rate recovers to more than 75% after the next shutdown action, ensuring that the alarm status remains visible until the problem is resolved.

[0068] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An intelligent control system for a dust suppression baffle in a ship unloader hopper, characterized in that, include: The trigger module is used to calculate the wedge-shaped opening area and the pump air dust discharge flow rate formed by the deviation of the flipping angular velocity of the two side baffles based on the feedback signals of the oil cylinder stroke switches driven by the hydraulic valve groups on the left and right sides respectively. Based on the difference between the local low pressure area generated inside the hopper by the baffle rotation disturbance and the external air pressure, the pump air dust discharge flow rate is calculated in combination with the wedge opening area. When the pump air dust discharge flow rate exceeds the dust discharge flow alarm threshold determined based on the calibration data of the on-site dust sensor, the trigger module outputs a pump air effect trigger signal to the distribution module. The allocation module is used to divide the cast steel wind baffles on both sides of the hopper into an active side and a passive side according to the wind direction angle based on the pumping effect trigger signal, and obtain the main and passive side allocation result; The release module includes a calculation unit, a locking unit, and a closing unit. The calculation unit is used to substitute the master-slave side allocation result and the maximum locking torque of the superimposed hydraulic lock into the safety margin constraint to calculate the pre-locking angle of the active side cast steel baffle. The locking unit is used to drive the active side hydraulic valve group to move the active side cast steel baffle to the pre-locking angle and lock it by the superimposed hydraulic lock, so that a V-shaped guide groove is formed in front of the hopper. The closing unit is used to drive the passive side hydraulic valve group to follow and close the passive side cast steel baffle until the extension position is triggered by the limit switch. After the superimposed hydraulic lock is released, the active side cast steel baffle is driven to be completely closed, resulting in a double-sided closed state. The locking module is used to correct the correlation model between the pre-locking angle and the sealing efficiency using the least squares method based on the dust concentration change rate output by the dust sensor under the double-sided closed state, so as to obtain the corrected pre-locking angle. The superimposed hydraulic lock then locks the active side cast steel windshield according to the corrected pre-locking angle.

2. The intelligent control system for the dust suppression baffle of the unloading machine hopper according to claim 1, characterized in that, The triggering module is used for: Based on the scan cycle count from the moment the switching command of the left hydraulic valve group and the right hydraulic valve group is issued, the feedback signals of the left cylinder limit switch and the right cylinder limit switch are integrated to obtain the left baffle flip angle and the right baffle flip angle. Multiply the sine difference between the left and right baffle rotation angles by the sum of the width of the cast steel baffle along the hopper opening direction and the heights of the lower and middle cast steel baffles, and perform area conversion processing on the deviation of the rotation angles of the two baffles to obtain the wedge-shaped opening area. Based on the average of the left and right baffle flip angles, the product of the average flip angle of both sides and the baffle rotation radius is squared and multiplied by the air density coefficient to calculate the pressure difference of the airflow disturbance inside the hopper, thus obtaining the pressure difference inside the hopper. Substituting the wedge-shaped opening area and the internal pressure difference of the hopper into the dust discharge flow rate calculation formula, the pumping intensity is compared with the threshold. When the dust discharge flow rate exceeds the dust discharge flow rate alarm threshold, a pumping effect trigger signal is obtained.

3. The intelligent control system for the dust suppression baffle of the unloading machine hopper according to claim 1, characterized in that, The allocation module is used for: Based on the pumping effect trigger signal, the wind direction angle output by the wind speed and wind direction sensor is divided into intervals. When the wind direction angle enters the interval from 0° directly in front of the hopper clockwise to 180°, the left cast steel wind baffle is marked as the active side and the right cast steel wind baffle is marked as the passive side. When the wind direction angle enters the interval from 180° to 360°, the right cast steel wind baffle is marked as the active side and the left cast steel wind baffle is marked as the passive side, thus obtaining the preliminary allocation result of the active and passive sides. Based on the preliminary allocation results of the main and secondary sides, for the working condition where the wind direction angle enters the oblique wind range of 45° to 135°, the cosine value of the difference between the wind direction angle and 90° is used as the oblique wind correction coefficient. The product of the windward area of ​​the cast steel windbreak plate on the active side and the square of the wind speed is used to correct the oblique wind load, and the transverse wind load on the active side is obtained. The active side lateral wind load and the passive side lateral wind load are compared in magnitude. The side bearing the larger wind load is identified as the active side and the side bearing the smaller wind load is identified as the passive side. The preliminary allocation result of the active and passive sides is verified and corrected to obtain the allocation result of the active and passive sides. Based on the master-slave side allocation result, the active side identification signal and the active side lateral wind load are written into the PLC data register, and the master-slave side identification is stored to obtain the master-slave side allocation result and the active side lateral wind load for step S3.

4. The intelligent control system for the dust suppression baffle of the unloading machine hopper according to claim 1, characterized in that, The computing unit is used for: Multiply the active side lateral wind load stored in the master-slave side allocation result by the lever arm length from the center of gravity of the active side baffle to the axis of the rotating bearing seat, and calculate the wind load moment borne by the active side cast steel wind baffle in the pre-locked position to obtain the active side wind load moment. Based on the product of the effective cylinder diameter of a single cylinder in the active side hydraulic valve group and the locking oil pressure of the superimposed hydraulic lock, the total maximum locking force of the two active side cylinders is calculated and processed. Then, the total maximum locking force is multiplied by the distance from the cylinder action point to the axis of the rotating bearing seat to obtain the maximum locking torque of the superimposed hydraulic lock. Substituting the active side wind load moment and the maximum locking moment of the superimposed hydraulic lock into the 80% safety margin constraint, the lower limit of the pre-locking angle that satisfies the requirement that the active side wind load moment does not exceed 80% of the maximum locking moment of the superimposed hydraulic lock is solved by inverse cosine calculation to obtain the pre-locking angle of the active side cast steel wind deflector.

