A chute blockage detection control system and method for a high-cold region belt conveyor

Abstract

The application discloses a chute blockage detection control system and method for a belt conveyor in an alpine region, which comprises a first group of blockage sensors, a second group of blockage sensors, an ambient temperature sensor, a data acquisition module, an adaptive signal processing module, a hierarchical execution module and a remote communication module; wherein the two groups of blockage sensors are respectively installed at different height positions of the chute, and are used for realizing hierarchical detection of light blockage and heavy blockage; the adaptive signal processing module is internally provided with a temperature compensation algorithm and a Kalman filtering algorithm, can dynamically adjust a blockage determination threshold according to the ambient temperature, and can inhibit signal interference caused by coal dust and vibration; the hierarchical execution module starts a vibration device when light blockage occurs, and links a belt conveyor to stop when heavy blockage occurs; and the application has the advantages of high adaptability to an alpine environment, high detection accuracy, good anti-interference performance, support for remote monitoring and hierarchical disposal and the like.

Description

Technical Field

[0001] This invention relates to the field of safety monitoring technology for conveying equipment in coal preparation plants, specifically to a detection and control system and method for chute blockage of belt conveyors in cold regions. Background Technology

[0002] Belt conveyors are the core equipment for material transport in the surface production system of coal preparation plants. As a key component for material transfer, the smooth operation of the chute directly affects the normal operation of the belt conveyor. In coal preparation plants in cold regions, the extremely low winter temperatures (reaching as low as -39°C) cause materials to easily freeze and clump, easily leading to chute blockage. Simultaneously, the high levels of coal dust and intense vibration in coal preparation plants further exacerbate the risk of chute blockage. If chute blockage is not detected and addressed promptly, it can lead to material spillage, equipment overload, motor burnout, and even safety accidents, causing production interruptions and economic losses.

[0003] Existing chute blockage detection devices mostly use a single sensor, which has the following problems: First, they have poor adaptability to cold environments; the sensor sensitivity decreases and is prone to false alarms in low-temperature environments, making them unable to work properly. Second, the detection is delayed; it is often only detected after material accumulation is severe and blockage has already occurred, making it impossible to achieve proactive detection and timely handling. Third, they have weak anti-interference capabilities; factors such as coal dust and vibration can easily cause distortion of the detection signal, resulting in a high false alarm rate. Fourth, they cannot achieve graded handling; after a blockage, the machine can only be simply shut down, affecting production efficiency.

[0004] In addition, most existing detection devices lack remote communication capabilities, making them unsuitable for the unattended operation mode of belt conveyors and failing to meet the needs of intelligent upgrading of coal preparation plants. Summary of the Invention

[0005] The purpose of this invention is to provide a detection and control system and method for chute blockage of belt conveyors in high-altitude and cold regions, so as to solve the problems of existing bone marrow extraction devices mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a blockage detection and control system for belt conveyor chutes in high-altitude and cold regions, comprising:

[0007] The first set of blockage sensors 1 is installed at the bottom of the vertical sidewall of the chute at the first height position, and is used to detect mild blockage;

[0008] The second set of blockage sensors 2 is installed at the bottom of the vertical sidewall of the chute at the second height position, and is used to detect severe blockage, wherein the second height is greater than the first height;

[0009] Ambient temperature sensor 3 is installed near the chute to collect ambient temperature data.

[0010] Data acquisition module 4 is used to synchronously acquire the pressure signals and ambient temperature signals of each group of blockage sensors;

[0011] The adaptive signal processing module 5 has a built-in temperature compensation algorithm that dynamically adjusts the blockage judgment threshold of the first group and / or the second group of blockage sensors according to the ambient temperature, and outputs a mild blockage control signal or a severe blockage control signal.

[0012] The graded execution module 6 includes a vibration linkage unit 61 and a shutdown linkage unit 62. The vibration linkage unit 61 starts the chute vibration device 611 in response to a slight blockage control signal, and the shutdown linkage unit 62 triggers the belt conveyor 621 to stop in response to a severe blockage control signal.

