An intelligent detection and self-adaptive cleaning system and control method for material sticking on a shovel bucket

Abstract

This invention provides an intelligent detection and adaptive cleaning system and control method for sticky material in electric shovel buckets, belonging to the technical field of electric shovel excavation equipment in open-pit coal mines. The method includes: acquiring the current weight of the bucket after unloading and calculating the weight difference to determine the degree of sticky material; automatically matching and executing a corresponding vibration cleaning strategy based on the degree of sticky material, and simultaneously activating a micro-heating device in frozen sticky conditions; verifying the cleaning process again, and automatically repeating if the standard is not met. The system includes a tension sensor, a control unit, and a vibrator. This invention achieves quantitative perception and closed-loop management of sticky material through non-contact weighing comparison, placing all sensors outside the material contact area to completely avoid impact damage, and cleverly utilizing the waste heat of the electric shovel's hydraulic system to achieve zero-energy frozen sticky material management, thereby significantly improving the effective volume utilization rate of the bucket and achieving adaptive bucket maintenance with minimal downtime and manual intervention.

Description

Technical Field

[0001] This invention relates to the field of electric shovel excavation equipment technology for open-pit coal mines, and in particular to an intelligent detection and adaptive cleaning system and control method for material adhering to the bucket of an electric shovel. Background Technology

[0002] Electric shovels are core mining equipment in open-pit coal mines, and the bucket, as the core working component for excavation and loading, directly impacts mine productivity. Field practice shows that when electric shovels excavate sticky materials such as high-moisture coal and mudstone, material easily adheres to the inner wall of the bucket, forming a continuously accumulating "dead zone." This significantly reduces the effective bucket capacity and decreases the excavation capacity per bucket. To restore bucket capacity, the common practice is to use a backhoe excavator for auxiliary cleaning after the main shovel is shut down. A single cleaning typically takes 30 to 60 minutes, severely restricting the continuous operating efficiency of the electric shovel and increasing non-productive time costs. Especially in cold winter mining areas, material freezes and adheres to the inner wall of the bucket. The "anchoring effect" formed by ice crystals and the metal wall makes the adhesion strength much higher than that of wet adhesion at room temperature, drastically increasing the difficulty of cleaning.

[0003] To address this issue, some existing solutions, such as installing anti-sticking protrusions on the bucket backplate and vibration devices on the side plates, while providing some cleaning effect, rely heavily on operator experience or fixed time intervals for vibration activation and deactivation, lacking online quantitative sensing capabilities to assess the actual degree of adhesion to the bucket's inner wall. This open-loop control approach creates a contradiction: "vibration's effectiveness is unknown, but not vibrating risks incomplete unloading," potentially leading to wasted energy from ineffective vibrations or delayed material removal. Furthermore, some exploratory solutions attempt to directly detect adhesion using sensors on the inner wall, but these sensors are easily damaged due to the severe material impact and abrasion during excavation, making their reliability insufficient for the harsh conditions of mining areas. Existing technologies also lack automated, low-energy-consumption solutions to the core challenge of winter freezing and adhesion. More critically, none of the above solutions establish a closed-loop control system from material detection and strategy execution to effect verification, failing to ensure thorough unloading operations. Summary of the Invention

[0004] To address the aforementioned technical problems in related technologies, this invention proposes an intelligent detection and adaptive cleaning system and control method for material adhering to the bucket of an electric shovel, which can overcome the above-mentioned shortcomings of the prior art.

[0005] To achieve the above-mentioned technical objectives, the technical solution of the present invention is implemented as follows: A smart detection and adaptive cleaning system for material adhering to the bucket of an electric shovel; The intelligent detection and adaptive cleaning system for sticky material in the electric shovel bucket includes: The material adhesion detection unit includes a tension sensor for measuring the weight of the bucket and the material. The control unit is electrically connected to the adhesive detection unit and is used to receive detection data, determine the degree of adhesiveness, and issue control commands. The execution unit includes a vibrator mounted on the outer wall of the bucket side plate, the vibrator receiving instructions from the control unit to operate with an adjustable vibration frequency and duration; The control unit is configured to perform closed-loop verification of the cleaning effect based on the feedback from the adhesive detection unit after the cleaning operation, and to control the execution unit to repeat the operation if the target is not met.

