An automatic sprinkler dust suppression system based on belt load sensing

Abstract

This invention discloses an automatic sprinkler dust suppression system and control method based on belt load sensing, belonging to the field of dust removal technology for mining material conveying. Addressing the problems of slow operation, water waste, low intelligence, and high maintenance costs associated with traditional manual sprinkler systems, this invention employs a non-contact load sensing detection scheme. The system utilizes the difference in belt sag between no-load and loaded conditions, identifying the load status and outputting a signal via an inductive proximity switch. Combined with a PLC-built-in 30s-60s delay anti-shake logic, it prevents accidental start / stop of the sprinkler system. A filter tank and pressure reducing valve are installed in the sprinkler pipeline to ensure a stable and clean water supply. This invention enables on-demand dust removal with automatic sprinkler operation under load and automatic shutdown under no-load conditions. Field application verification shows that the system operates stably, has strong adaptability, effectively reduces equipment wear, and achieves an annual comprehensive economic benefit of 2.647 million yuan. It has low modification costs and high promotional value.

Description

Technical Field

[0001] This invention belongs to the field of dust removal technology for mining material conveying, specifically relating to an automatic spray dust suppression system and control method based on belt load sensing. Background Technology

[0002] In the mining, metallurgy, and building materials industries, belt conveyors are widely used for material transport. Large amounts of dust are easily generated at material transfer points, polluting the working environment, harming personnel health, accelerating wear on conveyor equipment, and increasing maintenance costs. Currently, the mainstream dust removal methods are divided into dry dust collection and wet spray dust suppression. Baghouse-type dry dust collectors are ineffective at handling high-humidity, high-concentration dust, and have high investment and operating costs. Traditional wet spray systems are mostly manually controlled, with lag in start-up and shutdown, easily leading to asynchrony between spraying and material transport. This not only wastes water resources but also relies on manual monitoring and cannot automatically adjust according to the material load on the belt, lacking sufficient intelligence. Therefore, there is an urgent need in this field for a dust suppression system that can automatically sense belt load and achieve intelligent start-up and shutdown of the spray system. Summary of the Invention

[0003] This invention aims to solve the problems of traditional belt-driven dust suppression systems, such as slow manual operation, waste of water resources due to empty spraying, low level of intelligence, and high equipment operation and maintenance costs.

[0004] To achieve the above objectives, this invention provides an automatic dust suppression spraying system based on belt load sensing, comprising a belt conveyor, a signal acquisition unit, a signal processing and control unit, and a spraying execution unit. The signal acquisition unit consists of an inductive proximity switch and an adjustable mounting bracket. The adjustable mounting bracket is fixedly mounted on the frame of the belt conveyor, and the inductive proximity switch is mounted on the adjustable mounting bracket with its probe facing the lower surface of the belt. This inductive proximity switch can output different switching signals according to the changes in belt sag under no-load and loaded conditions. The signal processing and control unit uses a PLC, which is electrically connected to the inductive proximity switch. It can receive the aforementioned switching signals and run delay anti-shake logic, ultimately outputting spraying start / stop control commands; the delay anti-shake duration is set to 30s–60s to avoid malfunctions caused by belt vibration. The spraying execution unit includes a solenoid valve and spray nozzles. The solenoid valve is electrically connected to the PLC, and the spray nozzles are arranged in the dust-generating area of ​​the belt conveyor to achieve targeted dust suppression. Furthermore, the spraying unit is also equipped with a pressure reducing valve and a filter tank, which are arranged sequentially along the water supply pipeline on the inlet side of the solenoid valve to stabilize the water pressure, filter impurities in the water, and prevent the spray nozzles from clogging.

[0005] The present invention also discloses a control method for the above-mentioned system, which specifically includes the following steps: S1: The system is powered on and initialization is complete; the PLC enters standby mode. S2: The inductive proximity switch detects the belt sagging status in real time and continuously outputs the corresponding switching signal; S3: The PLC receives a switch signal, detects a load trigger signal, and outputs a sprinkler start command after a delay and confirmation; after the trigger signal disappears and is confirmed after a delay, it outputs a sprinkler stop command. S4: The solenoid valve opens or closes the water circuit according to the command, controls the start and stop of the spray nozzles, and keeps the spraying action synchronized with the belt load status.

