A high-power coal conveying site slag cleaning robot system and method

Abstract

This invention relates to a high-power coal conveying site slag removal robot system and method, belonging to the field of coal mine cleaning. It includes a high-power adaptive slag removal actuator for powerfully crushing and stripping hard, caking coal lumps and accumulated slag at the coal conveying site; a flexible hose and intelligent follow-up deployment mechanism for achieving closed-loop conveying of slag and preventing pipeline entanglement during robot movement; a high-negative-pressure gas-solid separation and collection device for source extraction and filtration of crushed slag and associated dust; and a multi-sensor fusion and central control unit, which communicates with the high-power adaptive slag removal actuator, the flexible hose and intelligent follow-up deployment mechanism, and the high-negative-pressure gas-solid separation and collection device to coordinate the actions of each module. This invention, through the coordinated control of robot-end slag crushing, flexible hose constant tension conveying, and negative-pressure gas-solid separation at the collection end, can solve the problems of difficult-to-clean clumps of accumulated slag, easy pipeline entanglement, and dust dispersion during the cleaning process at the coal conveying site.

Description

Technical Field

[0001] This invention relates to the field of coal mine cleaning, specifically to a high-power coal conveying site slag removal robot system and method. Background Technology

[0002] At bulk material conveying sites such as thermal power plants, coal washing plants, and port terminals, coal slag is prone to scattering, accumulating, and caking inside the coal conveyor belt corridors and transfer towers. Long-term slag accumulation not only corrodes equipment and increases the operating resistance of the coal conveyor belt, but also poses a safety hazard of spontaneous combustion.

[0003] Currently, slag removal at coal conveying sites relies heavily on manual labor, which presents problems such as high labor intensity, harsh working environments (high dust and noise), and high safety risks. In recent years, although some cleaning robots have emerged, they still face the following significant technical bottlenecks: Insufficient power to handle hard lumps: Existing robot actuators have low power and can only clean surface dust or loose coal slag, but are powerless against compacted or hard slag lumps.

[0004] Disorganized pipeline management: Sludge removal operations often require external power cables and sewage hoses. When the robot moves through narrow corridors, the hoses are prone to tangling, knotting, or being run over by the robot's tracks, severely limiting the robot's operating radius and autonomy.

[0005] Secondary dust pollution is serious: mechanical sweeping often raises a lot of dust, and the lack of effective source dust suppression and collection methods leads to further deterioration of the cleaning site environment.

[0006] Therefore, how to provide a high-power coal conveying site slag removal robot system and method has become a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0007] To address at least one technical problem in the prior art, the present invention provides a high-power coal conveying site slag removal robot system and method to solve the problems of difficult-to-clean slag clumps, easy entanglement of pipelines, and dust flying during the cleaning process at coal conveying sites.

[0008] To achieve the above objectives, the present invention provides a high-power coal conveying site slag removal robot system, comprising: a high-power adaptive slag removal actuator, a flexible hose and intelligent follow-up extension and retraction mechanism, a high negative pressure gas-solid separation and collection device, and a multi-sensor fusion and central control unit. The high-power adaptive slag removal actuator is used to powerfully crush and strip hard, caking coal blocks and slag at the coal conveying site. The flexible hose and intelligent follow-up extension mechanism are used to realize the closed-loop transportation of slag and the anti-entanglement management of pipelines during robot movement. The high negative pressure gas-solid separation and collection device is used to extract and filter the crushed slag and associated dust at the source. The multi-sensor fusion and central control unit are respectively connected to the high-power adaptive slag removal actuator, the flexible hose and intelligent follow-up extension mechanism, and the high negative pressure gas-solid separation and collection device to coordinate the actions of each module and realize the linkage control of powerful slag breaking, constant tension hose extension and retraction, instantaneous high negative pressure suction and two-stage gas-solid separation.

[0009] Furthermore, the high-power adaptive slag removal actuator includes: a cutting tooth milling drum, a frequency conversion drive and reduction assembly, and an adaptive suspension support; The surface of the cutting milling drum is uniformly distributed with highly wear-resistant carbide cutting teeth in a spiral shape, which are used to provide cutting and milling functions. The variable frequency drive and reduction assembly uses a variable frequency drive motor connected to a planetary gear reducer to provide variable high torque power output for the cutting milling drum. The adaptive suspension bracket is connected between the robot body and the cutting tooth milling drum. It integrates a bidirectional pressure sensor and a damping shock absorber. When the cutting tooth hits an extremely hard foreign object, the adaptive suspension bracket allows for a small yield displacement to protect the mechanical structure. At the same time, the bidirectional pressure sensor feeds back the resistance signal to the multi-sensor fusion and central control unit in real time.