[0006] Furthermore, the material adhesion detection unit also includes a pressure sensor installed on the hydraulic cylinder pipeline of the electric shovel bucket, and / or an angle sensor installed at the connection between the bucket and the stick; the control unit is also used to collect data from the pressure sensor and / or the angle sensor to assist in judging the degree of material adhesion.

[0007] Furthermore, the execution unit also includes a heating element embedded below the wear-resistant liner on the inner wall of the bucket side plate and the back plate. The heating element is connected to the return oil pipeline of the electric shovel hydraulic system through a heat exchange system to utilize the waste heat of the hydraulic oil for heating. The control unit is also used to control the start and stop of the heating element.

[0008] According to another aspect of the present invention, a control method for an intelligent detection and adaptive cleaning system for material adhering to an electric shovel bucket is provided; The control method for the intelligent detection and adaptive cleaning system for material adhering to the electric shovel bucket includes the following steps: Step S1: After the electric shovel completes the unloading operation, obtain the current weight of the bucket; Step S2: Compare the current weight with the preset empty bucket weight threshold and calculate the weight difference; Step S3: Determine the degree of material adhesion to the inner wall of the bucket based on the weight difference; Step S4: Based on the degree of material adhesion, automatically match and execute the corresponding cleaning strategy. The cleaning strategy includes at least starting the vibrator with different vibration parameters. Step S5: After the cleaning strategy is completed, the bucket weight is obtained again to verify the cleaning effect. If the weight difference does not reach the preset cleaning completion standard, the corresponding cleaning strategy is automatically repeated.

[0009] Further, in step S1, obtaining the current weight of the bucket specifically involves: using a tension sensor installed on the lifting wire rope of the electric shovel to collect tension data when the bucket returns to a horizontal position after unloading, in order to calculate the current weight.

[0010] Further, in step S3, the degree of material adhesion to the inner wall of the bucket is determined based on the weight difference, specifically as follows: When the weight difference is greater than or equal to 2 tons and less than 5 tons, it is judged as slight adhesion. When the weight difference is greater than or equal to 5 tons and less than 10 tons, it is judged as moderately sticky material; When the weight difference is greater than or equal to 10 tons, it is judged as heavily adhesive material.

[0011] Further, in step S4, automatically matching and executing the corresponding cleaning strategy based on the degree of adhesion includes: When the material is determined to be slightly stuck, the strategy is to not start the vibrator or to vibrate at a frequency of 10-15Hz for 3-5 seconds. When the material is determined to be moderately sticky, the strategy is to start the vibrator and vibrate at a frequency of 20-30Hz for 8-12 seconds. When the material is determined to be heavily sticky at room temperature, the strategy is to start the vibrator and vibrate at a frequency of 40-60Hz for 15-20 seconds. When the ambient temperature is below 0℃, the material type is high-moisture coal or mudstone, and it is determined to be heavily sticky, it is determined to be a frozen sticky working condition. The strategy is to start the vibrator to vibrate at a frequency of 40-60Hz for 15-20 seconds, and simultaneously start the micro heating device to heat the inner wall of the bucket.

[0012] Furthermore, the heat source of the micro-heating device is taken from the residual heat of the return oil of the electric shovel hydraulic system, and the heat is transferred to the wear-resistant liner below the inner wall of the bucket through the heat exchange pipeline, with a heating target temperature of 5-15℃.

[0013] Furthermore, in step S5, the automatic repetition of the corresponding cleaning strategy is as follows: if the cleaning effect does not meet the standard, the cleaning is automatically repeated 1 to 2 times, and the vibration frequency of the exciter increases by 10% each time the cleaning is repeated, and if a heating step is included, the heating time increases by 5 seconds; if the standard is still not met after repeating 2 times, an alarm signal is issued to prompt manual intervention.