[0006] Compared with the prior art, the present invention has the following beneficial effects: The invention features a high degree of automation, reducing manual labor. It identifies the load status based on changes in belt sag under no-load and load conditions, automatically controlling the start and stop of the sprinkler system without manual intervention. This avoids the lag issues inherent in manual control and reduces on-site maintenance labor costs.

[0007] Spraying on demand saves water resources. This invention activates the spraying system only when the conveyor belt generates dust and automatically shuts off when unloaded, reducing ineffective water spraying and improving water resource utilization.

[0008] This invention reduces equipment wear and tear and lowers maintenance costs. It suppresses dust diffusion, reduces dust wear and corrosion on components such as bearings, rollers, and motors, extends equipment lifespan, and reduces losses from spare parts replacement and downtime.

[0009] Fourth, it optimizes the working environment and protects personnel health. This invention effectively reduces on-site dust concentration, improves working conditions, and meets relevant environmental protection and occupational health requirements.

[0010] Fifth, it offers significant overall economic benefits. This invention reduces production costs through water conservation, loss reduction, and other methods. Taking the Benxi Iron and Steel pre-selection operation area as an example, the annual comprehensive economic benefit after applying this solution can reach 2.647 million yuan.

[0011] Sixth, the structure is simple and reliable, facilitating widespread application. This invention employs non-contact detection, ensuring stable equipment operation, concise control logic, low modification costs, and compatibility with different types of belt conveyors, making it widely applicable. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the structure of an automatic spray dust suppression system based on belt load sensing as described in this invention.

[0013] Explanation of reference numerals in the attached figures: In the diagram: 1. Inductive proximity switch 2. Adjustable mounting bracket 3. PLC 4. Solenoid valve 5. Spray nozzle 6. Belt 7. Filter tank 8. Pressure reducing valve 9. Water supply pipeline Detailed Implementation

[0014] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0015] This invention relates to an automatic spray dust suppression system based on belt load sensing, primarily applied to belt conveyors in industries such as mining, metallurgy, and building materials. It is used for wet spraying to control dust generated during material transfer. The entire system is arranged around the belt 6 and includes detection components, control components, and a spray water supply system.

[0016] As shown in the figure, an adjustable mounting bracket 2 is installed below the belt 6, and an inductive proximity switch 1 is mounted on the bracket. The sensor probe is facing the lower surface of the belt 6. When the belt 6 is running unloaded, it is relatively straight, and the distance between it and the inductive proximity switch 1 is beyond the effective detection range. When the belt 6 is carrying material and sags, the distance between the two decreases, and the inductive proximity switch 1 can stably sense and output a switching signal.

[0017] The signal collected by the inductive proximity switch 1 is transmitted to the PLC3, which processes the signal. During equipment operation, the PLC3 has a built-in 30s to 60s delay anti-shake logic, which can filter out interference caused by belt 6 starting and stopping vibration and momentary sporadic material falling, thus preventing the spraying device from malfunctioning.

[0018] The spraying section consists of a solenoid valve 4, spray nozzles 5, a filter tank 7, and a pressure reducing valve 8, with each component connected sequentially via a water supply pipeline 9. Water first passes through the filter tank 7 to remove impurities, then the pressure reducing valve 8 stabilizes the water pressure before it flows through the solenoid valve 4. The solenoid valve 4 is controlled by the PLC 3 to either open or close the water path, and finally, the spray nozzles 5, located in the dust-generating area of ​​the conveyor belt 6, complete the targeted spraying operation.

[0019] This invention is also equipped with a corresponding control method. After the equipment is powered on, PLC3 enters standby mode. Inductive proximity switch 1 monitors the condition of belt 6 in real time and continuously outputs signals. PLC3 determines the belt load status in combination with the delay rule and synchronously controls the start and stop of the spraying, so that the spraying action is synchronized with the belt conveying condition.

[0020] The following embodiments are implemented based on the technical solution of the present invention, and provide detailed implementation methods and specific operation processes. However, the scope of protection of the present invention is not limited to the following embodiments.