[0010] Furthermore, the flexible hose and intelligent follow-up winding mechanism include a high-torque servo reel, a bidirectional cross screw cable feeder, and a tension detection guide wheel assembly; The high-torque servo reel is mounted on a base on one side of the high negative pressure gas-solid separation and collection device, and is used to wind and release the flexible conveying hose. The inlet of the flexible conveying hose corresponds to the outlet of the high-power adaptive slag removal actuator. The bidirectional cross screw cable guide is mechanically linked to the main shaft of the high-torque servo reel. When the high-torque servo reel winds up and unwinds the flexible material conveying hose, the fork of the bidirectional cross screw cable guide moves back and forth on the screw of the bidirectional cross screw cable guide, forcibly guiding the large-diameter, heavy-load flexible material conveying hose to be arranged layer by layer, tightly and neatly on the high-torque servo reel, preventing the flexible material conveying hose from stacking and getting stuck. The tension detection guide wheel assembly is installed at the release end of the flexible material conveying hose. It detects the tension on the flexible material conveying hose through displacement or spring deformation and outputs a continuous tension electrical signal.

[0011] Furthermore, the high negative pressure gas-solid separation and collection device includes a high-power Roots vacuum pump, a Venturi accelerator tube structure and a material conveying pipe, a primary cyclone separator and a secondary pulse bag filter. A high-power Roots vacuum pump provides a negative pressure air field. A Venturi accelerator tube structure is provided at the connection between the material conveying pipe and the cover of the slag removal actuator. One end of the Venturi accelerator tube structure is connected to the outlet of the flexible material conveying hose, and the other end is connected to the material conveying pipe to increase the local suction wind speed. The primary cyclone separator is connected to the conveying pipe. It uses the centrifugal force generated by the rotation of the airflow to first settle large particles of coal slag and heavy coal blocks into the bottom ash storage hopper. A rotary ash discharge valve is installed at the bottom of the ash storage hopper to achieve continuous ash discharge. The secondary pulse bag dust collector receives the dust-laden gas separated by the primary cyclone separator, performs high-precision filtration of fine dust, and finally discharges clean air.

[0012] Furthermore, the multi-sensor fusion and central control unit includes a 3D binocular vision camera, a torque sensor, a tension sensor, and a central PLC controller. The 3D binocular vision camera is used to acquire video data, the torque sensor is used to detect the torque of the variable frequency drive motor, and the tension sensor is used to detect the tension electrical signal of the tension detection guide wheel assembly. The 3D binocular vision camera, torque sensor, tension sensor, and bidirectional pressure sensor are all communicatively connected to the central PLC controller. The central PLC controller coordinates and controls the actions of each module by running a built-in slag removal expert control algorithm.

[0013] A method for on-site slag removal in high-power coal conveying, implemented using any of the above-mentioned high-power coal conveying on-site slag removal robot systems, includes the following steps: Step S1: Operating Condition Sensing and Analysis of Physical Characteristics of Accumulated Slag The slag removal robot enters the work area, and the front-end 3D binocular vision camera continuously scans the terrain ahead to obtain the three-dimensional shape data of the accumulated slag. By combining multi-sensor fusion with the central control unit, visual topography data and on-site working condition preset models are used to initially determine the physical state of the accumulated slag ahead. Step S2: Adaptive Parameter Matching and Heavy-Duty Slag Crushing Operation Conventional cutting mode: If the material is determined to be loose coal slag, the multi-sensor fusion and central control unit control the variable frequency drive motor to run at high speed and low torque, and the robot maintains normal speed to move forward; Heavy-duty slag breaking mode: If the visual judgment is that it is a high-hardness slab block, and the bidirectional pressure sensor in the adaptive suspension support detects that the impact resistance exceeds the safety threshold, the multi-sensor fusion and central control unit immediately reduce the chassis travel speed of the slag cleaning robot, simultaneously reduce the speed of the cutting tooth milling drum and greatly increase its output torque, and use the powerful milling action of the carbide cutting teeth to cut and peel off the coal slime slab. Step S3: Instantaneous high negative pressure combined with suction and two-stage gas-solid separation At the moment the heavy-load slag breaking mode is triggered, the multi-sensor fusion and central control unit send a surge load signal to the high negative pressure gas-solid separation and collection device. The high-power Roots vacuum pump enters the overload high-frequency operation state in advance, forming an instantaneous extremely high negative pressure in the casing of the slag removal actuator. Combined with the Venturi acceleration tube structure, a large amount of splashing debris and dust generated during the powerful crushing is immediately sucked into the conveying pipe, blocking the spread of dust from the source. The drawn-in mixture enters a primary cyclone separator for particle settling and a secondary pulse bag filter for gas purification. Step S4: Constant tension follow-up expansion and contraction and automatic pipeline alignment Throughout the entire process of the slag removal robot moving forward, backward, or turning, the flexible hose and the intelligent follow-up extension and retraction mechanism enter a constant tension cruise state. Active cable release: When the slag removal robot moves forward and away, the tension detection guide wheel group detects that the tension has increased and exceeded the set upper limit threshold. The high torque servo reel starts to rotate forward and actively releases the flexible conveying hose. Automatic winding and straightening: When the cleaning robot retreats or stops, causing the tension to decrease and fall below the set lower threshold, the high-torque servo reel starts to reverse and tighten the flexible material conveying hose; during this process, the bidirectional cross screw wire guide operates synchronously, guiding the flexible material conveying hose to be evenly laid on the high-torque servo reel.