5. The intelligent control system for the dust suppression baffle of the unloading machine hopper according to claim 4, characterized in that, The locking unit is used for: Based on the difference between the pre-lock angle and the initial fully open angle of 90° of the active side cast steel baffle, the set flow rate of the superimposed throttle valve in the active side hydraulic valve group and the geometric parameters of the cylinder are converted to obtain the time required for the active side baffle to move to the pre-lock angle. Based on the time required for the active side baffle to move to the pre-lock angle, a reversing command is sent to the active side electromagnetic reversing valve to drive the two active side cylinders to extend. The PLC scan cycle count is timed. When the time reaches the required time, a holding command is sent to the active side electromagnetic reversing valve to obtain the pre-lock position holding state of the active side cast steel baffle. Based on the pre-locked position of the active side cast steel baffle, the superimposed hydraulic lock automatically engages and locks, hydraulically locking the active side cast steel baffle at the pre-locked angle. At this time, the active side cast steel baffle forms an oblique blocking barrier while the driven side cast steel baffle remains in a 90° open position, resulting in a V-shaped guide channel in front of the hopper.

6. The intelligent control system for the dust suppression baffle of the unloader hopper according to claim 5, characterized in that, The closing unit is used for: Based on the completion signal of the V-shaped guide groove, a reversing command is sent to the driven side electromagnetic reversing valve to drive the two oil cylinders in the driven side hydraulic valve group to extend, and the one-way throttle valve speed adjustment process is performed on the following closing process of the driven side cast steel baffle. When the two extended limit switches on the driven side are triggered at the same time, the driven side cast steel baffle is in a fully closed state. Based on the fully closed state of the driven side cast steel wind baffle, an unlocking command is sent to the active side superimposed hydraulic lock to release the hydraulic lock of the active side cast steel wind baffle at the pre-locking angle. Then, a continuing reversing command is sent to the active side solenoid reversing valve to drive the two active side cylinders to continue extending until the two active side extension limit switches are triggered simultaneously. This drives the remaining stroke of the active side cast steel wind baffle from the pre-locking angle to full closure, resulting in the fully closed state of the active side cast steel wind baffle. The fully closed state of the driven side cast steel wind baffle and the fully closed state of the active side cast steel wind baffle are combined and confirmed. The two sets of superimposed hydraulic locks are simultaneously engaged and locked. The lower cast steel wind baffle and the middle cast steel wind baffle completely seal both sides of the hopper. The upper industrial rubber wind baffle is attached to the edge of the top opening of the hopper, resulting in a double-sided closed state.

7. The intelligent control system for the dust suppression baffle of the unloading machine hopper according to claim 1, characterized in that, The locking module is used for: Based on the aforementioned double-sided closed state, the difference between the dust concentration reference value output by the dust sensor before the baffle is closed and the measured dust concentration value output after the baffle is closed is divided by the dust concentration reference value. The sealing efficiency of this sequential closing action is calculated to obtain the dust concentration change rate. The pre-lock angle, wind speed, wind direction angle and dust concentration change rate of this action are written into the PLC data register as a set of observation data. The historical action data is accumulated and stored in a rolling manner. When the number of accumulated observation data sets reaches 10 sets, the pre-lock angle associated dataset is obtained. A design matrix is ​​constructed by taking 10 sets of observation data from the pre-locking angle association dataset. The dust concentration change rate is the dependent variable, and the pre-locking angle, wind speed, and wind direction cosine are the independent variables. The design matrix and the dependent variable vector are solved by the least squares method to obtain the regression coefficients of the association model between the pre-locking angle and the sealing efficiency. Substitute the current wind speed and wind direction angle into the regression coefficients of the correlation model, perform inverse solution processing on the lower limit of the pre-locking angle corresponding to the sealing efficiency threshold, take the larger value of the inverse solution result and the pre-locking angle calculated under the safety margin constraint of the superimposed hydraulic lock, and obtain the corrected pre-locking angle. The superimposed hydraulic lock then locks the active side cast steel windbreak plate according to the corrected pre-locking angle.

8. The intelligent control system for the dust suppression baffle of the unloading machine hopper according to claim 7, characterized in that, The dust concentration baseline value is the arithmetic mean of the dust sensor output values ​​within 5 consecutive PLC scanning cycles before the baffle is closed.

9. The intelligent control system for the dust suppression baffle of the unloading machine hopper according to claim 8, characterized in that, If the number of accumulated observation data sets is less than 10, the corrected pre-locking angle is directly taken as the pre-locking angle calculated under the safety margin constraint of the superimposed hydraulic lock.

10. The intelligent control system for the dust suppression baffle of the unloader hopper according to claim 9, characterized in that, The sealing efficiency threshold is 75%. When the dust concentration change rate is less than 75%, the side curtain sealing compensation command is triggered, and the local control box outputs an alarm signal.

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