[0021]

Example

[0022] In this embodiment, the corresponding equipment model is matched according to the on-site working conditions. The inductive proximity switch 1 is the OMRON E2E-X5ME1 model with a rated detection distance of 5mm; the PLC3 is the Siemens S7-200 SMART SR20 programmable controller; and the solenoid valve 4 is the IDEX brand stainless steel two-position two-way solenoid valve, which is suitable for harsh working conditions with high dust and continuous operation.

[0023] During on-site installation, an adjustable mounting bracket 2 is welded and fixed below the bearing section before the material unloading point of the belt conveyor. The inductive proximity switch 1 is then fixedly installed facing the lower surface of the belt 6. Under no-load conditions, the distance between the inductive proximity switch 1 and the belt 6 is adjusted to 7mm, which is greater than the rated detection distance of the sensor, and the system does not trigger the spraying action. When the belt 6 is carrying material, it undergoes sagging deformation due to the weight of the material, and the distance between the sensor and the belt 6 decreases to 4mm, which is less than the rated detection distance. The sensor can then stably output a load trigger signal.

[0024] To avoid false triggering caused by belt start-stop vibration and sporadic material drop, this embodiment sets the start-up delay and stop-down delay T1 and T2 of PLC3 to 45s, which is within a reasonable parameter range and effectively improves the stability and accuracy of system operation.

[0025] After the system upgrade was completed and put into actual production operation, the entire set of equipment operated stably and reliably, with the spray start and stop actions perfectly synchronized with the material conveying conditions of belt 6. The dust concentration on site decreased significantly after the upgrade, effectively mitigating the wear and corrosion of conveyor equipment such as belts, rollers, and motors caused by dust, thus reducing the probability of equipment failure and maintenance costs. According to actual on-site statistics, this upgrade can save 2.4083 million yuan in equipment spare parts costs and reduce downtime losses by 238,700 yuan annually, resulting in a total annual comprehensive economic benefit of 2.647 million yuan. The overall upgrade effect met the expected production and environmental protection requirements.

[0026] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An automatic sprinkler dust suppression system based on belt load sensing, characterized in that, The system includes a belt conveyor, a signal acquisition unit, a signal processing and control unit, and a spray execution unit. The signal acquisition unit comprises an inductive proximity switch and an adjustable mounting bracket. The adjustable mounting bracket is fixed to the frame of the belt conveyor, and the inductive proximity switch is mounted on the bracket with its probe facing the lower surface of the belt. The inductive proximity switch outputs different switching signals based on the change in belt sag under no-load and loaded conditions. The signal processing and control unit is a PLC, electrically connected to the inductive proximity switch, used to receive the switching signals, execute delayed anti-jitter logic, and output spray start / stop control commands. The spray execution unit includes a solenoid valve and spray nozzles. The solenoid valve is electrically connected to the PLC, and the spray nozzles are located in the dust-generating area of ​​the belt conveyor.

2. The automatic sprinkler dust suppression system based on belt load sensing according to claim 1, characterized in that, When the belt is unloaded, the distance between the belt and the inductive proximity switch is outside the effective detection range of the proximity switch; when the belt is carrying material and sags, the distance between the belt and the inductive proximity switch enters the effective detection range.

3. The automatic sprinkler dust suppression system based on belt load sensing according to claim 1, characterized in that, The delay time corresponding to the delay anti-jitter logic set inside the PLC is 30s to 60s.

4. The automatic sprinkler dust suppression system based on belt load sensing according to claim 1, characterized in that, The spraying actuator also includes a pressure reducing valve and a filter tank arranged sequentially along the water supply pipeline, with the pressure reducing valve and the filter tank located on the water inlet side of the solenoid valve.

5. A control method for an automatic sprinkler dust suppression system based on belt load sensing according to any one of claims 1 to 4, characterized in that... Includes the following steps: S1: The system is powered on and initialization is complete; the PLC enters standby mode. S2: The inductive proximity switch detects the sagging state of the belt in real time and continuously outputs the corresponding switching signal; S3: The PLC receives switch signals. If a load trigger signal is detected, it outputs a sprinkler start command after a delay and confirmation. If the trigger signal disappears, it outputs a sprinkler stop command after a delay and confirmation. S4: The solenoid valve opens or closes the water circuit according to the received command, controls the start and stop of the spray nozzles, and synchronizes the spraying action with the belt load status.

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