[0014] The beneficial effects of this invention are as follows: 1. Overcoming the challenge of cleaning hard clumps: By adopting a high-power actuator that is adaptively adjusted based on the physical characteristics of the slag, the limitation of traditional slag cleaning robots that can only sweep but not break is broken, and the slag cleaning efficiency and thoroughness are greatly improved.

[0015] 2. Solving the problem of pipeline entanglement: The innovative design of the robot-hose-collection device collaborative layout and follow-up retraction mechanism enables the robot to carry out long-distance, highly flexible and continuous operations in complex industrial corridors.

[0016] 3. Achieve green and environmentally friendly slag removal: The deeply integrated negative pressure suction and gas-solid separation system enables immediate crushing and suction, fundamentally blocking secondary dust generation and greatly improving the working environment at the coal conveying site. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a structural block diagram of the slag removal actuator of the present invention; Figure 3 This is a schematic diagram of the flexible hose and intelligent follow-up extension and retraction mechanism of the present invention; Figure 4 This is a structural block diagram of the flexible hose and intelligent follow-up extension and retraction mechanism of the present invention; Figure 5 This is a schematic diagram of the high negative pressure gas-solid separation and collection device of the present invention; Figure 6 This is a structural block diagram of the high negative pressure gas-solid separation and collection device of the present invention; Figure 7 This is a structural block diagram of the multi-sensor fusion and central control unit of the present invention; Figure 8 This is a flowchart of the method of the present invention.

[0018] In the figure: 1-High torque servo reel; 2-Two-way cross screw cable guide; 3-Tension detection guide wheel assembly; 4-Flexible conveying hose; 5-High power Roots vacuum pump; 6-Venturi accelerator tube structure; 7-Conveying pipe; 8-First-stage cyclone separator; 9-Second-stage pulse bag dust collector; 10-Ash hopper; 11-Rotary ash discharge valve. Detailed Implementation

[0019] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] It should be noted that the terms "first," "second," etc., 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 for the embodiments of this application described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus 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 apparatus.

[0021] In this application, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "middle," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing this application and its embodiments, and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation.

[0022] Furthermore, in addition to indicating location or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in some cases to indicate a certain dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0023] Furthermore, the terms "installation," "setup," "equipped with," "connection," "linking," and "socketing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral structure; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium, or an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0024] To achieve the above objectives, refer to Figure 1 The present invention provides a high-power coal conveying site slag removal robot system, characterized in that it includes: a high-power adaptive slag removal actuator, a flexible hose and intelligent follow-up extension mechanism, a high negative pressure gas-solid separation and collection device, and a multi-sensor fusion and central control unit. The high-power adaptive slag removal actuator is used to powerfully crush and strip hard, caking coal blocks and slag at the coal conveying site. The flexible hose and intelligent follow-up extension mechanism are used to realize the closed-loop transportation of slag and the anti-entanglement management of pipelines during robot movement. The high negative pressure gas-solid separation and collection device is used to extract and filter the crushed slag and associated dust at the source. The multi-sensor fusion and central control unit are respectively connected to the high-power adaptive slag removal actuator, the flexible hose and intelligent follow-up extension mechanism, and the high negative pressure gas-solid separation and collection device to coordinate the actions of each module and realize the linkage control of powerful slag breaking, constant tension hose extension and retraction, instantaneous high negative pressure suction and two-stage gas-solid separation.

[0025] refer to Figure 2 The high-power adaptive slag removal actuator includes: a cutting tooth milling drum, a frequency conversion drive and reduction assembly, and an adaptive suspension support; The surface of the cutting milling drum is uniformly distributed with highly wear-resistant carbide cutting teeth in a spiral shape, which are used to provide cutting and milling functions. The variable frequency drive and reduction assembly uses a variable frequency drive motor connected to a planetary gear reducer to provide variable high torque power output for the cutting milling drum. The adaptive suspension bracket is connected between the robot body and the cutting tooth milling drum. It integrates a bidirectional pressure sensor and a damping shock absorber. When the cutting tooth hits an extremely hard foreign object, the adaptive suspension bracket allows for a small yield displacement to protect the mechanical structure. At the same time, the bidirectional pressure sensor feeds back the resistance signal to the multi-sensor fusion and central control unit in real time.

