A super processing capacity intelligent dry separator and a sorting control program algorithm flow

Abstract

The application discloses a large processing capacity intelligent dry separator and a sorting control program algorithm process, which comprises a full protection shell, and a vibration distributor, a belt conveying system, an intelligent identification system and an intelligent blowing execution system are arranged in the full protection shell in sequence; an electric control system, a software platform, a high-pressure gas supply unit and a dust removal ventilation unit are also provided; the vibration distributor is installed on the feeding side of the full protection shell, a discharge port of the vibration distributor is connected with a feeding end of the belt conveying system, the intelligent identification system is arranged in the middle section of the belt conveying system, and the intelligent blowing execution system is installed on the head discharge side of the belt conveying system; the high-pressure gas supply unit is connected with the intelligent blowing execution system through pipelines, and the dust removal ventilation unit is connected with the upper part of the full protection shell through pipelines. The application is used to solve the technical problem that it is difficult to meet the high-capacity sorting in a narrow workshop space under the premise of ensuring the sorting precision and the equipment service life.

Description

Technical Field

[0001] This invention belongs to the field of dry separator technology, and particularly relates to an intelligent dry separator with ultra-high processing capacity and the algorithm flow of the sorting control program. Background Technology

[0002] Traditionally, the sorting of lump coal involves manual picking to remove gangue and debris, relying on continuous and repetitive manual labor. However, with large material volumes and numerous impurities, the sorting effect is easily affected by human factors such as worker fatigue and lack of concentration, making it impossible to consistently guarantee the removal rate of gangue and debris. Insufficiently removed gangue increases the power consumption of the lump coal crusher, equipment wear and tear, and maintenance workload, increasing the production load and processing costs of the downstream washing and beneficiation system. Simultaneously, the gangue continuously wears down pipelines, chutes, and other conveying equipment, and the large pieces of gangue, when crushed and exposed to water, produce a large amount of secondary coal slime, further burdening the coal slime water system.

[0003] Manual coal preparation operations are noisy and dusty, resulting in high labor intensity for workers and significant personal safety and occupational health hazards. Recruiting workers for these positions is becoming increasingly difficult. Furthermore, this process requires a large number of on-site workers, leading to low overall production efficiency, which contradicts the trend of intelligent coal preparation plant development.

[0004] To replace manual sorting, the industry has gradually developed intelligent dry separators. These machines employ dual-source recognition technology combining X-ray and CCD images, integrating coal quality characteristic analysis models and big data analysis to digitally distinguish between coal and gangue. They rely on high-pressure airflow to complete automatic sorting, achieving a higher sorting accuracy than manual sorting. Existing intelligent dry separators are suitable for sorting particle sizes of 50-300mm. According to the group standard T / CCT012-2023 "Design Specification for Dry Coal Preparation Engineering," the processing capacity per meter of conveyor belt width within this particle size range is 100t / h.

[0005] With the maturity of dry coal preparation technology, intelligent dry separators have become the mainstream equipment for replacing manual sorting in aging screening workshops. However, existing screening workshops are old and have limited internal installation space. At the same time, downstream coal washing plants are continuously increasing their capacity, and the market is placing higher demands on the unit bandwidth processing capacity of intelligent dry separators. If two conventional intelligent dry separators are installed in the existing workshop, the space width cannot meet the installation requirements, while a single machine is difficult to match production needs. This hinders the intelligent transformation of screening workshops and restricts the improvement of coal preparation plant economic efficiency. The industry urgently needs intelligent dry separators with large single-unit processing capacity.

[0006] Currently, the belt speed of mainstream intelligent dry separators on the market is generally 2-2.5 m / s. Representative manufacturers include Tangshan Shenzhou, Tianjin Meiteng, and Beijing Hollister. Under the condition of 50-300 mm sorting particle size, the processing capacity per meter of belt width is 100 t / h. There are currently no intelligent dry separators in the industry with belt speeds exceeding 3 m / s and ultra-large processing capacity.

[0007] The existing intelligent dry separator belts operate at low speeds, limiting the overall processing capacity of the equipment. Simply increasing the belt speed would be constrained by multiple factors, including belt lifespan, detector data processing rate, material conveying stability, software calculation speed, and the response and execution capabilities of the blowing mechanism. This would make it impossible to achieve high-volume production while ensuring sorting accuracy and equipment lifespan, and would be difficult to meet the market demand for high-capacity sorting in confined workshop spaces. Summary of the Invention

[0008] To address the above problems, this invention provides an intelligent dry separator with ultra-high processing capacity and an algorithm flow for the sorting control program.

