A spiral introduction shaping reflux device and method for coal near-infrared online detection

Abstract

This invention relates to the field of online coal quality detection technology, and discloses a spiral guide, shaping, and reflux device and method for near-infrared online detection of coal. The device includes a main conveying and diversion sampling unit, with a spiral lifting guide unit connected to the discharge end of the main conveying and diversion sampling unit. A buffer stabilizing unit is connected to the discharge end of the spiral lifting guide unit. A detection conveyor belt is located below the buffer stabilizing unit. Above the detection conveyor belt, along the coal sample conveying direction, a primary coal seam shaping state sensing integrated unit and a real-time near-infrared detection unit are arranged sequentially. A post-detection reflux unit is located at the discharge end of the detection conveyor belt. This invention, through an integrated system of continuous diversion sampling of the main coal flow, stable spiral lifting feeding, active shaping and anti-clogging with a liftable scraper, and undisturbed reflux of coal powder after detection, achieves the active construction of a stable and quantifiable detection window, eliminates interference from coal seam thickness fluctuations and scraper blockage, and improves the repeatability of coal quality detection data and the reliability of continuous device operation.

Description

Technical Field

[0001] This invention relates to the field of online coal quality detection technology, and more specifically to a spiral guide shaping and reflux device and method for near-infrared online detection of coal. Background Technology

[0002] As a crucial component of my country's energy structure, real-time online monitoring of coal quality is of great significance for production regulation and cost control in industries such as thermal power generation and coal processing. Near-infrared spectroscopy, with its advantages of speed, non-destructive testing, and online capability, has gradually become the mainstream technology for online coal quality monitoring. Currently, existing online coal quality spectroscopy monitoring solutions have gradually integrated basic functions such as sampling, transportation, leveling, and closed-loop testing, to some extent replacing traditional manual sampling and testing methods and improving the efficiency of coal quality monitoring. However, in practical engineering applications, there are still many core shortcomings that are incompatible with the requirements for continuous and stable online monitoring.

[0003] Existing solutions generally adopt a passive detection mode of "testing coal flow as it occurs," which essentially lacks the ability to actively construct coal seam detection windows and manage the system's state. They treat coal seam leveling merely as an auxiliary means rather than a prerequisite for detection, and lack a standardized and quantifiable evaluation system for detection windows. When coal seams experience localized accumulation, excessive thickness fluctuations, edge warping, or discontinuity interruptions, the resulting detection windows exhibit poor stability, directly leading to insufficient repeatability and representativeness of spectral detection results, and even data distortion, thus failing to provide reliable coal quality data support for the production process.

[0004] Meanwhile, existing technologies lack coordination between different stages. For example, in the front-end feeding stage, direct feeding or simple lifting structures are often used to introduce and divert coal samples. During the coal sample transportation process, problems such as large instantaneous flow fluctuations and strong impacts from falling materials easily occur, making it difficult to form a uniform and continuous initial coal layer, which increases the difficulty of subsequent shaping stages. In the shaping and anti-clogging stage, most rely on fixed scrapers or adjustable scrapers with simple adjustment logic, which can only achieve a single passive leveling function. They lack the ability to identify coal accumulation, adhesion, lifting, edge overflow, and clogging trends in front of the scraper. The scraper itself can easily become a source of clogging in the system. Once clogging occurs, it will cause the equipment to shut down, seriously affecting the reliability of continuous operation.

[0005] Furthermore, existing solutions lack effective closed-loop linkage control in the perception and execution stages. While some solutions introduce contour detection or visual monitoring sensors, they are only used for single coal seam thickness measurement or post-fault alarms, failing to integrate visual anti-blocking information with contour detection information, and unable to proactively adjust the scraper's operating strategy based on the real-time state of the coal seam. Simultaneously, most solutions still rely on intermittent acquisition or post-accumulation sampling for spectral detection, making real-time spectral acquisition and analysis difficult during continuous coal sample transport. The return processing of detected coal samples is also insufficiently considered; some solutions suffer from poor return flow, coal residue, and even additional waste, not only wasting coal resources but also potentially significantly interfering with the normal operation of the existing coal conveying system, making them unsuitable for long-term, continuous online deployment requirements in industrial settings. Summary of the Invention

[0006] In view of this, the present invention provides a spiral guide shaping and reflux device and method for near-infrared online detection of coal. In the scenario of near-infrared online detection of coal, through continuous diversion sampling of the main coal flow, stable feeding by spiral lifting, active shaping and anti-blocking of the liftable scraper integrating visual anti-blocking and contour detection, and undisturbed reflux of coal powder after detection, it can actively build a stable and quantifiable detection window, eliminate the interference of coal seam thickness fluctuation and scraper blockage on detection, and improve the repeatability of coal quality detection data and the reliability of continuous operation of the device.