[0026] This invention employs a milling drum with helically distributed carbide cutting teeth, combined with a variable frequency motor and a planetary gear reducer (providing high torque and low speed output). It can powerfully cut and peel away heavily compacted coal slurry with a thickness exceeding 15cm, producing slag particles smaller than 3cm after cutting. This completely overcomes the power bottleneck of traditional robots, which can only sweep up surface dust and cannot break hard slurries. The adaptive suspension support integrates bidirectional pressure sensors and damping shock absorbers. When the cutting teeth encounter extremely hard foreign objects (such as iron or stones), it allows a maximum retraction displacement of 50mm, effectively preventing mechanical structural breakage. Simultaneously, it provides real-time resistance signal feedback, providing a basis for subsequent parameter adjustments. Combined with multi-sensor fusion and a central control unit, it can automatically switch between high-speed, low-torque and low-speed, high-torque modes based on the hardness of the slurry, optimizing energy consumption while ensuring slurry breaking effect and avoiding ineffective idling or overheating due to overload.

[0027] refer to Figure 3 and Figure 4 The flexible hose and intelligent follow-up winding mechanism include a high-torque servo reel 1, a bidirectional cross screw cable feeder 2, and a tension detection guide wheel assembly 3; The high-torque servo reel 1 is mounted on a base on one side of the high negative pressure gas-solid separation and collection device, and is used to wind and release the flexible conveying hose 4. The inlet of the flexible conveying hose 4 corresponds to the outlet of the high-power adaptive slag removal actuator. The bidirectional cross screw cable guide 2 is mechanically linked to the main shaft of the high-torque servo reel 1. When the high-torque servo reel 1 winds up and unwinds the flexible material conveying hose 4, the fork of the bidirectional cross screw cable guide 2 reciprocates on the screw of the bidirectional cross screw cable guide 2, forcibly guiding the large-diameter, heavy-load flexible material conveying hose 4 to be arranged layer by layer, tightly and neatly on the high-torque servo reel, preventing the flexible material conveying hose from stacking and jamming. The tension detection guide wheel assembly 3 is installed at the release end of the flexible material conveying hose 4. It detects the tension on the flexible material conveying hose through displacement or spring deformation and outputs a continuous tension electrical signal.

[0028] This invention uses a tension-detecting guide wheel assembly to sense the hose tension in real time, combined with a constant tension closed-loop control of the servo reel, to achieve active forward cable release and automatic backward cable reeling. This keeps the 150mm large-diameter heavy-duty conveying hose in a state of slight tension suspension, preventing the hose from dragging on the ground, being crushed by the track, or getting tangled and stuck, greatly expanding the robot's effective operating radius in narrow corridors. A bidirectional cross-screw cable guide is mechanically linked to the reel spindle, with a fork reciprocating on the screw, forcibly guiding the hose to be arranged layer by layer, tightly and neatly on the reel, preventing stacking jams or tangling, ensuring smooth and reliable release and reeling operations, especially suitable for reciprocating slag removal operations requiring frequent forward / backward movement. It provides precise force data on the flexible conveying hose for multi-sensor fusion and the central control unit, upgrading pipeline management from passive protection to active follow-up, a key support for the autonomous movement of the slag removal robot.

[0029] refer to Figure 5 and Figure 6 The high negative pressure gas-solid separation and collection device includes a high-power Roots vacuum pump 5, a Venturi accelerator tube structure 6 and a material conveying pipe 7, a first-stage cyclone separator 8 and a second-stage pulse bag dust collector 9. A high-power Roots vacuum pump 5 provides a negative pressure air field. A Venturi accelerator tube structure 6 is provided at the connection between the material conveying pipe 7 and the cover of the slag removal actuator. One end of the Venturi accelerator tube structure 6 is connected to the outlet of the flexible material conveying hose, and the other end is connected to the material conveying pipe 7 to increase the local suction wind speed. The primary cyclone separator 8 is connected to the conveying pipe 7. It uses the centrifugal force generated by the rotation of the airflow to first settle large particles of coal slag and heavy coal blocks into the bottom ash storage hopper 10. A rotary ash discharge valve 11 is installed at the bottom of the ash storage hopper 10 to achieve continuous ash discharge. The secondary pulse bag dust collector 9 receives the dust-laden gas separated by the primary cyclone separator 8, performs high-precision filtration of fine dust, and finally discharges clean air.