[0014] Furthermore, it also includes auxiliary judgment steps: during the unloading process, the hydraulic pressure and action time of the electric shovel tipper cylinder are monitored in real time; when the pressure peak of the tipper cylinder exceeds the normal range or the action speed is lower than the normal threshold, the presence of sticky material residue is verified, and the result of the degree of sticky material judged by the weight difference is mutually verified.

[0015] The beneficial effects of this invention are as follows: By employing an indirect detection method that compares the weight of the material after unloading outside the bucket, the risk of sensor damage under digging impact is avoided, ensuring the reliability of the detection system. By quantifying the degree of material adhesion into light, medium, and heavy, and matching the graded vibration intensity and duration, precise cleaning on demand is achieved, avoiding the energy loss from blind vibration. For frozen and stuck conditions, the invention innovatively utilizes the residual heat from the return oil of the electric shovel's hydraulic system to micro-heat the inner wall of the bucket, softening the frozen interface in a zero-energy manner and working in conjunction with vibration to peel off the frozen material, overcoming the pain point of cleaning during shutdowns in high-altitude and cold mining areas. By introducing a closed-loop verification mechanism for weight verification after cleaning, it is ensured that the bucket can be restored to a preset clean state after each loading and unloading operation, guaranteeing the thoroughness of unloading. Attached Figure Description

[0016] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0017] Figure 1 This is a structural block diagram of an intelligent detection and adaptive cleaning system for sticky material in an electric shovel bucket according to the present invention. Figure 2 This is a schematic diagram showing the installation position of the detection element in the intelligent detection and adaptive cleaning system for sticky material in an electric shovel bucket according to the present invention. Figure 3 This is a schematic diagram showing the installation position of the vibrator and heating element of the intelligent detection and adaptive cleaning system for sticky material in the electric shovel bucket according to the present invention. Figure 4 This is a flowchart illustrating the control method of an intelligent detection and adaptive cleaning system for material adhering to an electric shovel bucket, as described in this invention.

[0018] Explanation of reference numerals in the attached figures: 1: Tension sensor; 2: Pressure sensor; 3: Vibrator; 4: Heating element; 5: Wear-resistant liner; 6: Bottom liner; 7: Electric shovel lifting wire rope; 8: Hydraulic cylinder pipeline; 9: Back plate. Detailed Implementation

[0019] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. 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] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0021] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. Furthermore, the terms "installed," "connected," and "linked" should be interpreted broadly; for example, they may refer to a fixed connection, a detachable connection, or an integral connection; they may refer to a mechanical connection or an electrical connection; they may refer to a direct connection or an indirect connection through an intermediate medium; and they may refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0022] like Figures 1 to 3 As shown, an intelligent detection and adaptive cleaning system for sticky material in an electric shovel bucket according to an embodiment of the present invention includes: The material adhesion detection unit includes a tension sensor for measuring the weight of the bucket and the material. The control unit is electrically connected to the adhesive detection unit and is used to receive detection data, determine the degree of adhesiveness, and issue control commands. The execution unit includes a vibrator mounted on the outer wall of the bucket side plate, the vibrator receiving instructions from the control unit to operate with an adjustable vibration frequency and duration; The control unit is configured to perform closed-loop verification of the cleaning effect based on the feedback from the adhesive detection unit after the cleaning operation, and to control the execution unit to repeat the operation if the target is not met.

[0023] According to an embodiment of the present invention, an intelligent detection and adaptive cleaning system for sticky material in an electric shovel bucket includes, in a specific embodiment, a pressure sensor installed on the hydraulic cylinder pipeline of the electric shovel bucket, and / or an angle sensor installed at the connection between the bucket and the stick; the control unit is further used to collect data from the pressure sensor and / or the angle sensor to assist in determining the degree of sticky material.

[0024] According to an embodiment of the present invention, an intelligent detection and adaptive cleaning system for sticky material in an electric shovel bucket is provided. In a specific embodiment, the execution unit further includes a heating element embedded below the wear-resistant liner on the inner wall of the bucket side plate and back plate. The heating element is connected to the return oil pipeline of the electric shovel hydraulic system through a heat exchange system to utilize the residual heat of the hydraulic oil for heating. The control unit is also used to control the start and stop of the heating element.