[0007] To achieve the above objectives, the present invention provides a spiral guide shaping and reflux device for near-infrared online detection of coal, comprising a main conveying diversion sampling unit, a spiral lifting guide unit connected to the discharge end of the main conveying diversion sampling unit, a buffer stabilizing unit connected to the discharge end of the spiral lifting guide unit, a detection conveyor belt arranged below the buffer stabilizing unit, a primary coal seam shaping state sensing integrated unit and a real-time near-infrared detection unit arranged sequentially above the detection conveyor belt along the coal sample conveying direction, and a post-detection reflux unit arranged at the discharge end of the detection conveyor belt, the discharge end of the post-detection reflux unit being connected to the main coal conveying belt below; It also includes a control unit, which is electrically connected to the spiral lifting and guiding unit, the integrated primary coal seam shaping state sensing unit, and the real-time near-infrared detection unit. The integrated primary coal seam shaping state sensing unit includes a mounting bracket, which is fixed above the detection conveyor belt. The mounting bracket is equipped with a liftable scraper, a lifting actuator for driving the liftable scraper to move up and down, and a visual anti-blocking unit for identifying abnormal coal conditions in front of the scraper. A contour detection sensor for detecting coal seam state parameters is located behind the mounting bracket. The lifting actuator, the visual anti-blocking unit, and the contour detection sensor are all electrically connected to the control unit.

[0008] Preferably, the control unit is equipped with a blockage risk judgment module and a window compliance judgment module. The output priority of the blockage risk judgment module is higher than that of the window compliance judgment module. When the visual anti-blockage unit detects a blockage trend, the control unit prioritizes controlling the lifting actuator to drive the liftable scraper to lift and avoid the blockage, and suspends the detection triggering of the real-time near-infrared detection unit.

[0009] Preferably, the real-time near-infrared detection unit includes a spectral probe, a probe lifting drive mechanism, and a probe ranging element. The spectral probe is mounted on a probe mounting base, which is mounted above the detection conveyor belt via a vertical guide mechanism. The probe lifting drive mechanism is connected to the probe mounting base. The probe ranging element is fixed on the probe mounting base. Both the spectral probe and the probe ranging element are electrically connected to the control unit.

[0010] Preferably, the spiral lifting and guiding unit includes a spiral conveying cylinder, a spiral shaft disposed inside the spiral conveying cylinder, spiral blades fixed on the spiral shaft, and a drive motor for driving the spiral shaft to rotate. The lower part of the spiral conveying cylinder has a feed inlet connected to the discharge end of the main conveying diversion sampling unit, and the upper part has a discharge outlet connected to the feed end of the buffer stabilizing unit. The drive motor is electrically connected to the control unit.

[0011] Preferably, the post-inspection return unit includes a tail scraper and a guide chute. The tail scraper is positioned above the discharge end of the inspection conveyor belt, and the upper end of the guide chute connects to the discharge end of the inspection conveyor belt, while the lower end connects to the main coal conveyor belt below.

[0012] The present invention provides a spiral induction, shaping, and reflux method for near-infrared online detection of coal, applied to the spiral induction, shaping, and reflux device for near-infrared online detection of coal as described above, comprising the following steps: S1: Coal samples are continuously extracted from the main coal flow through the main conveying diversion sampling unit and transported to the spiral lifting inlet unit; S2: The coal sample is lifted by the spiral lifting and introducing unit and introduced into the buffer stabilizing unit. After being stabilized by the buffer stabilizing unit, it falls onto the detection conveyor belt to form the initial coal layer. S3: The initial coal seam enters the primary coal seam shaping state perception integrated unit along the detection conveyor belt. The abnormal state of the coal material in front of the scraper is identified by the visual anti-blocking unit, and the state parameters of the coal seam are detected by the contour detection sensor. S4: The control unit drives the lifting actuator to shape, limit thickness, or lift and avoid obstacles based on the detection signals from the vision anti-blocking unit and the contour detection sensor, thus actively building a stable detection window. S5: When the control unit determines that the detection window meets the standard, it triggers the real-time near-infrared detection unit to perform real-time spectral acquisition and coal quality analysis of the coal seam. S6: After the coal sample has been tested, it is returned to the main coal conveyor belt below by the post-testing return unit and returns to the original conveying process.

[0013] Preferably, in step S4, the control unit prioritizes the judgment of blockage risk. When a blockage trend is detected in front of the scraper, the liftable scraper is driven to rise to avoid it, and the near-infrared detection trigger is paused. After the blockage risk is eliminated, the shaping control and window determination are performed according to the coal seam state parameters.

[0014] Preferably, in step S5, during the detection process, the real-time near-infrared detection unit detects the distance between the spectral probe and the coal seam surface in real time through the probe ranging element. The control unit drives the probe lifting drive mechanism to adjust the vertical position of the spectral probe according to the detected distance signal, so that the spectral probe and the coal seam surface maintain the set detection distance.

[0015] Preferably, in step S4, the control unit comprehensively determines whether the detection window meets the standard based on the parameters of coal seam thickness, flatness and continuity output by the contour detection sensor, and the parameters of coal accumulation state, edge state and blockage risk output by the visual anti-blocking unit.

[0016] Preferably, in step S5, when the control unit determines that the detection window does not meet the standard, it does not trigger near-infrared detection and continues to drive the liftable scraper to perform shaping adjustment or material stabilization adjustment until the detection window meets the standard.

[0017] As can be seen from the above technical solutions, compared with the prior art, the spiral guide shaping and reflux device and method for near-infrared online detection of coal provided by the present invention has the following beneficial effects: 1. By combining continuous diversion sampling of the main coal flow with a spiral lifting and introducing unit, stable and continuous coal sample supply is achieved. Then, an integrated primary coal seam shaping and status monitoring unit, which integrates a liftable scraper, a visual anti-blocking unit, and a contour detection sensor, performs active shaping and status monitoring. This can transform the originally loose and fluctuating coal seam into a standardized detection window with uniform thickness, flat surface, and continuous stability. Spectral detection is only triggered when all indicators such as the thickness, flatness, continuity, and anti-blocking safety status of the detection window meet the preset requirements, fundamentally ensuring the consistency of spectral acquisition conditions and significantly improving the repeatability and representativeness of coal quality test results.