[0030] This invention utilizes a high-power Roots vacuum pump combined with a Venturi accelerator tube structure to create an instantaneous extremely high negative pressure within the casing of the slag-cleaning actuator, increasing the local suction velocity to over 30 m / s. This immediately draws the large amount of splashed debris and dust generated during the powerful crushing process into the conveying pipe, blocking dust diffusion at the source and preventing environmental degradation at the cleaning site. The primary cyclone separator uses centrifugal force to settle over 95% of large coarse particles, which fall into the ash storage hopper and are continuously discharged through a rotary ash discharge valve, reducing the burden on subsequent filtration. The secondary pulse bag filter performs high-precision filtration of fine dust, ultimately releasing clean air with a dust-free exhaust port, meeting environmental protection and occupational health requirements. At the moment the heavy-load slag-crushing mode is triggered, the system can pre-increase the vacuum pump frequency to an overload state, ensuring a simultaneous increase in suction capacity during peak dust periods, achieving precise timing matching between slag crushing and suction, and preventing dust escape.

[0031] refer to Figure 7The multi-sensor fusion and central control unit includes a 3D binocular vision camera, a torque sensor, a tension sensor, and a central PLC controller. The 3D binocular vision camera is used to acquire video data, the torque sensor is used to detect the torque of the variable frequency drive motor, and the tension sensor is used to detect the tension electrical signal of the tension detection guide wheel assembly. The 3D binocular vision camera, torque sensor, tension sensor, and bidirectional pressure sensor are all communicatively connected to the central PLC controller. The central PLC controller coordinates and controls the actions of each module by running a built-in slag removal expert control algorithm.

[0032] This invention uses a 3D binocular vision camera to acquire the three-dimensional morphology of accumulated slag. Combined with a pre-set on-site model, it preliminarily determines the physical state, providing a data foundation for parameter matching. By integrating visual data, motor torque, hose tension, and impact resistance signals, and running a slag-cleaning expert control algorithm through a central PLC controller, it achieves more reliable obstacle recognition and operation mode judgment than a single sensor, avoiding false triggers or missed judgments. It can simultaneously adjust the chassis travel speed, milling drum speed / torque, vacuum pump negative pressure, and servo reel winding and unwinding actions, enabling parallel collaboration of multiple actuators. This ensures synchronized response of all modules during heavy-duty slag breaking, achieving optimal operational results through tight hardware and software coupling.

[0033] refer to Figure 8 The present invention also provides a method for a high-power coal conveying on-site slag removal machine, comprising the following steps: Step S1: Operating Condition Sensing and Analysis of Physical Characteristics of Accumulated Slag The slag removal robot enters the work area, and the front-end 3D binocular vision camera continuously scans the terrain ahead to obtain the three-dimensional morphological data of the slag (to calculate the thickness and volume). Multi-sensor fusion and central control unit combine visual shape data with on-site working condition preset model to preliminarily determine the physical state of the slag accumulation ahead (e.g., surface dust, loose coal slag or compacted clumps). Step S2: Adaptive Parameter Matching and Heavy-Duty Slag Crushing Operation Conventional cutting mode: If the material is determined to be loose coal slag, the multi-sensor fusion and central control unit control the variable frequency drive motor to run at high speed and low torque, and the robot maintains normal speed to move forward; Heavy-duty slag breaking mode (PID closed-loop control): If the visual judgment is that it is a high-hardness slab block, and the bidirectional pressure sensor in the adaptive suspension support detects that the impact resistance exceeds the safety threshold, the multi-sensor fusion and central control unit immediately reduce the chassis travel speed of the slag cleaning robot, simultaneously reduce the speed of the cutting tooth milling drum and greatly increase its output torque, and use the powerful milling action of the carbide cutting teeth to cut and peel off the coal slime slab. Step S3: Instantaneous high negative pressure combined with suction and two-stage gas-solid separation At the moment the heavy-load slag breaking mode is triggered, the multi-sensor fusion and central control unit send a surge load signal to the high negative pressure gas-solid separation and collection device. The high-power Roots vacuum pump enters the overload high-frequency operation state in advance (maintained for 3 to 5 seconds), forming an instantaneous extremely high negative pressure in the casing of the slag removal actuator. Combined with the Venturi acceleration tube structure, a large amount of splashing debris and dust generated during the powerful crushing is immediately sucked into the conveying pipe, blocking the spread of dust from the source. The drawn-in mixture enters a primary cyclone separator for particle settling and a secondary pulse bag filter for gas purification. Step S4: Constant tension follow-up expansion and contraction and automatic pipeline alignment Throughout the entire process of the slag removal robot moving forward, backward, or turning, the flexible hose and the intelligent follow-up extension and retraction mechanism enter a constant tension cruise state. Active cable release: When the slag removal robot moves forward and away, the tension detection guide wheel group detects that the tension has increased and exceeded the set upper limit threshold. The high torque servo reel starts to rotate forward and actively releases the flexible conveying hose. Automatic winding and straightening: When the cleaning robot retreats or stops, causing the tension to decrease and fall below the set lower threshold, the high-torque servo reel starts to reverse and tighten the flexible material conveying hose. During this process, the bidirectional cross screw cable guide operates synchronously, guiding the flexible material conveying hose to be evenly laid on the high-torque servo reel. This step ensures that the flexible material conveying hose always maintains a slightly tensioned, suspended state, avoiding dragging, friction, or being run over by vehicles.