[0009] To achieve the above objectives, the present invention provides an intelligent dry separator with ultra-high processing capacity, comprising a fully protective shell. Along the material conveying flow direction, a vibrating material distributor, a belt conveyor system, an intelligent identification system, and an intelligent jet-blowing execution system are sequentially arranged inside the fully protective shell. It is also equipped with an electrical control system, a software platform, a high-pressure air supply unit, and a dust removal and ventilation unit. The vibrating material distributor is installed on the feed side of the fully protective shell, and its discharge port is connected to the feed end of the belt conveyor system. The intelligent identification system is located in the middle of the belt conveyor system, and the intelligent jet-blowing execution system is installed on the discharge side of the head of the belt conveyor system. The high-pressure air supply unit is connected to the intelligent jet-blowing execution system via pipelines, and the dust removal and ventilation unit is connected to the upper part of the fully protective shell via pipelines. The electrical control system and software platform are electrically connected to the belt conveyor system, the intelligent identification system, the intelligent jet-blowing execution system, and the high-pressure air supply unit, respectively.

[0010] Optionally, a sorting platform is installed inside the fully protective housing. The belt conveyor system is installed entirely on the sorting platform inside the fully protective housing, including a seamless annular conveyor belt, a drive roller, a redirecting roller, a variable frequency speed control motor, idlers, pallets, and a manual screw jack tensioning device. The tail of the conveyor belt surrounds the drive roller, and the head surrounds the redirecting roller. The drive roller is driven by the variable frequency speed control motor, and the variable frequency speed control motor is electrically connected to the frequency converter of the electrical control system. High-precision special idlers are arranged below the conveyor belt. The idlers in the middle section corresponding to the detection area of ​​the intelligent identification system are replaced with pallets, which are in close contact with the lower surface of the conveyor belt. The tail of the seamless annular conveyor belt is tensioned by a jack.

[0011] Optionally, the total length of the conveyor belt is 8.5m, the diameter of the drive drum is 500mm, and the diameter of the redirecting drum is 320mm; the speed adjustment range of the conveyor belt is 3-3.75m / s; the spacing between the idlers is 300mm, and the allowable circular runout of the idlers is less than 0.2mm.

[0012] Optionally, the intelligent identification system is fixed to one side of the sorting platform and includes an X-ray emitting device and a radiation receiving device. The X-ray emitting device is installed in a sealed explosion-proof box with a lead liner. The X-ray emitting device integrates a high-voltage power supply, an X-ray tube, and a filament power supply. The filament power supply is electrically connected to the X-ray tube filament, and the high-voltage output terminal of the high-voltage power supply is connected to the filament and the anode target, respectively. The radiation receiving device is a detector, which is arranged below the tray, between the upper and lower surfaces of the conveyor belt, and vertically opposite to the beam outlet of the X-ray emitting device above. The detector includes a digital board and an analog board. Each analog board has multiple detector channels. The detectors are arranged at equal intervals. The detector is equipped with a high-response detector card with a data transmission rate of 600Mbps. The detector has a gigabit Ethernet, fiber optic, or camera connection interface and is connected to the host.

[0013] Optionally, the intelligent jetting execution system is installed on the material drop side of the head redirecting roller of the belt conveyor system, including a jetting valve, a double-row matrix high-pressure nozzle, a jetting control board, a jetting drive board, and a high-frequency solenoid valve; the high-pressure air supply unit includes an air compressor and a high-pressure gas storage tank, the air compressor is connected to the high-pressure gas storage tank through a pipeline, and the high-pressure gas storage tank is connected to the jetting valve and each set of high-frequency solenoid valves through pipelines, with each high-frequency solenoid valve corresponding to a set of high-pressure nozzles; the double-row matrix high-pressure nozzles are at a 45° angle to the horizontal plane towards the material's parabolic trajectory; the jetting valve is electrically connected to the software platform and the electrical control system; the fully protective shell has a gangue chute and a coal chute respectively below the double-row matrix high-pressure nozzles, and an adjustable baffle is provided between the gangue chute and the coal chute.

[0014] Optionally, the electrical control system is electrically connected to the variable frequency speed control motor, the intelligent identification system, the jet valve, the baffle plate, the air compressor, and the induced draft fan. The electrical control system has functions of power supply and distribution for the whole machine, sequential start and stop, acquisition of operating parameters, and fault alarm. The PLC of the electrical control system binds the output frequency of the frequency converter with the jet delay time.

[0015] Optionally, the software platform includes a server and a software system. The server is connected to the intelligent identification system and the electrical control system via optical fiber. The software system has built-in mathematical analysis models, big data analysis modules, AI intelligent algorithms, and sorting control programs. It can collect material identification data and belt running speed parameters, determine whether the material is coal or gangue, calculate the coordinates and dimensions of the material on the conveyor belt, and send control commands to the intelligent injection execution system for injection delay, position, nozzle number, and valve opening time.