[0018] 2. The control unit adopts a control logic that prioritizes the judgment of blockage risk over the judgment of window compliance. When the visual anti-blockage unit detects a blockage trend such as coal accumulation, edge overflow, or coal powder retention in front of the scraper, it prioritizes driving the liftable scraper to lift and avoid the blockage and suspends the detection trigger. The shaping control and detection process will resume after the blockage risk is eliminated. This can effectively prevent hard blockage in front of the scraper, avoid the shutdown of the device due to blockage, and greatly improve the reliability of continuous operation of the device.

[0019] 3. The real-time near-infrared detection unit is equipped with a height-adjustable spectral probe with an integrated probe ranging element. It can dynamically adjust the vertical distance between the probe and the coal seam according to the real-time contour data of the coal seam surface, so that the two are always kept within the set optimal detection range. This effectively eliminates the influence of small fluctuations in coal seam thickness, surface undulations and local material lifting on the spectral acquisition accuracy, and further improves the accuracy of coal quality analysis results.

[0020] 4. The spiral lifting and inlet unit adopts a closed spiral conveying structure. While continuously lifting the coal sample from the main conveyor belt below to the upper independent detection path, it can initially disperse and uniformly convey the coal sample through the rotation of the spiral blades, avoiding the instantaneous accumulation and impact caused by direct material drop. Combined with the temporary storage and material equalization function of the buffer stabilizing unit, it can effectively reduce the instantaneous flow fluctuation of the coal sample, providing a stable supply basis for subsequent coal seam shaping and spectral detection.

[0021] 5. The post-inspection return unit, through the cooperation of the tail scraper and the guide chute, can scrape off all the coal sample and coal powder adhering to the surface of the inspection conveyor belt after the inspection is completed, and naturally guide it back to the main coal conveyor belt below, so that the coal sample can re-enter the original main coal flow. The entire return process does not require additional power equipment, does not produce any waste material, and will not cause significant interference to the normal operation of the original coal conveying system. It is very suitable for long-term, continuous online deployment and use in industrial sites. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the overall structure of the spiral guide shaping and reflux device for near-infrared online detection of coal according to the present invention. Figure 2 This is a partially enlarged schematic diagram of the integrated primary coal seam shaping state sensing unit of the present invention; Figure 3 This is a schematic diagram of the real-time spectral detection area and the post-detection coal powder reflux path of the present invention; Figure 4 This is a flowchart illustrating the working process of the spiral inlet shaping and reflux device of the present invention. Figure 5 This is a control framework diagram for the state determination and detection triggering of the detection window in this invention.

[0024] Explanation of reference numerals in the attached diagram: 1-Main conveyor diversion sampling unit, 2-Spiral lifting and inlet unit, 3-Buffer and material stabilization unit, 4-Detection conveyor belt, 5-Integrated unit for sensing the shaping status of primary coal seam, 6-Real-time near-infrared detection unit, 7-Post-detection return unit, 8-Lower main coal conveyor belt, 9-Control unit, 10-Spiral conveyor cylinder, 11-Spiral shaft, 12-Spiral blade, 13-Initial coal seam, 14-Inlet, 15-Outlet, 16-Accumulation area in front of scraper, 17-Buffer hopper, 18-Pushing structure, 19-Mounting bracket, 20-Liftable scraper, 21-Lifting actuator, 22-Visual anti-clogging unit, 23-Contour detection sensor, 24-Detection window, 25-Shaped coal seam, 26-Real-time spectral detection area, 27-Tail guide structure, 28-Natural material drop channel, 29-Coal powder return path, 30-Guide chute, 31-Sealed detection cabinet. Detailed Implementation

[0025] 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. The following description of an exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0026] like Figure 1 As shown, this invention discloses a spiral guide shaping and reflux device for near-infrared online detection of coal. The device includes a main conveying and diversion sampling unit 1, a spiral lifting and guiding unit 2 connected to the discharge end of the main conveying and diversion sampling unit 1, a buffer stabilizing unit 3 connected to the discharge end of the spiral lifting and guiding unit 2, a detection conveyor belt 4 arranged below the buffer stabilizing unit 3, a primary coal seam shaping state sensing integrated unit 5 and a real-time near-infrared detection unit 6 arranged sequentially above the detection conveyor belt 4 along the coal sample conveying direction, a post-detection reflux unit 7 arranged at the discharge end of the detection conveyor belt 4, and the discharge end of the post-detection reflux unit 7 connected to the main coal conveying belt 8 below. It also includes a control unit 9, which is electrically connected to the spiral lifting and guiding unit 2, the primary coal seam shaping state sensing integrated unit 5, and the real-time near-infrared detection unit 6. This device breaks through the passive detection mode of existing technology, which is "testing as soon as coal arrives". Through the integrated system design of front-end spiral lifting for stable feeding, primary unit active sensing and shaping to prevent blockage, triggering detection after meeting standards, and non-disturbing return after detection, it actively constructs a stable and measurable window that meets the requirements of near-infrared spectroscopy detection. It fundamentally solves the problems of poor repeatability, insufficient representativeness, easy blockage, and large interference with the original coal conveying system in existing solutions, and realizes truly continuous, stable and reliable online coal quality detection.