[0025] Secondly, such as Figure 4 As shown, a control method for an intelligent detection and adaptive cleaning system for sticky material in an electric shovel bucket according to an embodiment of the present invention includes the following steps: Step S1: After the electric shovel completes the unloading operation, obtain the current weight of the bucket; Step S2: Compare the current weight with the preset empty bucket weight threshold and calculate the weight difference; Step S3: Determine the degree of material adhesion to the inner wall of the bucket based on the weight difference; Step S4: Based on the degree of material adhesion, automatically match and execute the corresponding cleaning strategy. The cleaning strategy includes at least starting the vibrator with different vibration parameters. Step S5: After the cleaning strategy is completed, the bucket weight is obtained again to verify the cleaning effect. If the weight difference does not reach the preset cleaning completion standard, the corresponding cleaning strategy is automatically repeated.

[0026] According to an embodiment of the present invention, a control method for an intelligent detection and adaptive cleaning system for material adhering to an electric shovel bucket is described. In a specific embodiment, in step S1, obtaining the current weight of the bucket specifically involves: using a tension sensor installed on the lifting wire rope of the electric shovel to collect tension data when the bucket returns to a horizontal position after unloading material in order to calculate the current weight.

[0027] According to an embodiment of the present invention, a control method for an intelligent detection and adaptive cleaning system for material adhesion in an electric shovel bucket is described. In a specific embodiment, step S3, determining the degree of material adhesion on the inner wall of the bucket based on the weight difference, specifically involves: When the weight difference is greater than or equal to 2 tons and less than 5 tons, it is judged as slight adhesion. When the weight difference is greater than or equal to 5 tons and less than 10 tons, it is judged as moderately sticky material; When the weight difference is greater than or equal to 10 tons, it is judged as heavily adhesive material.

[0028] According to an embodiment of the present invention, a control method for an intelligent detection and adaptive cleaning system for sticky material in an electric shovel bucket, in a specific embodiment, step S4, which involves automatically matching and executing a corresponding cleaning strategy based on the degree of sticky material, includes: When the material is determined to be slightly stuck, the strategy is to not start the vibrator or to vibrate at a frequency of 10-15Hz for 3-5 seconds. When the material is determined to be moderately sticky, the strategy is to start the vibrator and vibrate at a frequency of 20-30Hz for 8-12 seconds. When the material is determined to be heavily sticky at room temperature, the strategy is to start the vibrator and vibrate at a frequency of 40-60Hz for 15-20 seconds. When the ambient temperature is below 0℃, the material type is high-moisture coal or mudstone, and it is determined to be heavily sticky, it is determined to be a frozen sticky working condition. The strategy is to start the vibrator to vibrate at a frequency of 40-60Hz for 15-20 seconds, and simultaneously start the micro heating device to heat the inner wall of the bucket.

[0029] According to an embodiment of the present invention, a control method for an intelligent detection and adaptive cleaning system for sticky material in an electric shovel bucket is provided. In a specific embodiment, the heat source of the micro-heating device is taken from the residual heat of the return oil of the electric shovel hydraulic system. The heat is transferred to the area below the wear-resistant liner on the inner wall of the bucket through a heat exchange pipeline. The target heating temperature is 5-15℃.

[0030] According to an embodiment of the present invention, a control method for an intelligent detection and adaptive cleaning system for sticky material in an electric shovel bucket is described. In a specific embodiment, in step S5, the automatic repetition of the corresponding cleaning strategy is as follows: when the cleaning effect does not meet the standard, the cleaning is automatically repeated 1 to 2 times, and each time the cleaning is repeated, the vibration frequency of the vibrator increases by 10%, and if a heating step is included, the heating time increases by 5 seconds; if the standard is still not met after repeating twice, an alarm signal is issued to prompt manual intervention.