[0013] The remote communication module 7 is used to upload blockage status and ambient temperature data to the unattended monitoring platform 8 and receive remote control commands.

[0014] Furthermore, the adaptive signal processing module 5 also includes a Kalman filter unit for filtering the pressure signal to suppress noise interference caused by coal dust and vibration.

[0015] Furthermore, the first set of blockage sensors 1 is installed at one-third of the height of the bottom of the chute, and the second set of blockage sensors 2 is installed at two-thirds of the height of the bottom of the chute; each set of blockage sensors includes at least 4 sensors, which are evenly distributed or staggered around the chute.

[0016] Furthermore, the blockage sensor includes an active detection gate, a reset elastic element, and a micro switch;

[0017] The active detection door is hinged to the sensor housing, with one end extending into the chute, and is used to rotate around the hinge axis when pushed by the material.

[0018] The reset elastic element applies a restoring force to the active detection gate, keeping it in its initial position;

[0019] The micro switch is located on the rotation path of the active detection gate. When the active detection gate is pushed to the trigger position by the material, the micro switch outputs a blockage signal.

[0020] Furthermore, the angle of motion required for the activity detection gate to rotate from its initial position to the trigger position is no greater than 5°, and the maximum allowable rotation limit angle of the activity detection gate is no greater than 10°.

[0021] Compared with the prior art, the beneficial effects of the present invention are:

[0022] 1. Strong adaptability to cold environments: The working temperature range of the material blockage sensor and the ambient temperature sensor is -40℃ to 70℃. The built-in temperature compensation algorithm can avoid malfunctions caused by low temperatures, making it suitable for the cold and dusty environment of Shengli Energy Coal Preparation Plant.

[0023] 2. To achieve advanced detection and graded handling, two sets of sensors at different heights are used to detect mild blockage and severe blockage respectively. Mild blockage triggers the rapping device to clear the material, while severe blockage triggers a shutdown. This not only prevents the fault from escalating but also reduces production downtime and improves production efficiency.

[0024] 3. Strong anti-interference capability: Kalman filtering algorithm is used to remove signal interference. The sensor adopts explosion-proof, dustproof and vibration-resistant design, with high detection accuracy and low false alarm rate.

[0025] 4. Supports remote communication and control, enabling real-time transmission of detection results to the unattended monitoring platform for remote monitoring and handling. It is compatible with the unattended operation mode of belt conveyors, improving the intelligence level of coal preparation plants.

[0026] 5. It has a simple structure and is easy to install. It can be seamlessly integrated with the existing rapping devices and belt conveyor control systems in coal preparation plants. The modification cost is low and it is easy to promote and apply. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the blockage detection and control system in this invention;

[0028] Figure 2 This is a schematic diagram showing the location of the blockage sensor on the cross-section of the chute in this invention;

[0029] Figure 3 This is a block diagram of the hierarchical execution logic of the adaptive signal processing module of the present invention;

[0030] Figure 4 This is a flowchart of data acquisition and signal processing in this invention.

[0031] In the diagram: 1. First set of material blockage sensors; 2. Second set of material blockage sensors; 3. Ambient temperature sensor; 4. Data acquisition module; 5. Adaptive signal processing module; 6. Graded execution module; 61. Vibration linkage unit; 611. Chute vibration device; 62. Stop linkage unit; 621. Belt conveyor; 7. Remote communication module; 8. Unattended monitoring platform. Detailed Implementation

[0032] In the description of this invention, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," "tail," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the 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, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0033] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0034] like Figure 1-4 As shown, the present invention provides a technical solution: a blockage detection and control system for belt conveyor chutes in high-altitude and cold regions, comprising:

[0035] The first set of blockage sensors 1 is installed at the bottom of the vertical sidewall of the chute at the first height position, and is used to detect mild blockage;

[0036] The second set of blockage sensors 2 is installed at the bottom of the vertical sidewall of the chute at the second height position, and is used to detect severe blockage, wherein the second height is greater than the first height;

[0037] Ambient temperature sensor 3 is installed near the chute to collect ambient temperature data.