[0027] The main conveyor diversion sampling unit 1 is located on one side of the main coal conveyor belt 8 below. It adopts a small side diversion structure, which can continuously extract representative coal samples from the continuously conveyed main coal flow, avoiding the problems of insufficient coal sample representativeness and delayed detection data caused by intermittent sampling. The extracted coal samples are transported to the feed end of the screw lifting and guiding unit 2. The screw lifting and guiding unit 2 includes a screw conveyor cylinder 10, a screw shaft 11 set in the screw conveyor cylinder 10, a screw blade 12 fixed on the screw shaft 11, and a drive motor that drives the screw shaft 11 to rotate. The lower part of the screw conveyor cylinder 10 has a feed port 14 that communicates with the discharge end of the main conveyor diversion sampling unit 1, and the upper part has a discharge port 15 that communicates with the feed end of the buffer stabilizing unit 3. The drive motor is electrically connected to the control unit 9. The spiral lifting and guiding unit 2 is not simply a lifting mechanism, but a composite functional unit used to achieve continuous receiving, closed lifting, stable transfer, and directional dropping of diverted coal samples. It not only continuously lifts coal samples located near the main conveyor belt 8 below to the independent detection path above, achieving a compact arrangement of upper and lower layers, but more importantly, it disperses and evenly transports the coal samples during the lifting process through the rotation of the spiral blades 12, avoiding instantaneous accumulation and impact when the diverted coal samples fall directly, thus providing a good foundation for subsequent buffering and stabilization and coal seam shaping. The control unit 9 can control the conveying speed of the spiral lifting and guiding unit 2 by adjusting the speed of the drive motor. When the amount of diverted coal sample is large, the speed is increased to enhance the lifting capacity and prevent accumulation at the feed end; when the amount of diverted coal sample is small, the speed is reduced, allowing the coal sample to enter the buffering and stabilization unit 3 in a gentler manner, reducing the impact of falling material and fluctuations in coal seam thickness.

[0028] The buffer stabilizing unit 3 includes a buffer hopper 17 and a material leveling structure 18 located at the outlet of the buffer hopper 17. The inlet of the buffer hopper 17 is connected to the outlet 15 of the screw conveyor unit 2. The buffer stabilizing unit 3 is equipped with a material level detection element, which is electrically connected to the control unit 9. The buffer hopper 17 can temporarily store coal samples, effectively reducing the instantaneous flow fluctuation of the coal samples. The material leveling structure 18 can make the coal samples fall evenly onto the detection conveyor belt 4 below, forming an initial coal layer 13 with a relatively uniform thickness. The screw conveyor unit 2 can also be linked with the material level signal of the buffer hopper 17. The control unit 9 adjusts the speed of the drive motor in real time according to the material level signal detected by the material level detection element in the buffer hopper 17. When the material level is too high, the screw conveyor speed is reduced or the feeding is stopped. When the material level is too low, the screw conveyor speed is increased, thereby ensuring a continuous and stable supply of coal samples on the subsequent detection conveyor belt 4 and avoiding material interruption or overload.

[0029] like Figure 2As shown, the detection conveyor belt 4 is horizontally arranged below the buffer and stabilizing unit 3 to receive coal samples falling from the buffer and stabilizing unit 3 and to sequentially transport the coal samples to the underside of the primary coal seam shaping state sensing integrated unit 5 and the real-time near-infrared detection unit 6. The primary coal seam shaping state sensing integrated unit 5 is one of the core innovative units of this device. It differs from the single fixed scraper structure in the existing technology, and is a composite unit that integrates sensing, judgment and execution functions. Its core function is to transform the coal seam from a "transportable" state to a "detectable" state, actively constructing a stable detection window 24 that meets the requirements of near-infrared spectroscopy detection, rather than simply scraping the coal seam. The integrated unit 5 for sensing the shaping status of the primary coal seam includes a mounting bracket 19, which is fixed above the detection conveyor belt 4. The mounting bracket 19 is equipped with a liftable scraper 20, a lifting actuator 21 for driving the scraper 20 up and down, a visual anti-blocking unit 22 for identifying abnormal coal conditions in front of the scraper, and a contour detection sensor 23 for detecting coal seam status parameters. The lifting actuator 21, the visual anti-blocking unit 22, and the contour detection sensor 23 are all electrically connected to the control unit 9. The liftable scraper 20 is arranged perpendicular to the conveying direction of the detection conveyor belt 4, and a gap is formed between its bottom edge and the upper surface of the detection conveyor belt 4 for the coal seam to pass through. By adjusting the size of this gap through the lifting actuator 21, the thickness limitation and shaping treatment of the coal seam can be achieved. The visual anti-blocking unit 22 is arranged in front of the liftable scraper 20 and can identify abnormal states such as coal accumulation, local blockage, adhesion, material lifting, edge lifting, skew, material flow interruption, and edge overflow in front of the scraper in real time. The contour detection sensor 23 can collect parameters such as the height, thickness, surface flatness and continuity of the coal seam. The control unit 9 drives the lifting actuator 21 to drive the liftable scraper 20 to perform corresponding actions based on these detection signals, so as to realize active shaping and active blockage avoidance, fundamentally preventing the scraper itself from becoming a source of blockage in the system.