[0031] According to an embodiment of the present invention, a control method for an intelligent detection and adaptive cleaning system for sticky material in an electric shovel bucket includes, in a specific embodiment, an auxiliary judgment step: during the unloading process, the hydraulic pressure and action time of the electric shovel bucket cylinder are monitored in real time; when the peak pressure of the bucket cylinder exceeds the normal range or the action speed is lower than the normal threshold, the presence of sticky material residue is verified, and the result of the degree of stickiness determined by the weight difference is mutually verified.

[0032] To facilitate understanding of the above technical solutions of the present invention, the following detailed description of the above technical solutions of the present invention is provided through specific embodiments and working principles.

[0033] Example 1 This embodiment provides a specific implementation of an intelligent detection and adaptive cleaning system for material adhering to the bucket of an electric shovel.

[0034] (I) System Hardware Composition and Layout To realize this invention, it is first necessary to adapt the sensing and actuator mechanisms of the existing WK-35 or WK-20 electric shovels. The system as a whole consists of three parts working together: a material adhesion detection unit, a control unit, and an execution unit.

[0035] Layout and working principle of the adhesive detection unit: To address the problem that sensors in existing technologies are easily damaged by material impact, this invention adopts a fully indirect measurement scheme, in which all detection elements are installed outside the bucket or in the hydraulic lines, achieving complete physical isolation from the excavated material.

[0036] A high-precision strain gauge tension sensor is connected in series at the fixed end of the lifting wire rope of the electric shovel. Its working principle is that after the electric shovel completes a standard operating cycle of digging-rotating-unloading, the bucket returns to a preset horizontal position without load. At this point, the tension on the lifting wire rope is equal to the sum of the bucket's own weight and the weight of the material remaining on its inner wall. The controller collects the tension value at this specific moment, thus accurately obtaining the bucket's "current weight."

[0037] Meanwhile, pressure sensors are installed on the inlet and outlet oil lines of the electric shovel's bucket cylinder. Their auxiliary judgment principle is that when the bucket tilts to unload, if the inner wall is smooth and free of residue, the material will slide smoothly under gravity, resulting in a stable load on the bucket cylinder and a normal pressure curve. Conversely, if there are large pieces or large areas of wet, sticky material, the sliding lag during the tilting process will increase the unloading resistance, leading to an abnormally high pressure peak in the bucket cylinder and a prolonged unloading time. This signal corroborates the gravity difference signal from the tension sensor, improving the robustness of the detection.

[0038] The layout and operating principle of the execution unit are as follows: The execution unit receives control commands and performs cleaning actions. Two servo-phase vibration motors, acting as vibrators, are mounted on the outer walls of both sides of the bucket via high-strength bases. This location is within the shaded area of ​​the bucket's outer contour, ensuring no contact with the ore or rock during excavation. The vibrators work by utilizing the centrifugal force generated by the high-speed rotation of paired eccentric blocks to create directional or non-directional excitation forces. This forces the bucket sidewalls to bend and vibrate at a specific frequency and amplitude. These vibration waves propagate within the bucket's metal structure, causing fatigue cracks to form at the adhesive interface between the adhering material and the bucket wall under alternating stress, ultimately leading to separation and detachment.

[0039] To combat freezing and sticking in winter, a network of pressure-resistant stainless steel heat exchange pipes is pre-laid beneath the wear-resistant lining plates on the inner walls of the bucket's side and back plates. These pipes are connected to the oil-water heat exchanger of the electric shovel's hydraulic system via a shut-off valve assembly, forming a closed-loop micro-heating subsystem. The working principle is as follows: During operation, the hydraulic system continuously performs work, and the return oil temperature is typically stable between 40-60°C. This heat is originally waste heat dissipated into the environment through the radiator. This invention extracts this waste heat through the heat exchanger and transfers it to the heat transfer medium within the pipes. After circulation, the medium gently heats the inner wall of the bucket, with the target temperature only needing to be controlled to raise the frozen interface temperature to 5-15°C. It is within this temperature range that the anchoring force between ice crystals and the metal surface decreases dramatically, while the quality of the material itself remains unaffected.