[0016] Optionally, the dust removal and ventilation unit is located outside the fully protective housing and includes a dust removal device and an induced draft fan; a dust-laden airflow outlet is provided at the upper part of the fully protective housing, the dust-laden airflow outlet is connected to the air inlet end of the dust removal device through an air inlet pipe, and the air outlet end of the dust removal device is connected to the induced draft fan through a connecting pipe.

[0017] Optionally, a coal conveyor belt is connected below the coal chute, and a gangue conveyor belt is connected below the gangue chute.

[0018] The sorting control program of an intelligent dry separator with ultra-high processing capacity includes the following steps: S1: The intelligent identification system performs X-ray detection on materials within +50mm of the identification area to determine whether the material is coal or gangue; if it is determined to be gangue, it is marked as not to be injected; if it is determined to be coal, it calculates the particle size and the distance between the materials and enters the injection mode determination process. S2: For materials identified as coal, perform oversized material condition judgment. When the material particle size is >300mm, control the simultaneous opening of the double-row nozzles. If the distance between the oversized material and the surrounding material is too small, prioritize the injection of the oversized material. When the material particle size is ≤300mm, enter the material distance judgment process. S3: Detect the center distance between the current material and the previous material. If the distance is >50mm, proceed to the particle size subdivision judgment process; if the distance is ≤50mm, proceed to the timing conflict avoidance process. S4: When the spacing is greater than 50mm, if the material particle size is >150mm, it is judged as large material and the large valve nozzle is controlled to operate; if the material particle size is ≤150mm, it is judged as small material and the small valve nozzle is controlled to operate. The front and rear materials are sprayed alternately by the upper and lower rows of nozzles; when the front and rear materials are the same size, the corresponding specification nozzle is used uniformly; when the sizes are different, the corresponding nozzle is matched according to the material specification. S5: When the spacing is less than or equal to 50mm, adjust the strategy according to the working status of the nozzle of the previous material; if the previous material opens the small valve nozzle, the current material uses the large valve nozzle; if the previous material does not open the small valve nozzle, the current material uses the small valve nozzle; if both before and after are large materials and the spacing is too close, increase the number of valves opened and extend the valve opening time when the next material is sprayed; if both before and after are small materials and the spacing is too close, switch to the large valve nozzle for the next material, reduce the number of valves opened and shorten the valve opening time.

[0019] The beneficial effects of this invention are as follows: 1. This invention can significantly improve the processing capacity of equipment within a limited plant space, solving the pain point of existing old screening workshops being too small to accommodate additional sorting equipment. The belt speed is increased to 3-3.75m / s, and for the sorting of 50-300mm lump coal and gangue, the processing capacity per meter of belt is increased from the traditional 100t / h to 150t / h, a 50% increase in unit belt capacity. A single unit can meet the production needs of a high-capacity coal preparation plant without the need for plant expansion, significantly reducing the investment cost of plant renovation.

[0020] 2. This invention optimizes the structure of the belt conveyor system, effectively reducing belt wear and extending the service life of the conveyor belt under high-speed operation. The total length of the conveyor belt is increased to 8.5m, while the specifications of the drive roller and idler roller are enlarged to reduce belt bending loss during high-speed rotation; the idlers are densified to a spacing of 300mm and use high-precision idlers with a circular runout of less than 0.2mm; the identification area uses a pallet instead of idlers; and a manual screw jack tensioning structure at the tail end can suppress belt sagging and material jolting, reduce belt tearing and deviation problems during high-speed conveying, and reduce the frequency of belt replacement and maintenance costs.

[0021] 3. This invention maintains a stable material state under high belt speed conditions, ensuring the accuracy of X-ray intelligent identification. The high-speed belt can quickly separate the materials, preventing them from piling up and sticking together; the high-precision idlers and the identification area plate work together to eliminate high-speed rolling and floating of materials, ensuring a stable flat material state. Paired with a 600Mbps high-transmission-rate detector card, data acquisition and transmission are lag-free, enabling accurate acquisition of the material's equivalent atomic number, dimensions, and coordinate information, without reducing identification accuracy due to belt speed increases.

[0022] 3. This invention employs a dual-row matrix high-pressure nozzle paired with an AI intelligent sorting algorithm to effectively resolve the timing conflict caused by high-speed material throwing, ensuring the sorting accuracy of coal and gangue. The dual-row nozzles are aligned with the material's parabolic trajectory at a 45° angle to the horizontal plane. For conventional materials, the upper and lower rows are alternately sprayed, allowing time for air exchange with the solenoid valves. For extra-large materials with a particle size greater than 300mm, the dual rows can be controlled to spray synchronously, ensuring sufficient thrust. When timing conflicts occur due to insufficient material spacing, the system automatically switches nozzle specifications and adjusts the number and duration of valve openings to compensate. Simultaneously, the electrical control system binds the belt speed to the spraying delay and can automatically adjust the baffle plate to adapt to the dynamic material drop point, preventing material spillage, missed spraying, and incorrect spraying, resulting in stable and reliable sorting performance.