[0030] The control unit 9 is equipped with a window status index calculation module, a blockage risk judgment module, a window compliance judgment module, a scraper adjustment module, a spectral detection trigger module, a spectral quality judgment module, and a coal quality analysis result output module. The window status index calculation module calculates the average thickness, maximum thickness, minimum thickness, peak-to-valley difference, thickness standard deviation, and continuous stable length of the coal seam based on multi-point height data sequences collected by the contour detection sensor 23 within the detection window 24. Based on continuous image frames collected by the visual anti-blocking unit 22 in the area in front of the scraper, it obtains the coal accumulation area, edge overflow ratio, coal seam coverage, empty zone or material breakage status, and coal residence time using coal area segmentation and edge extraction methods. The blockage risk judgment module generates a blockage risk value based on the coal pile area, coal pile height or estimated height, residence time, and edge overflow ratio. When any parameter exceeds the corresponding threshold or the blockage risk value reaches a preset risk threshold, a blockage trend is determined. The window compliance judgment module determines whether the detection window 24 meets the standards based on whether the average thickness is within the target range, whether the peak-to-valley difference and thickness standard deviation are less than the threshold, whether the continuous stable length and coal seam coverage meet the threshold, and whether the blockage risk value is lower than the safety threshold. It then outputs scraper adjustment instructions and detection trigger instructions.

[0031] Specifically, the coal area segmentation of the visual anti-blocking unit 22 can be achieved using grayscale threshold segmentation, background subtraction, edge detection, or a calibrated image recognition model; the blockage risk value can be calculated using a weighted normalization fusion method, for example, according to Rb=w1×A / A0+w2×Hp / H0+w3×Tr / T0+w4×B / B0, where A is the coal accumulation area in front of the scraper, Hp is the coal pile height or estimated height, Tr is the coal residence time, B is the edge overflow ratio, A0, H0, T0, and B0 are the corresponding preset benchmark values, and w1, w2, w3, and w4 are weighting coefficients. When Rb reaches the preset risk threshold, or any parameter among A, Hp, Tr, and B exceeds its upper limit threshold, the control unit 9 determines that there is a blockage trend; when the average coal seam thickness is within the target thickness range, the peak-to-valley difference and thickness standard deviation are less than the corresponding threshold, the coal seam coverage and continuous stable length reach the corresponding threshold, and Rb is lower than the safety threshold, the control unit 9 determines that the detection window 24 meets the standard. The output priority of the blockage risk judgment module is higher than that of the window compliance judgment module. This is a key design feature of the device's control logic, ensuring continuous operation under all circumstances. When the visual anti-blockage unit 22 detects that the area of ​​the coal pile in front of the scraper exceeds a preset area threshold, the height of the coal pile exceeds a preset height threshold, the coal dust stays in front of the scraper for a longer than a preset time, or there is obvious overflow at the two sides, the control unit 9 determines that there is a risk of accumulation or a blockage trend. At this time, even if the average thickness of the coal layer is within the target thickness range, the control unit 9 does not trigger near-infrared detection. Instead, it prioritizes outputting a scraper lifting avoidance signal to the lifting actuator 21, causing the liftable scraper 20 to rise a preset distance, releasing the locally accumulated coal dust, and preventing blockage in front of the scraper. At the same time, the detection triggering of the real-time near-infrared detection unit 6 is paused. After the blockage risk value drops below the safety threshold, the control unit 9 recalculates the status index of the detection window 24 and determines whether to trigger near-infrared detection. This priority setting effectively prevents the scraper from becoming a source of blockage in the system, ensuring the reliability of continuous operation of the device and solving the problem of frequent device shutdowns caused by scraper blockage in the prior art.

[0032] The window status index calculation module receives the average thickness, maximum thickness, minimum thickness, peak-to-valley difference, thickness fluctuation degree, thickness standard deviation, and continuous stable length of the coal seam output by the contour detection sensor 23. Simultaneously, it receives the coal seam coverage, edge integrity, empty zone state, edge overflow state, edge overflow ratio, and blockage risk value output by the visual anti-blocking unit 22. These parameters are combined to calculate the status index of the detection window 24. It is important to note that the window status index of this device is not directly measured by a single sensor, but is calculated jointly from contour detection data, visual recognition data, and continuous frame state change data. This is the core foundation for the active construction of the detection window 24. When the average coal seam thickness is within the allowable range of the target thickness, the peak-to-valley difference is less than a preset threshold, the thickness standard deviation is less than a preset threshold, the continuous stable length meets the preset requirements, and the visual anti-blocking unit 22 does not detect any blockage risk, the control unit 9 determines that the current detection window 24 meets the standards, outputs a scraper position holding signal to maintain the current shaping height of the liftable scraper 20, and outputs a real-time near-infrared detection trigger command. When the contour detection sensor 23 detects that the average thickness of the coal seam is greater than the upper limit of the target thickness, and the visual anti-blocking unit 22 does not detect any obvious risk of blockage, the control unit 9 determines that the coal seam is too thick but the material flow is still in a shapeable state. At this time, it outputs a scraper descent control signal to the lifting actuator 21, causing the liftable scraper 20 to descend a preset distance to perform thickness-limited shaping of the coal seam, forming the shaped coal seam 25. When the contour detection sensor 23 detects that the average thickness of the coal seam is less than the lower limit of the target thickness, or the visual anti-blocking unit 22 identifies that there are empty belts, material breaks, or insufficient coal seam coverage on the detection conveyor belt 4, the control unit 9 determines that the coal seam is too thin or the material flow is not continuous. At this time, it outputs a scraper rise control signal to the lifting actuator 21, causing the liftable scraper 20 to rise a preset distance to avoid excessive scraping and maintain the continuity of the coal seam. When the detection window 24 does not meet the standard, the near-infrared detection is not triggered, and the shaping adjustment or material stabilization adjustment continues until the detection window 24 meets the standard. When both excessive coal seam thickness and blockage risk exist simultaneously, control unit 9 prioritizes lifting the scraper to avoid obstruction, rather than continuing to lower it to the thickness limit. Once the blockage risk is eliminated, control unit 9 then resumes scraper reshaping control based on coal seam thickness, smoothness, and continuity. Through the above control logic, the system can convert visual anti-blockage information and contour detection information into executable control commands such as scraper descent, ascent, lifting to avoid obstruction, position maintenance, and pause detection.