[0040] Control unit: The control unit uses an industrial-grade PLC and is installed inside the electric shovel's electrical room. The controller collects data from sensors such as tension and pressure in real time through analog input modules, and interacts with the electric shovel's main control system through digital or bus communication to obtain status information such as ambient temperature, material type settings, and bucket working posture. It also has a built-in algorithm for classifying the degree of material adhesion and a cleaning strategy database, playing a core decision-making role in the closed loop of detection-judgment-execution-verification.

[0041] (II) Control methods and work processes The system's control method fully integrates an intelligent closed loop of "quantitative perception - hierarchical decision-making - collaborative execution - closed-loop verification," with the specific process as follows: Step 1: Detection trigger and weighing comparison When the controller determines from the attitude signal that the electric shovel has completed a unloading action and the bucket has returned to a horizontal position, it automatically initiates a material adhesion detection program. At this time, the controller reads the value from the tension sensor, calculates the current total weight of the bucket, and subtracts it from the pre-stored standard empty bucket weight benchmark value to obtain the weight difference ΔW. For example, if the standard empty bucket weight of a certain model is 15 tons, and the actual measured weight after unloading is 22 tons, then ΔW is 7 tons.

[0042] Step 2: Grading of material adhesion degree and multi-signal fusion judgment The controller classifies the material adhesion status based on the range within which ΔW falls. Specific classification thresholds are shown in the table below:

[0043] Table 1: Classification Threshold Comparison Table While determining the weight, the controller retrieves the pressure curve of the tipping cylinder from the most recent unloading process as an auxiliary analysis. If ΔW indicates moderate material adhesion, but the pressure peak and action time do not show any abnormal increase, the system will tend to trust the weight determination result, but will still perform cleanup. It will simply mark the confidence difference of this determination in the log to provide data for subsequent strategy optimization.

[0044] Step 3: Matching and Executing Adaptive Cleanup Strategies Based on the viscosity grade and external operating conditions, the controller automatically retrieves the corresponding control commands from the strategy library to drive the execution unit to operate. For slight material adhesion: the system enters silent mode, does not start the vibrator, or vibrates briefly for 3 seconds at the lowest starting frequency of 10Hz, only performing slight vibration to avoid energy waste.

[0045] For moderately sticky materials: the vibrator starts immediately, and the frequency converter drives the motor to operate in the mid-frequency range of 20-30Hz, vibrating continuously for 8-12 seconds. This frequency range is close to a certain natural frequency of the middle and rear of the bucket, which can excite a more obvious resonant response of the bucket wall with a relatively small energy input, thus peeling the wet and sticky materials off the wall.

[0046] If the material is heavily viscous, it should be handled in two separate processes: Normal temperature operation: The vibrator vibrates continuously at a high frequency of 40-60Hz for 15-20 seconds, using strong excitation force and high-cycle fatigue stress to force the severely adhered layer to disintegrate.

[0047] Freeze-bonding mode: When the ambient temperature sensor detects that the air temperature is below 0℃, and the operator's preset material code corresponds to high-moisture coal or mudstone, the system determines that it has entered freeze-bonding mode. At this time, based on the high-frequency vibration of the vibrator, the shut-off valve of the heating subsystem opens simultaneously. The high-temperature hydraulic oil in the hydraulic system's return oil line flows through the heat exchanger, transferring heat to the medium in the heat exchange line, and begins to gently heat the bucket wall. Its core mechanism is: heat-vibration synergy: micro-heating precisely heats the frozen interface between the material and the bucket wall from the extremely low temperature to the softening temperature range. At this time, the strength of the ice crystal anchoring structure is greatly reduced, but the large pieces of frozen material themselves do not melt into mud. Then, the shear stress applied by the high-frequency vibration easily overcomes the weakened interface bonding force, causing the frozen material to fall off in sheets or blocks. This process ensures efficient and thorough cleaning, and achieves zero additional energy consumption by utilizing waste heat.