[0023] 4. This invention features a fully enclosed protective shell and an independent dust removal and ventilation unit, enabling dust-free and environmentally friendly operation. All sorting processes, including material application, identification, and blowing, are completed within the enclosed shell. Dust-laden airflow generated during production is collected from the top of the shell and sent to a dust removal device for purification before being discharged, significantly reducing on-site dust concentration, improving the working environment, and minimizing equipment wear and occupational health hazards caused by dust. Attached Figure Description

[0024] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0025] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0026] Figure 2 This is a schematic diagram to show part of the structure of the idler rollers and pallets.

[0027] Figure 3 This is a partial structural diagram to show the blowing distance between the X-ray emitting device and the double-row matrix high-pressure nozzles.

[0028] Figure 4 This is a partial structural diagram of the drive roller and the redirecting roller.

[0029] Figure 5 It is an algorithm flowchart.

[0030] Explanation of reference numerals in the attached figures 1. Fully Protective Housing; 11. Sorting Platform; 2. Vibrating Distributor; 3. Belt Conveyor System; 31. Conveyor Belt; 32. Drive Drum; 33. Idling Drum; 34. Variable Frequency Speed ​​Control Motor; 35. Idler Roller; 36. Pallet; 4. Intelligent Identification System; 41. X-ray Emitting Device; 42. X-ray Receiving Device; 5. Intelligent Pulse Jetting Execution System; 51. Pulse Jetting Valve; 52. Double-Row Matrix High-Pressure Nozzle; 53. Gangue Chute; 54. Coal Chute; 6. High-Pressure Air Supply Unit; 61. Air Compressor; 62. High-Pressure Gas Storage Tank; 63. Pipeline; 7. Dust Removal and Ventilation Unit; 71. Dust Removal Device; 72. Exhaust Fan; 73. Air Inlet Pipe; 74. Connecting Pipe; 8. Coal Belt; 9. Gangue Belt. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0032] Reference Figure 1This is an intelligent dry separator with ultra-high processing capacity. The entire machine is encased in a fully protective shell 1. Along the material flow direction, the main body of the equipment is arranged sequentially with a vibrating distributor 2, a belt conveyor system 3, an intelligent identification system 4, and an intelligent jet-blowing execution system 5. It is also equipped with an electrical control system (not shown in the figure), a software platform (not shown in the figure), a high-pressure air supply unit 6, and a dust removal and ventilation unit 7. The vibrating distributor 2 is installed on the feed side of the fully protective shell 1, and its discharge port connects to the feed end of the belt conveyor system 3. The intelligent identification system 4 is located at... Reference Figure 1-4 The belt conveyor system 3 is located in the middle section, with an intelligent jet-blowing execution system 5 installed at the discharge side of the head of the belt conveyor system 3. A high-pressure air supply unit 6 is connected to the intelligent jet-blowing execution system 5 via pipelines, and a dust removal and ventilation unit 7 is connected to the upper part of the fully protective housing 1 via pipelines. The electrical control system and software platform are electrically connected to the belt conveyor system 3, the intelligent identification system 4, the intelligent jet-blowing execution system 5, and the high-pressure air supply unit 6, respectively. The entire set of equipment works collaboratively to complete the dry intelligent sorting of 50-300mm lump coal and gangue, achieving a super-large processing capacity of 150t / h per meter of belt width within a limited plant space, while balancing material conveying stability, identification accuracy, and jet-blowing sorting effect.

[0033] Reference Figure 1-4 The fully protective housing 1 houses a sorting platform 11. The belt conveyor system 3 is installed on the sorting platform 11. The conveyor belt 31 is 8.5m long. The feed end is connected to the vibrating distributor 2. The tail of the conveyor belt 31 is surrounded by a 500mm diameter drive roller 32, and the head is surrounded by a 320mm diameter redirecting roller 33. The drive roller 32 is equipped with a variable frequency speed control motor 34, which is electrically connected to the frequency converter of the electrical control system. The speed of the conveyor belt 31 can be adjusted to 3-3.75m / s. High-precision special idlers 35 are evenly distributed below the conveyor belt 31. The idlers 35 are spaced 300mm apart and the allowable circular runout of the idlers 35 is less than 0.2mm. The idlers 35 are removed from the detection area of ​​the intelligent recognition system 4 in the middle section of the conveyor belt 31 and replaced with a support plate 36. The support plate 36 is close to the lower surface of the belt. The tail of the conveyor belt 31 is equipped with a manual screw jack tensioning device for tensioning the seamless annular conveyor belt 31. During operation, the raw coal is evenly spread onto the high-speed conveyor belt 31 by the vibrating distributor 2. The conveyor belt 31 quickly widens the gap between the materials to prevent them from piling up and sticking together. After the material passes smoothly through the detection area of ​​the pallet 36, it is conveyed to the head roller. The larger roller can reduce the rotational loss of the conveyor belt 31 under high-speed operation and extend the service life of the conveyor belt 31.