[0033] In this embodiment, the target coal seam thickness can be set to 20 mm, the allowable thickness range to be set to 17 mm to 23 mm, the peak-to-valley difference threshold to be set to 5 mm, the thickness fluctuation threshold to be set to 3 mm, the coal seam coverage threshold to be set to 90%, the continuous stable length threshold to be set to 300 mm, and the blockage risk threshold to be set to 0.6. The above values ​​are only one example; in actual applications, they can be adjusted according to the coal type, coal powder particle size, conveying speed, near-infrared detection spot size, and detection area length. For example, when the contour detection sensor 23 detects that the average coal seam thickness is 21 mm, the peak-to-valley difference is 3 mm, the thickness fluctuation is 2 mm, and the continuous stable length is 360 mm, and the visual anti-blocking unit 22 detects that the coal seam coverage is 95%, there are no obvious empty zones, no obvious edge overflow, and the blockage risk value is 0.3, the control unit 9 determines that the current detection window 24 status indicators meet the preset requirements and outputs a real-time near-infrared detection trigger command, causing the near-infrared detection unit to perform spectral acquisition on the current coal seam; when the contour detection sensor 23 detects that the average coal seam thickness is 26 mm, exceeding the target thickness limit, or the peak-to-valley difference is 8 mm, exceeding the preset peak-to-valley difference threshold, the control unit 9 determines that the current coal seam thickness or flatness does not meet the requirements of the detection window 24, at which point near-infrared detection is not triggered, and a scraper descent and shaping signal is output, causing the liftable scraper 20 to adjust the coal seam. Thickness limiting and leveling are performed. When the contour detection sensor 23 detects that the average coal seam thickness is 14 mm, which is lower than the target thickness limit, or when the visual anti-blocking unit 22 detects that the coal seam coverage in the detection area is less than 90%, or that there are empty zones or material breaks, the control unit 9 determines that the continuity of the current detection window 24 is insufficient. At this time, near-infrared detection is not triggered, and a scraper lifting signal or a material stabilization adjustment signal is output to avoid excessive scraping and restore the continuity of the coal seam. When the visual anti-blocking unit 22 detects that the coal pile area in front of the scraper continues to increase, the edge overflow is obvious, or the blockage risk value reaches 0.6 or above, the control unit 9 determines that there is an accumulation risk or blockage trend. At this time, even if the average coal seam thickness is within the target thickness range, the control unit 9 does not trigger near-infrared detection, but instead prioritizes outputting a scraper lifting avoidance signal to raise the scraper a preset distance to release the coal powder accumulated in front of the scraper.

[0034] The real-time near-infrared detection unit 6 is located downstream of the integrated unit 5 for sensing the shaping state of the primary coal seam. It includes a sealed detection cabinet 31, a spectral probe, a probe mounting base, a vertical guide mechanism, a probe lifting drive mechanism, and a probe ranging element. The sealed detection cabinet 31 is positioned above the detection conveyor belt 4, providing a light-shielding, dust-proof, and relatively stable detection environment to prevent interference from external light and dust on the spectral acquisition results. The probe mounting base is installed above the detection conveyor belt 4 inside the sealed detection cabinet 31 via the vertical guide mechanism. The probe lifting drive mechanism is connected to the probe mounting base, and the probe ranging element is fixed to the probe mounting base. Both the spectral probe and the probe ranging element are electrically connected to the control unit 9. During the detection process, the probe ranging element continuously monitors the distance between the spectral probe and the coal seam surface. The control unit 9, based on this distance signal, drives the probe lifting mechanism to adjust the vertical position of the spectral probe, ensuring that the probe maintains a set detection distance or range within a set distance range. This reduces spectral acquisition errors caused by coal seam thickness fluctuations, surface undulations, or localized material uplift. When abnormal coal seam uplift is detected, the spectral probe can be moved upwards to avoid the abnormality, protecting the detection components from damage. The spectral quality judgment module assesses the quality of the acquired spectral data. If the spectral data is unqualified, abnormal spectra are removed and the detection is repeated. If the spectral data is qualified, the coal quality analysis module performs coal quality analysis and outputs the final coal quality analysis results. This device emphasizes completing online spectral acquisition and analysis directly during continuous coal sample transport, rather than simply accumulating samples before measurement. This enables true real-time spectral detection, providing timely and accurate coal quality data for the production process.