[0048] Step 3: Closed-loop effect verification and adaptive reverberation After the set vibration and heating are completed, the system waits for a few seconds until the bucket stabilizes. Then, the control unit performs the weighing test again and calculates the weight difference ΔW' after cleaning.

[0049] If ΔW' < 2 tons, meaning the weight of the remaining material is below the preset cleanliness threshold, it is determined to be "cleaning complete", the control process ends, and the electric shovel can continue to be used in the next digging cycle.

[0050] If ΔW' ≥ 2 tons, it indicates that the sticky material is abnormally stubborn and the initial cleaning did not meet the standard. At this time, the system automatically triggers the repeated cleaning mechanism: the excitation frequency of the previous cleaning is automatically increased by 10%, and if heating is involved, the heating time is extended by 5 seconds, and a second cleaning is performed. This adaptive upgrade is repeated a maximum of 2 times. If the weight difference still exceeds the standard after 2 repeated cleanings, it indicates that there may be mechanical structural jamming in the bucket or sensor malfunction. The system will stop the automatic cleaning program and issue an audible and visual alarm signal to the operator in the cab, prompting manual intervention.

[0051] Through the description of the above embodiments, the entire system forms a complete technical solution with external weighing as the core sensing means, graded vibration as the fundamental removal method, waste heat utilization as the path to break the frozen adhesion, and post-cleaning weight verification as a closed-loop guarantee. This solution solves the four major pain points of existing technologies: inability to quantitatively detect, blind cleaning strategies, difficulty in handling frozen adhesion conditions, and lack of guaranteed cleaning results, and has extremely high industrial practical value.

[0052] In summary, by employing the above-mentioned technical solution of this invention, the risk of sensor damage under excavation impact is avoided by using an indirect detection method that compares the weight after unloading outside the bucket, thus ensuring the reliability of the detection system. By quantifying the degree of material adhesion into light, medium, and heavy and matching the graded vibration intensity and duration, precise cleaning on demand is achieved, avoiding the energy loss from blind vibration. For frozen and sticky conditions, the residual heat from the return oil of the electric shovel's hydraulic system is innovatively used to micro-heat the inner wall of the bucket, softening the frozen interface in a zero-energy manner and working with vibration to peel off the frozen material, overcoming the pain point of cleaning during shutdowns in high-altitude and cold mining areas. By introducing a closed-loop verification mechanism for weight verification after cleaning, it is ensured that the bucket can be restored to a preset clean state after each loading and unloading operation, guaranteeing the thoroughness of unloading.

[0053] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A smart detection and adaptive cleaning system for material adhering to the bucket of an electric shovel, characterized in that, include: The material adhesion detection unit includes a tension sensor for measuring the weight of the bucket and the material. The control unit is electrically connected to the adhesive detection unit and is used to receive detection data, determine the degree of adhesiveness, and issue control commands. The execution unit includes a vibrator mounted on the outer wall of the bucket side plate, the vibrator receiving instructions from the control unit to operate with an adjustable vibration frequency and duration; The control unit is configured to perform closed-loop verification of the cleaning effect based on the feedback from the adhesive detection unit after the cleaning operation, and to control the execution unit to repeat the operation if the target is not met.

2. The intelligent detection and adaptive cleaning system for sticky material in an electric shovel bucket according to claim 1, characterized in that, The material adhesion detection unit also includes a pressure sensor installed on the hydraulic cylinder pipeline of the electric shovel bucket, and / or an angle sensor installed at the connection between the bucket and the stick; the control unit is also used to collect data from the pressure sensor and / or the angle sensor to help determine the degree of material adhesion.

3. The intelligent detection and adaptive cleaning system for sticky material in an electric shovel bucket according to claim 1, characterized in that, The execution unit also includes a heating element embedded below the wear-resistant liner on the inner wall of the bucket side plate and the back plate. The heating element is connected to the return oil pipeline of the electric shovel hydraulic system through a heat exchange system to utilize the waste heat of the hydraulic oil for heating. The control unit is also used to control the start and stop of the heating element.