[0034] Reference Figure 1-4The intelligent identification system 4 is fixed to one side of the sorting platform 11 and includes an X-ray emitting device 41 and a radiation receiving device 42. The X-ray emitting device 41 is installed entirely in a sealed explosion-proof box with a lead liner. The radiation receiving device 42 is a detector, which is arranged below the tray 36, between the upper and lower surfaces of the conveyor belt 31, and vertically opposite the X-ray source outlet above. The X-ray emitting device is installed entirely in a sealed explosion-proof box with a lead liner, which is dustproof and has low radiation leakage. The main body of the X-ray emitting device 41 is the X-ray source, which integrates a high-voltage power supply, an X-ray tube, and a filament power supply. d is the blowing distance between the X-ray source of the X-ray emitting device 41 and the double-row matrix high-voltage nozzles 52. The filament power supply is responsible for heating the filament of the X-ray tube. The high-voltage output terminal of the high-voltage power supply is connected to both ends of the filament and the anode target, respectively, to build a high-voltage electric field, driving the active electrons at the filament to accelerate towards the anode target, forming a high-speed electron stream. When the high-speed electron stream collides with atoms and electrons in their outer orbits, causing them to ionize and release energy, X-rays are generated. X-rays are generated by the excitation of inner-shell electrons in atoms. Their frequency and photon energy are lower than gamma rays, and they emit no radiation after power is cut off. The X-ray receiving device 42 is a detector installed between the upper and lower surfaces of the conveyor belt 31, opposite the X-ray source outlet, to receive X-rays that have passed through the conveyor belt 31 and the material. It includes digital and analog boards. Each analog board has multiple detector channels, and the detectors are arranged at equal intervals, the spacing of which is set according to the required recognition resolution. By closely arranging multiple analog boards, an X-ray detector matching the width of the fabric installation device can be formed. The X-rays pass through the object being measured and reach the detector. Based on the magnitude of the signal received by the detector, equivalent atomic information of the material can be obtained, enabling the identification and classification of the material. To meet the requirements of high processing power, the detector uses a high-response detector card, high-throughput data transmission (600Mbps), and has easy-to-use and reliable gigabit Ethernet, fiber optic, or camera connection interfaces for connection to a host computer.

[0035] Reference Figure 1-4The intelligent jetting execution system 5 is installed on the material drop side of the head redirecting roller 33 of the belt conveyor system 3. It consists of a jetting valve 51, a double-row matrix high-pressure nozzle 52, a jetting control board, a jetting drive board, and a high-frequency solenoid valve. The high-pressure air supply unit 6 includes an air compressor 61 and a high-pressure gas storage tank 62. The air compressor 61 is connected to the high-pressure gas storage tank 62 through a pipeline 63. The high-pressure gas output pipeline from the storage tank is connected to the jetting valve 51 and each set of high-frequency solenoid valves. Each solenoid valve corresponds to a set of high-pressure nozzles. The double-row nozzles are at a 45° angle to the horizontal plane towards the trajectory of the material's parabolic motion. The jetting valve 51 is electrically connected to the software platform and the electrical control system. The fully protective housing 1 has a gangue chute 53 and a coal chute 54 below the double-row nozzles. An adjustable baffle is set between the two chutes. When the material detaches from the conveyor belt 31 and moves in a parabolic motion, the software platform issues instructions for the injection delay, nozzle number, and valve opening duration. The injection valve 51 drives the solenoid valve to open, and the high-pressure airflow hits the target gangue, changing its trajectory and falling into the gangue chute 53. The raw coal that is not injected maintains its original trajectory and falls into the coal chute 54. The double-row nozzles adopt a rotating injection logic, with the front and rear materials being acted on by the upper and lower rows of nozzles in sequence, allowing time for air exchange for the solenoid valve. For oversized materials, the double-row nozzles can be controlled to spray air synchronously. The electrical control system automatically adjusts the position of the baffle plate according to the real-time speed of the conveyor belt 31 to adapt to different drop points and prevent materials from flying out of the sorting area.

[0036] The electrical control system is electrically connected to the variable frequency speed control motor 34, X-ray recognition system, jet valve 51, baffle plate adjustment mechanism, air compressor 61, and induced draft fan 72. It is responsible for the power supply and distribution of the whole machine, sequential start and stop, acquisition of operating parameters, and fault alarm functions. The electrical control PLC binds the output frequency of the frequency converter with the jet delay time.