[0035] like Figure 3 As shown, the post-test return unit 7 is located at the discharge end of the testing conveyor belt 4, including a tail scraper and a guide chute 30. The tail scraper is positioned above the discharge end of the testing conveyor belt 4, effectively scraping away coal dust adhering to the surface of the testing conveyor belt 4. The upper end of the guide chute 30 connects to the discharge end of the testing conveyor belt 4, and the lower end connects to the main coal conveyor belt 8 below. After testing, the coal sample is transported to the discharge end with the testing conveyor belt 4. Under the action of gravity and the tail scraper, it leaves the testing conveyor belt 4 and naturally falls back to the main coal conveyor belt 8 below via the guide chute 30, rejoining the original main coal flow and returning to the original conveying process. The entire return process does not require additional power equipment, does not generate additional waste material, and does not significantly interfere with the normal operation of the original coal conveying system, making it very suitable for long-term online deployment in industrial sites.

[0036] For example, 4- Figure 5 As shown, the spiral introduction, shaping, and reflux method for near-infrared online detection of coal disclosed in this invention includes the following steps: S1: Coal samples are continuously extracted from the main coal flow through the main conveying diversion sampling unit 1 and transported to the spiral lifting and guiding unit 2; S2: The coal sample is lifted by the spiral lifting and introducing unit 2 and introduced into the buffer stabilizing unit 3. After being stabilized by the buffer stabilizing unit 3, it falls onto the detection conveyor belt 4 to form the initial coal layer 13. S3: The initial coal seam 13 enters the first-level coal seam shaping state perception integrated unit 5 along with the detection conveyor belt 4. The abnormal state of the coal material in front of the scraper is identified by the visual anti-blocking unit 22, and the state parameters of the coal seam are detected by the contour detection sensor 23. S4: The control unit 9 drives the lifting actuator 21 to move the liftable scraper 20 to shape, limit thickness or lift and avoid obstacles based on the detection signals of the visual anti-blocking unit 22 and the contour detection sensor 23, and actively builds a stable detection window 24. S5: When the control unit 9 determines that the detection window 24 meets the standard, it triggers the real-time near-infrared detection unit 6 to perform real-time spectral acquisition and coal quality analysis of the coal seam. S6: After the coal sample has been tested, it is returned to the main coal conveyor belt 8 below via the return unit 7 and returns to the original conveying process.

[0037] In step S2, the material level in the buffer stabilizing unit 3 is detected in real time by the material level detection element. The control unit 9 adjusts the conveying speed of the screw lifting and guiding unit 2 according to the material level signal to maintain the stability of the material level in the buffer stabilizing unit 3 and ensure the continuity of coal sample supply.

[0038] In step S4, the control unit 9 prioritizes the judgment of blockage risk. When a blockage trend is detected in front of the scraper, the liftable scraper 20 is driven to rise to avoid it, and the near-infrared detection trigger is paused. After the blockage risk is eliminated, the shaping control and window determination are performed according to the coal seam state parameters.

[0039] In step S5, during the detection process, the real-time near-infrared detection unit 6 detects the distance between the spectral probe and the coal seam surface in real time through the probe ranging element. The control unit 9 drives the probe lifting drive mechanism to adjust the vertical position of the spectral probe according to the detected distance signal, so that the spectral probe and the coal seam surface maintain the set detection distance and ensure the accuracy of spectral acquisition.

[0040] In specific implementation, the visual anti-blocking unit 22 can be any one of an industrial camera, depth camera, binocular camera, or machine vision module; the contour detection sensor 23 can be any one of a 3D laser contour sensor, line laser height measuring device, or visual height measuring module; the liftable scraper 20 can be any one of an integral scraper, segmented scraper, flexible edge scraper, or angle adjustable scraper; the lifting actuator 21 can be any one of an electric cylinder, screw module, pneumatic cylinder, hydraulic cylinder, or servo lifting mechanism; the spiral lifting and guiding unit 2 can be an integrated spiral conveying and lifting structure, or a spiral lifting and guiding material dropping combination structure; the post-inspection return path can be natural tail material dropping, tail scraper guiding return, chute return, or docking with the lower coal conveyor belt for return. The specific selection and structural form of the above components can be determined according to the actual application scenario and inspection requirements, and this invention does not impose specific limitations on them.

[0041] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A spiral guide shaping and reflux device for near-infrared online detection of coal, characterized in that, The system includes a main conveyor diversion sampling unit (1), the discharge end of which is connected to a spiral lifting and guiding unit (2), the discharge end of which is connected to a buffer stabilizing unit (3), a detection conveyor belt (4) is provided below the buffer stabilizing unit (3), and a primary coal seam shaping state sensing integrated unit (5) and a real-time near-infrared detection unit (6) are arranged sequentially above the detection conveyor belt (4) along the coal sample conveying direction. A post-detection return unit (7) is provided at the discharge end of the detection conveyor belt (4), and the discharge end of the post-detection return unit (7) is connected to the main coal conveying belt (8) below. It also includes a control unit (9), which is electrically connected to the spiral lifting and guiding unit (2), the first-level coal seam shaping state sensing integrated unit (5), and the real-time near-infrared detection unit (6), respectively. The first-level coal seam shaping state sensing integrated unit (5) includes a mounting bracket (19), which is fixed above the detection conveyor belt (4). The mounting bracket (19) is provided with a liftable scraper (20), a lifting actuator (21) for driving the liftable scraper (20) to lift, and a visual anti-blocking unit (22) for identifying abnormal coal conditions in front of the scraper. A contour detection sensor (23) for detecting coal seam state parameters is provided behind the mounting bracket (19). The lifting actuator (21), the visual anti-blocking unit (22), and the contour detection sensor (23) are all electrically connected to the control unit (9).