[0034] Example

[0035] This embodiment takes a typical harsh working condition as an example, where a coal conveyor belt corridor had a serious coal leakage, and after long-term water accumulation and trampling by people, a 3-meter-long and approximately 15-cm-thick area of ​​heavily compacted and caking coal sludge was formed.

[0036] This embodiment provides a method for a high-power coal conveying on-site slag removal machine, including the following steps: Step 1: Initial System Deployment and Hardware Configuration Robot end: Employs an explosion-proof tracked mobile chassis. A cutting-tooth milling roller is mounted at the front of the chassis, driven by a 15kW variable frequency explosion-proof motor via a 1:40 planetary gear reducer. Both ends of the cutting-tooth milling roller are connected to the chassis via adaptive suspension brackets. These brackets are embedded with bidirectional pressure sensors with a range of 0-2000N and high-strength compression spring dampers.

[0037] Pipeline end: A wear-resistant flexible polyurethane steel wire hose with an inner diameter of 150mm is used to connect the robot to the collection device at the rear. The collection device is equipped with a 1.2-meter diameter high-torque servo reel. A bidirectional cross screw cable guide is installed in front of the high-torque servo reel. The fork of the bidirectional cross screw cable guide moves back and forth on the screw of the bidirectional cross screw cable guide as the high-torque servo reel rotates. A tension detection guide wheel group is installed at the release end of the flexible conveying hose.

[0038] Collection end: The negative pressure power source adopts a 22kW high-power Roots vacuum pump, a series tangential air inlet primary cyclone separator and a secondary pulse bag dust collector with 60 built-in membrane filter bags.

[0039] Step Two: Operating Condition Perception and Analysis

[0040] After the system is started, the slag removal robot moves within the coal conveying corridor at a cruising speed of 0.5 m / s. The 3D binocular vision camera at the front end scans the terrain ahead in real time. When it detects a road surface bulge 5 meters ahead, the multi-sensor fusion and central control unit (PLC) calculates the slag thickness to be 15 cm based on point cloud data and automatically determines that the area ahead is a high-thickness compacted zone.

[0041] Step 3: Obstacle Detection Buffer and Adaptive Powerful Slag Breaking

[0042] The slag removal robot moves to the slagging area, and the cutting tooth milling drum cuts into and compacts the coal slurry.

[0043] At this point, the hardware kicks in: the springs inside the adaptive suspension bracket are compressed, providing a maximum 50mm yield stroke to prevent mechanical breakage, and the bidirectional pressure sensor instantly detects a surge in reverse impact force to 800N, exceeding the preset normal threshold of 400N.

[0044] The multi-sensor fusion and central control unit immediately trigger the heavy-duty slag breaking mode: the forward speed of the tracked chassis is reduced sharply to 0.1 m / s; at the same time, the frequency converter is controlled to reduce the speed of the cutting tooth milling drum from 300 r / min to 100 r / min, and the output torque is increased to 150% of the rated value. The carbide cutting teeth on the cutting tooth milling drum, like a road milling machine, powerfully cut and crush the hard coal into slag with a diameter of less than 3 cm.

[0045] Step 4: Instantaneous high negative pressure linkage and zero dust collection

[0046] At the same instant the heavy-duty slag breaking mode is triggered, that is, one second before the cutting tooth milling drum will generate a large amount of dust, the multi-sensor fusion and central control unit sends a surge signal to the remote collection system via the bus.

[0047] At this point, the hardware kicks in: the Roots vacuum pump frequency converter immediately increases the frequency, instantly raising the negative pressure of the pipeline from the usual -15kPa to -30kPa and maintaining it for 5 seconds. The Venturi accelerator tube structure at the front of the casing increases the local suction velocity to over 30m / s. The flying coal chunks and the explosively dispersed ultra-fine coal powder are instantly sucked into the conveying pipe. Subsequently, more than 95% of the large particles of coarse slag are centrifuged and fall off in the primary cyclone separator, and the remaining micro-dust is filtered with high precision (0.5 microns) in the secondary bag filter, achieving a dust-free exhaust port.

[0048] Step 5: Fine-tuning and standardizing the constant tension of the pipeline

[0049] When the slag removal robot operates back and forth at a slow speed of 0.1m / s in the aforementioned 3-meter-long compacted area, the flexible hose and intelligent follow-up extension and retraction mechanism are constantly adjusted with constant tension throughout the process.