[0037] The software platform includes a server and a software system. The server connects to the intelligent identification system 4 and the electrical control system via fiber optic cable to collect material identification data and conveyor belt 31 running speed parameters in real time. It establishes suitable mathematical analysis models for different coal quality characteristics, and combines big data analysis and AI intelligent algorithms to determine whether the object being tested is coal or gangue, and calculates its precise coordinates and dimensions on the conveyor belt 31. Subsequently, it transmits control commands to the injection actuator, including injection delay time, position, nozzle number, and valve opening duration, to achieve precise injection. (Refer to...) Figure 5 The sorting control program on the software platform can automatically adjust the blowing sequence and nozzle working mode according to the material arrangement. The specific algorithm process includes the following steps: S1: For the "+50mm material" entering the identification area, the intelligent identification system 4 first uses X-ray analysis to determine the atomic number composition of the material and thus the properties of the coal gangue. If it is determined to be gangue: mark it directly as "no injection", and the material falls into the clean coal chute 54 along the original parabolic trajectory without the need to perform the subsequent injection process.

[0038] If it is determined to be coal: Simultaneously calculate the material's appearance size (particle size) and the distance between it and the materials before and after it, and enter the injection mode determination process.

[0039] S2: For materials identified as coal, the oversized lump condition determination will be prioritized. If the material particle size is >300mm: the software platform controls the upper and lower double-row nozzles to open synchronously (the large and small valves spray at the same time), and ensures the spraying accuracy of the oversized material by superimposing high-pressure airflow; if the oversized material is too close to the surrounding material, the oversized material is sprayed first, and the surrounding material is not sprayed temporarily to avoid airflow interference.

[0040] If the particle size of the material is ≤300mm: proceed to the material spacing determination process.

[0041] S3: Determine the center distance between the current material and the previous material to determine the solenoid valve's air exchange conditions. If the spacing is >50mm: the solenoid valve air exchange frequency requirement is met, and the particle size subdivision judgment (S4) is entered, and the nozzles are allocated according to the conventional rules.

[0042] If the spacing is ≤50mm: the air exchange frequency requirement of the solenoid valve is not met, and the timing conflict avoidance process (S5) is entered. The conflict between adjacent materials is resolved by adjusting the nozzle type and valve opening parameters.

[0043] S4: For materials with sufficient spacing, nozzles are allocated according to particle size, and an alternating upper and lower nozzle spraying logic is adopted: If the material particle size is >150mm: it is judged as large material. The software controls the corresponding large valve nozzle to operate (large valve blowing). The material before and after is blown by the upper and lower rows of nozzles in sequence, allowing sufficient air exchange time for the solenoid valve.

[0044] If the particle size of the material is ≤150mm, it is determined to be a small piece of material. The software controls the corresponding small valve nozzle to operate (small valve blowing), and the upper and lower nozzles are switched in turn.

[0045] Special note: If both the front and back sides are small pieces of material, use small valves to spray them all; if both the front and back sides are large pieces of material, use large valves to spray them all; if the sizes of the front and back materials are different, still follow the rule of "small valves spray small pieces, large valves spray large pieces".

[0046] S5: For materials that are too close together, dynamically adjust the blowing strategy based on the working status of the nozzles of the previous material: If the previous material has already opened the small valve nozzle (previous material opened small valve = Y”): the current material directly uses the large valve nozzle to avoid the solenoid valve from opening continuously and failing to exchange air.

[0047] If the previous material did not open the small valve nozzle (previous material opened small valve = "N"): the current material uses the small valve nozzle to ensure the continuity of the blowing sequence.

[0048] Special supplementary adjustments: When there are large blocks in front and large blocks behind, and the spacing is too close: if the front block is sprayed with a large valve and the back block needs to be sprayed with a small valve, the software will automatically increase and extend the number of valves opened and the valve opening time of the back block to compensate for insufficient airflow intensity.

[0049] If the material in front and behind is too small and the spacing is too close: replace the small piece of material in front with a large valve for spraying, and at the same time, appropriately reduce and shorten the number of valves opened and the valve opening time to avoid over-spraying.

[0050] Reference Figure 1 The dust removal and ventilation unit 7 is located outside the fully protective housing 1 and includes a dust removal device 71 and an induced draft fan 72. A dust-laden airflow outlet (not shown in the figure) is opened at the top of the fully protective housing 1, and an air inlet pipe 73 is fixedly connected to and connected to the air inlet of the dust removal device 71. A connecting pipe 74 is fixedly connected to and connects the dust removal device 71 and the induced draft fan 72. The equipment's material placement, identification, and blowing processes are all completed within the sealed housing. The dust-laden airflow generated during production is sent to the dust removal device 71 for purification through pipelines, and finally, clean air is discharged to the outside by the induced draft fan 72, achieving dust-free operation.

[0051] Reference Figure 1 After sorting, the coal chute 54 is connected to the coal conveyor belt 8 below, and the gangue chute 53 is connected to the gangue conveyor belt 9 below, respectively receiving the sorted raw coal and gangue, and transporting them outward to complete the entire dry sorting process.