2. The spiral guide shaping and reflux device for near-infrared online detection of coal according to claim 1, characterized in that, The control unit (9) is equipped with a blockage risk judgment module and a window compliance judgment module. The output priority of the blockage risk judgment module is higher than that of the window compliance judgment module. When the visual anti-blockage unit (22) detects a blockage trend, the control unit (9) prioritizes controlling the lifting actuator (21) to drive the liftable scraper (20) to lift and avoid the blockage, and suspends the detection trigger of the real-time near-infrared detection unit (6).

3. The spiral guide shaping and reflux device for near-infrared online detection of coal according to claim 1, characterized in that, The real-time near-infrared detection unit (6) includes a spectral probe, a probe lifting drive mechanism, and a probe ranging element. The spectral probe is mounted on a probe mounting base, which is mounted above the detection conveyor belt (4) via a vertical guide mechanism. The probe lifting drive mechanism is connected to the probe mounting base. The probe ranging element is fixed on the probe mounting base. Both the spectral probe and the probe ranging element are electrically connected to the control unit (9).

4. The spiral guide shaping and reflux device for near-infrared online detection of coal according to claim 1, characterized in that, The spiral lifting and guiding unit (2) includes a spiral conveying cylinder (10), a spiral shaft (11) disposed in the spiral conveying cylinder (10), spiral blades (12) fixed on the spiral shaft (11), and a drive motor for driving the spiral shaft (11) to rotate. The lower part of the spiral conveying cylinder (10) is provided with a feed inlet (14) connected to the discharge end of the main conveying diversion sampling unit (1), and the upper part is provided with a discharge outlet (15) connected to the feed end of the buffer stabilizing unit (3). The drive motor is electrically connected to the control unit (9).

5. The spiral guide shaping and reflux device for near-infrared online detection of coal according to claim 1, characterized in that, The post-inspection return unit (7) includes a tail scraper and a guide chute (30). The tail scraper is positioned above the discharge end of the inspection conveyor belt (4). The upper end of the guide chute (30) is connected to the discharge end of the inspection conveyor belt (4), and the lower end is connected to the main coal conveyor belt (8) below.

6. A spiral induction, shaping, and reflux method for near-infrared online detection of coal, applied to the spiral induction, shaping, and reflux device for near-infrared online detection of coal as described in any one of claims 1-5, characterized in that, Includes the following steps: S1: Coal samples are continuously extracted from the main coal flow through the main conveying diversion sampling unit (1) and transported to the spiral lifting and guiding unit (2). S2: The coal sample is lifted by the spiral lifting and introducing unit (2) and introduced into the buffer stabilizing unit (3). After being stabilized by the buffer stabilizing unit (3), it falls onto the detection conveyor belt (4) to form the initial coal layer (13). S3: The initial coal seam (13) enters the first-level coal seam shaping state perception integrated unit (5) along with the detection conveyor belt (4). The abnormal state of the coal material in front of the scraper is identified by the visual anti-blocking unit (22), and the state parameters of the coal seam are detected by the contour detection sensor (23). S4: The control unit (9) drives the lifting actuator (21) to drive the liftable scraper (20) to shape, limit thickness or lift and avoid obstacles based on the detection signals of the visual anti-blocking unit (22) and the contour detection sensor (23), and actively builds a stable detection window (24). S5: When the control unit (9) determines that the detection window (24) meets the standard, it triggers the real-time near-infrared detection unit (6) to perform real-time spectral acquisition and coal quality analysis of the coal seam; S6: After the coal sample is tested, it is sent back to the main coal conveyor belt (8) below through the post-testing return unit (7) and returned to the original conveying process.

7. The spiral introduction, shaping, and reflux method for near-infrared online detection of coal according to claim 6, characterized in that, In step S4, the control unit (9) prioritizes the judgment of blockage risk. When a blockage trend is detected in front of the scraper, the liftable scraper (20) is driven to lift and avoid it, and the near-infrared detection trigger is paused. After the blockage risk is relieved, the shaping control and window determination are performed according to the coal seam state parameters.

8. The spiral introduction, shaping, and reflux method for near-infrared online detection of coal according to claim 6, characterized in that, In step S5, the real-time near-infrared detection unit (6) detects the distance between the spectral probe and the coal seam surface in real time through the probe ranging element during the detection process. The control unit (9) drives the probe lifting drive mechanism to adjust the vertical position of the spectral probe according to the detected distance signal, so that the spectral probe and the coal seam surface maintain the set detection distance.

9. The spiral introduction, shaping, and reflux method for near-infrared online detection of coal according to claim 6, characterized in that, In step S4, the control unit (9) comprehensively determines whether the detection window (24) meets the standard based on the coal seam thickness, flatness and continuity parameters output by the contour detection sensor (23) and the coal accumulation state, edge state and blockage risk parameters output by the visual anti-blocking unit (22).

10. The spiral introduction, shaping, and reflux method for near-infrared online detection of coal according to claim 6, characterized in that, In step S5, when the control unit (9) determines that the detection window (24) does not meet the standard, it does not trigger near-infrared detection and continues to drive the liftable scraper (20) to perform shaping adjustment or material stabilization adjustment until the detection window (24) meets the standard.

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