[0050] First, the active line release is initiated. When the slag-cleaning robot moves forward at a micro distance and the tension detection guide wheel group experiences a tension exceeding the upper limit threshold of 30N, the servo reel rotates forward at an extremely slow angular velocity to release the flexible material conveying hose, stopping when the tension drops back to 20N.

[0051] Secondly, there's the automatic cable reel-in and anti-tangling feature. When the cleaning robot reverses and re-sweeps, causing the hose to loosen and the tension to drop below the lower threshold of 10N, the servo reel immediately reverses to tighten it. During this process, the bidirectional cross screw cable guide rotates accordingly, and its fork forcibly guides the retracted 150mm thick hose to be neatly and evenly wound in a single layer onto the high-torque servo reel. Throughout the process, it ensures that the hose maintains a slight tension suspension, never touching the ground or being crushed by the track.

[0052] In summary, based on the above examples of cleaning heavily caked coal sludge up to 15cm thick, it can be seen that in actual operation, when a sudden resistance of up to 800N is detected, the present invention can not only protect the hardware through the adaptive suspension support retraction, but also autonomously trigger the heavy-load mode, stimulating 150% overload torque to achieve powerful slag breaking. At the moment of cutting and breaking the sludge, the system precisely triggers a -30kPa overload high negative pressure suction, combined with two-stage gas-solid separation, completely avoiding dust explosions caused by heavy milling. At the same time, during the low-speed advancement and reversing sweeping of the sludge cleaning robot, the high-torque servo reel, with its constant tension closed-loop and cross-wiring mechanism set in the 10N to 30N range, always maintains the micro-tension suspension of the 150mm heavy-duty thick pipe. Through precise hardware and software coordination, this system perfectly realizes the comprehensive effects of efficient hard sludge breaking, pipeline interference prevention, and dust-free collection under extreme working conditions, possessing extremely strong industrial practical value.

[0053] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the technical scope of the present invention. Therefore, any minor modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A high-power coal conveying on-site slag removal robot system, characterized in that, include: High-power adaptive slag removal actuator, flexible hose and intelligent follow-up extension and retraction mechanism, high negative pressure gas-solid separation and collection device, and multi-sensor fusion and central control unit; The high-power adaptive slag removal actuator is used to powerfully crush and strip hard, caking coal blocks and slag at the coal conveying site. The flexible hose and intelligent follow-up extension mechanism are used to realize the closed-loop transportation of slag and the anti-entanglement management of pipelines during robot movement. The high negative pressure gas-solid separation and collection device is used to extract and filter the crushed slag and associated dust at the source. The multi-sensor fusion and central control unit are respectively connected to the high-power adaptive slag removal actuator, the flexible hose and intelligent follow-up extension mechanism, and the high negative pressure gas-solid separation and collection device to coordinate the actions of each module and realize the linkage control of powerful slag breaking, constant tension hose extension and retraction, instantaneous high negative pressure suction and two-stage gas-solid separation.

2. The high-power coal conveying on-site slag removal robot system as described in claim 1, characterized in that, The high-power adaptive slag removal actuator includes: a cutting tooth milling drum, a frequency conversion drive and reduction assembly, and an adaptive suspension support; The surface of the cutting milling drum is uniformly distributed with highly wear-resistant carbide cutting teeth in a spiral shape, which are used to provide cutting and milling functions. The variable frequency drive and reduction assembly uses a variable frequency drive motor connected to a planetary gear reducer to provide variable high torque power output for the cutting milling drum. The adaptive suspension bracket is connected between the robot body and the cutting tooth milling drum. It integrates a bidirectional pressure sensor and a damping shock absorber. When the cutting tooth hits an extremely hard foreign object, the adaptive suspension bracket allows for a small yield displacement to protect the mechanical structure. At the same time, the bidirectional pressure sensor feeds back the resistance signal to the multi-sensor fusion and central control unit in real time.

3. The high-power coal conveying on-site slag removal robot system as described in claim 2, characterized in that, The flexible hose and intelligent follow-up winding mechanism include a high-torque servo reel, a bidirectional cross screw cable feeder, and a tension detection guide wheel assembly. The high-torque servo reel is mounted on a base on one side of the high negative pressure gas-solid separation and collection device, and is used to wind and release the flexible conveying hose. The inlet of the flexible conveying hose corresponds to the outlet of the high-power adaptive slag removal actuator. The bidirectional cross screw cable guide is mechanically linked to the main shaft of the high-torque servo reel. When the high-torque servo reel winds up and unwinds the flexible material conveying hose, the fork of the bidirectional cross screw cable guide moves back and forth on the screw of the bidirectional cross screw cable guide, forcibly guiding the large-diameter, heavy-load flexible material conveying hose to be arranged layer by layer, tightly and neatly on the high-torque servo reel, preventing the flexible material conveying hose from stacking and getting stuck. The tension detection guide wheel assembly is installed at the release end of the flexible material conveying hose. It detects the tension on the flexible material conveying hose through displacement or spring deformation and outputs a continuous tension electrical signal.