[0052] The operating principle of this invention is as follows: the raw material is evenly spread onto the conveyor belt 31 by the vibrating distributor 2 and then conveyed to the intelligent identification system 4. The system digitally identifies the material based on differences in X-ray absorption and uses a machine vision sensor to measure the external features of the material to assist in precise positioning. The software platform collects relevant data in real time, establishes mathematical analysis models for different coal quality characteristics, and determines whether the object being tested is coal or gangue through big data analysis. It also calculates the accurate coordinate dimensions of the object on the conveyor belt 31 and transmits instructions such as the injection delay time and position information to the intelligent injection execution system 5. When the material reaches the head of the conveyor and falls in a parabolic trajectory after a certain delay from the detection position, the intelligent injection execution system 5 activates the high-speed solenoid valve at the corresponding position according to the instructions. The solenoid valve quickly drives the high-pressure air nozzle to inject high-pressure gas, applying a force to the target object to deviate from its original parabolic trajectory. The injected object is collected through the injected material chute, while the uninjected object maintains its original trajectory and is collected through the uninjected material chute, thus realizing fully automatic intelligent sorting of coal and gangue.

[0053] Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

Claims

1. An intelligent dry separator with ultra-high processing capacity, characterized in that: The system includes a fully protective housing (1). Along the material conveying direction, the fully protective housing (1) contains, in sequence, a vibrating material distributor (2), a belt conveyor system (3), an intelligent identification system (4), and an intelligent jetting execution system (5). It is also equipped with an electrical control system, a software platform, a high-pressure air supply unit (6), and a dust removal and ventilation unit (7). The vibrating material distributor (2) is installed on the feeding side of the fully protective housing (1), and its discharge port is connected to the feeding end of the belt conveyor system (3). The intelligent... The identification system (4) is located in the middle section of the belt conveyor system (3), and the intelligent jetting execution system (5) is installed on the discharge side of the head of the belt conveyor system (3). The high-pressure air supply unit (6) is connected to the intelligent jetting execution system (5) through a pipeline, and the dust removal and ventilation unit (7) is connected to the upper part of the full protective shell (1) through a pipeline. The electrical control system and software platform are electrically connected to the belt conveyor system (3), the intelligent identification system (4), the intelligent jetting execution system (5), and the high-pressure air supply unit (6), respectively.

2. The intelligent dry separator with ultra-high processing capacity according to claim 1, characterized in that: The sorting platform (11) is installed inside the fully protective housing (1). The belt conveyor system (3) is installed on the sorting platform (11) inside the fully protective housing (1). It includes a seamless annular conveyor belt (31), a drive roller (32), a redirecting roller (33), a variable frequency speed control motor (34), idlers (35), pallets (36), and a manual screw jack tensioning device. The tail of the conveyor belt (31) surrounds the drive roller (32), and the head surrounds the redirecting roller. Roller (33); the transmission roller (32) is connected to the variable frequency speed control motor (34), and the variable frequency speed control motor (34) is electrically connected to the frequency converter of the electrical control system; a high-precision special idler (35) is arranged below the conveyor belt (31), and the idler (35) is removed from the detection area of ​​the intelligent identification system (4) in the middle section and replaced with a pallet (36), and the pallet (36) is close to the lower surface of the conveyor belt (31); the tail of the conveyor belt (31) is tensioned with a jack.

3. The intelligent dry separator with ultra-high processing capacity according to claim 2, characterized in that: The conveyor belt (31) has a total length of 8.5m, the drive roller (32) has a diameter of 500mm, and the redirecting roller (33) has a diameter of 320mm; the speed adjustment range of the conveyor belt (31) is 3-3.75m / s; the spacing between the idlers (35) is 300mm, and the allowable circular runout of the idlers (35) is less than 0.2mm.

4. The intelligent dry separator with ultra-high processing capacity according to claim 2, characterized in that: The intelligent identification system (4) is fixed on one side of the sorting platform (11) and includes an X-ray emitting device (41) and a radiation receiving device (42). The X-ray emitting device (41) is installed in a sealed explosion-proof box with a lead liner. The X-ray emitting device (41) integrates a high-voltage power supply, an X-ray tube, and a filament power supply. The filament power supply is electrically connected to the filament of the X-ray tube. The high-voltage output terminal of the high-voltage power supply is connected to the filament and the anode target, respectively. The radiation receiving device (42) is a detector. The detector is arranged below the tray (36) and between the upper and lower surfaces of the conveyor belt (31), and is vertically opposite to the beam outlet of the X-ray emitting device (41) above. The detector includes a digital board and an analog board. The single analog board has multiple detector channels. The detectors are arranged at equal intervals. The detector is equipped with a high-response-speed detector card with a data transmission rate of 600Mbps. The detector has a gigabit Ethernet, fiber optic, or camera connection interface and is connected to the host.