4. A control method for an intelligent detection and adaptive cleaning system for material adhering to an electric shovel bucket, characterized in that, Includes the following steps: Step S1: After the electric shovel completes the unloading operation, obtain the current weight of the bucket; Step S2: Compare the current weight with the preset empty bucket weight threshold and calculate the weight difference; Step S3: Determine the degree of material adhesion to the inner wall of the bucket based on the weight difference; Step S4: Based on the degree of material adhesion, automatically match and execute the corresponding cleaning strategy. The cleaning strategy includes at least starting the vibrator with different vibration parameters. Step S5: After the cleaning strategy is completed, the bucket weight is obtained again to verify the cleaning effect. If the weight difference does not reach the preset cleaning completion standard, the corresponding cleaning strategy is automatically repeated.

5. The control method for an intelligent detection and adaptive cleaning system for material adhering to an electric shovel bucket according to claim 4, characterized in that, In step S1, obtaining the current weight of the bucket specifically involves: using a tension sensor installed on the lifting wire rope of the electric shovel to collect tension data when the bucket returns to a horizontal position after unloading, in order to calculate the current weight.

6. The control method for an intelligent detection and adaptive cleaning system for material adhering to an electric shovel bucket according to claim 4, characterized in that, In step S3, the degree of material adhesion to the inner wall of the bucket is determined based on the weight difference, specifically as follows: When the weight difference is greater than or equal to 2 tons and less than 5 tons, it is judged as slight adhesion. When the weight difference is greater than or equal to 5 tons and less than 10 tons, it is judged as moderately sticky material; When the weight difference is greater than or equal to 10 tons, it is judged as heavily adhesive material.

7. The control method for an intelligent detection and adaptive cleaning system for material adhering to an electric shovel bucket according to claim 6, characterized in that, In step S4, automatically matching and executing the corresponding cleaning strategy based on the degree of adhesion includes: When the material is determined to be slightly stuck, the strategy is to not start the vibrator or to vibrate at a frequency of 10-15Hz for 3-5 seconds. When the material is determined to be moderately sticky, the strategy is to start the vibrator and vibrate at a frequency of 20-30Hz for 8-12 seconds. When the material is determined to be heavily sticky at room temperature, the strategy is to start the vibrator and vibrate at a frequency of 40-60Hz for 15-20 seconds. When the ambient temperature is below 0℃, the material type is high-moisture coal or mudstone, and it is determined to be heavily sticky, it is determined to be a frozen sticky working condition. The strategy is to start the vibrator to vibrate at a frequency of 40-60Hz for 15-20 seconds, and simultaneously start the micro heating device to heat the inner wall of the bucket.

8. The control method for an intelligent detection and adaptive cleaning system for material adhering to an electric shovel bucket according to claim 7, characterized in that, The heat source of the micro-heating device is taken from the residual heat of the return oil in the hydraulic system of the electric shovel. The heat is transferred to the wear-resistant liner on the inner wall of the bucket through the heat exchange pipeline, and the target heating temperature is 5-15℃.

9. The control method for an intelligent detection and adaptive cleaning system for material adhering to an electric shovel bucket according to claim 4, characterized in that, In step S5, the automatic repetition of the corresponding cleaning strategy is as follows: if the cleaning effect does not meet the standard, the cleaning is automatically repeated 1 to 2 times, and the vibration frequency of the exciter increases by 10% each time the cleaning is repeated, and if a heating step is included, the heating time increases by 5 seconds; if the standard is still not met after repeating 2 times, an alarm signal is issued to prompt manual intervention.

10. The control method for an intelligent detection and adaptive cleaning system for material adhering to an electric shovel bucket according to claim 4, characterized in that, It also includes auxiliary judgment steps: during the unloading process, the hydraulic pressure and action time of the electric shovel tipper cylinder are monitored in real time; when the pressure peak of the tipper cylinder exceeds the normal range or the action speed is lower than the normal threshold, the presence of sticky material residue is verified, and the result of the sticky material degree judged by the weight difference is mutually verified.

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