4. The high-power coal conveying on-site slag removal robot system as described in claim 3, characterized in that, The high negative pressure gas-solid separation and collection device includes a high-power Roots vacuum pump, a Venturi accelerator tube structure and a material conveying pipe, a primary cyclone separator and a secondary pulse bag filter. A high-power Roots vacuum pump provides a negative pressure air field. A Venturi accelerator tube structure is provided at the connection between the material conveying pipe and the cover of the slag removal actuator. One end of the Venturi accelerator tube structure is connected to the outlet of the flexible material conveying hose, and the other end is connected to the material conveying pipe to increase the local suction wind speed. The primary cyclone separator is connected to the conveying pipe. It uses the centrifugal force generated by the rotation of the airflow to first settle large particles of coal slag and heavy coal blocks into the bottom ash storage hopper. A rotary ash discharge valve is installed at the bottom of the ash storage hopper to achieve continuous ash discharge. The secondary pulse bag dust collector receives the dust-laden gas separated by the primary cyclone separator, performs high-precision filtration of fine dust, and finally discharges clean air.

5. The high-power coal conveying on-site slag removal robot system as described in claim 4, characterized in that, The multi-sensor fusion and central control unit includes a 3D binocular vision camera, a torque sensor, a tension sensor, and a central PLC controller. The 3D binocular vision camera is used to acquire video data, the torque sensor is used to detect the torque of the variable frequency drive motor, and the tension sensor is used to detect the tension electrical signal of the tension detection guide wheel assembly. The 3D binocular vision camera, torque sensor, tension sensor, and bidirectional pressure sensor are all communicatively connected to the central PLC controller. The central PLC controller coordinates and controls the actions of each module by running a built-in slag removal expert control algorithm.

6. A method for on-site slag removal in high-power coal conveying, characterized in that, This is achieved through the high-power coal conveying on-site slag removal robot system as described in any one of claims 1-5, including the following steps: Step S1: Operating Condition Sensing and Analysis of Physical Characteristics of Accumulated Slag The slag removal robot enters the work area, and the front-end 3D binocular vision camera continuously scans the terrain ahead to obtain the three-dimensional shape data of the accumulated slag. By combining multi-sensor fusion with the central control unit, visual topography data and on-site working condition preset models are used to initially determine the physical state of the accumulated slag ahead. Step S2: Adaptive Parameter Matching and Heavy-Duty Slag Crushing Operation Conventional cutting mode: If the material is determined to be loose coal slag, the multi-sensor fusion and central control unit control the variable frequency drive motor to run at high speed and low torque, and the robot maintains normal speed to move forward; Heavy-duty slag breaking mode: If the visual judgment is that it is a high-hardness slab block, and the bidirectional pressure sensor in the adaptive suspension support detects that the impact resistance exceeds the safety threshold, the multi-sensor fusion and central control unit immediately reduce the chassis travel speed of the slag cleaning robot, simultaneously reduce the speed of the cutting tooth milling drum and greatly increase its output torque, and use the powerful milling action of the carbide cutting teeth to cut and peel off the coal slime slab. Step S3: Instantaneous high negative pressure combined with suction and two-stage gas-solid separation At the moment the heavy-load slag breaking mode is triggered, the multi-sensor fusion and central control unit send a surge load signal to the high negative pressure gas-solid separation and collection device. The high-power Roots vacuum pump enters the overload high-frequency operation state in advance, forming an instantaneous extremely high negative pressure in the casing of the slag removal actuator. Combined with the Venturi acceleration tube structure, a large amount of splashing debris and dust generated during the powerful crushing is immediately sucked into the conveying pipe, blocking the spread of dust from the source. The drawn-in mixture enters a primary cyclone separator for particle settling and a secondary pulse bag filter for gas purification. Step S4: Constant tension follow-up expansion and contraction and automatic pipeline alignment Throughout the entire process of the slag removal robot moving forward, backward, or turning, the flexible hose and the intelligent follow-up extension and retraction mechanism enter a constant tension cruise state. Active cable release: When the slag removal robot moves forward and away, the tension detection guide wheel group detects that the tension has increased and exceeded the set upper limit threshold. The high torque servo reel starts to rotate forward and actively releases the flexible conveying hose. Automatic winding and straightening: When the cleaning robot retreats or stops, causing the tension to decrease and fall below the set lower threshold, the high-torque servo reel starts to reverse and tighten the flexible material conveying hose; during this process, the bidirectional cross screw wire guide operates synchronously, guiding the flexible material conveying hose to be evenly laid on the high-torque servo reel.

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