5. The intelligent dry separator with ultra-high processing capacity according to claim 1, characterized in that: The intelligent jetting execution system (5) is installed on the material drop side of the head redirecting roller (33) of the belt conveyor system (3), and includes a jetting valve (51), a double-row matrix high-pressure nozzle (52), a jetting control board, a jetting drive board, and a high-frequency solenoid valve; the high-pressure air supply unit (6) includes an air compressor (61) and a high-pressure gas storage tank (62), the air compressor (61) is connected to the high-pressure gas storage tank (62) through a pipeline (63), and the high-pressure gas storage tank (62) is connected to the high-pressure gas storage tank (62) through pipelines respectively The blow valve (51) is connected to each group of high-frequency solenoid valves, and each high-frequency solenoid valve corresponds to a group of high-pressure nozzles; the double-row matrix high-pressure nozzles (52) are oriented at 45° to the horizontal plane toward the parabolic motion trajectory of the material; the blow valve (51) is electrically connected to the software platform and the electrical control system; the fully protective shell (1) is provided with gangue chute (53) and coal chute (54) below the double-row matrix high-pressure nozzles (52), and an adjustable baffle is provided between the gangue chute (53) and the coal chute (54).

6. The intelligent dry separator with ultra-high processing capacity according to claim 1, characterized in that: The electrical control system is electrically connected to the variable frequency speed control motor (34), the intelligent identification system (4), the jet valve (51), the baffle plate, the air compressor (61), and the induced draft fan (72). The electrical control system has the functions of power supply and distribution for the whole machine, sequential start and stop, acquisition of operating parameters, and fault alarm. The PLC of the electrical control system binds the output frequency of the frequency converter with the jet delay time.

7. The intelligent dry separator with ultra-high processing capacity according to claim 1, characterized in that: The software platform includes a server and a software system. The server is connected to the intelligent identification system (4) and the electrical control system via optical fiber. The software system has a built-in mathematical analysis model, big data analysis module, AI intelligent algorithm and sorting control program. It can collect material identification data and belt running speed parameters, determine whether the material is coal or gangue, calculate the coordinates and size information of the material on the conveyor belt (31), and send control instructions to the intelligent injection execution system (5) for injection delay, position, nozzle number and valve opening time.

8. The intelligent dry separator with ultra-high processing capacity according to claim 1, characterized in that: The dust removal and ventilation unit (7) is located outside the fully protective housing (1) and includes a dust removal device (71) and an induced draft fan (72). The upper part of the fully protective housing (1) has a dust-laden airflow outlet. The dust-laden airflow outlet is connected to the air inlet of the dust removal device (71) through an air inlet pipe (73). The air outlet of the dust removal device (71) is connected to the induced draft fan (72) through a connecting pipe (74).

9. The intelligent dry separator with ultra-high processing capacity according to claim 5, characterized in that: The coal chute (54) is connected to the coal conveyor belt (8) below, and the gangue chute (53) is connected to the gangue conveyor belt (9) below.

10. An algorithm flow for a sorting control program of an intelligent dry separator with ultra-high processing capacity as described in any one of claims 1-9, characterized in that: Includes the following steps: S1: The intelligent identification system (4) performs X-ray detection on the +50mm material entering the identification area to determine whether the material is coal or gangue; if it is determined to be gangue, it is marked as not to be injected; if it is determined to be coal, it calculates the particle size and the distance between the materials and enters the injection mode determination process. S2: For materials identified as coal, perform oversized material condition judgment. When the material particle size is >300mm, control the simultaneous opening of the double-row nozzles. If the distance between the oversized material and the surrounding material is too small, prioritize the injection of the oversized material. When the material particle size is ≤300mm, enter the material distance judgment process. S3: Detect the center distance between the current material and the previous material. If the distance is greater than 50mm, proceed to the particle size subdivision judgment process. If the spacing is ≤50mm, the timing conflict avoidance process will be initiated. S4: When the spacing is greater than 50mm, if the material particle size is >150mm, it is judged as large material and the large valve nozzle is controlled to operate; if the material particle size is ≤150mm, it is judged as small material and the small valve nozzle is controlled to operate. The front and rear materials are sprayed alternately by the upper and lower rows of nozzles; when the front and rear materials are the same size, the corresponding specification nozzle is used uniformly; when the sizes are different, the corresponding nozzle is matched according to the material specification. S5: When the spacing is less than or equal to 50mm, adjust the strategy according to the working status of the nozzle of the previous material; if the previous material opens the small valve nozzle, the current material uses the large valve nozzle; if the previous material does not open the small valve nozzle, the current material uses the small valve nozzle; if both before and after are large materials and the spacing is too close, increase the number of valves opened and extend the valve opening time when the next material is sprayed; if both before and after are small materials and the spacing is too close, switch to the large valve nozzle for the next material, reduce the number of valves opened and shorten the valve opening time.

Images