[0038] Data acquisition module 4 is used to synchronously acquire the pressure signals and ambient temperature signals of each group of blockage sensors;

[0039] The adaptive signal processing module 5 has a built-in temperature compensation algorithm that dynamically adjusts the blockage judgment threshold of the first group and / or the second group of blockage sensors according to the ambient temperature, and outputs a mild blockage control signal or a severe blockage control signal.

[0040] The graded execution module 6 includes a vibration linkage unit 61 and a shutdown linkage unit 62. The vibration linkage unit 61 starts the chute vibration device 611 in response to a slight blockage control signal, and the shutdown linkage unit 62 triggers the belt conveyor 621 to stop in response to a severe blockage control signal.

[0041] The remote communication module 7 is used to upload blockage status and ambient temperature data to the unattended monitoring platform 8 and receive remote control commands.

[0042] The material blockage sensor adopts a mechanical movable door structure with an operating angle of no more than 5° and a limiting angle of no more than 10°. The contact capacity is 1A / 125V (DC), 5A / 250V, or 480V (AC), with a protection rating of no less than IP65. The operating temperature range is -40℃ to 70℃, making it suitable for cold, dusty, and high-vibration environments. The material blockage sensors are divided into two groups, both installed on the vertical sidewalls of the chute and protected from direct material impact. The first group is installed at the bottom third of the chute to detect minor blockages; each group includes at least four sensors evenly distributed around the chute to ensure comprehensive detection. The second group is installed at the bottom two-thirds of the chute to detect severe blockages; each group includes at least four sensors, staggered from the first group to avoid blind spots.

[0043] The ambient temperature sensor is installed near the chute to collect the ambient temperature. Its operating temperature range is -40℃ to 70℃, and its measurement accuracy is not less than ±1℃, providing data support for temperature compensation of the detection signal.

[0044] The data acquisition module uses a high-precision ADC chip, which can synchronously acquire the pressure signal from the blockage sensor and the temperature signal from the ambient temperature sensor. The acquisition frequency is 0.5 times / second, ensuring the real-time performance and accuracy of the data. The acquired data is transmitted to the signal processing module through the SPI interface.

[0045] The signal processing module uses an STM32 microcontroller as the core controller and incorporates a filtering algorithm and a temperature compensation algorithm. The filtering algorithm uses Kalman filtering, which can remove signal interference caused by coal dust and vibration. The temperature compensation algorithm automatically adjusts the detection threshold of the blockage sensor according to the ambient temperature, avoiding sensor malfunctions caused by low temperatures and reducing the false alarm rate.

[0046] After processing the collected signals, the signal processing module identifies the blockage status of the chute and outputs the corresponding control signals.

[0047] The alarm module includes an audible and visual alarm, which can emit different colored audible and visual alarms according to the control signal of the signal processing module: a yellow audible and visual alarm for mild blockage and a red audible and visual alarm for severe blockage. The alarm volume is not less than 80dB to ensure that operators can detect the blockage in time.

[0048] The vibration linkage module is connected to the existing vibration device in the chute. When it receives a slight blockage control signal from the signal processing module, it starts the vibration device to clear the material accumulation in the chute through vibration and prevent the blockage from worsening. Once the blockage is cleared, the vibration device stops automatically.

[0049] The shutdown linkage module is connected to the belt conveyor control system. When it receives a severe blockage control signal from the signal processing module, it triggers a belt conveyor shutdown command to prevent the material from continuing to be conveyed, which would cause the blockage to worsen and protect the equipment safety. After the blockage fault is cleared, the belt conveyor can be manually reset through the remote monitoring platform to restore its operation.

[0050] The remote communication module supports both 5G and Ethernet communication methods, enabling real-time transmission of chute blockage status, alarm information, and ambient temperature data to the unattended monitoring platform for the belt conveyor. It also supports network interruption recovery, automatically storing data locally when the network is interrupted and uploading it automatically when the network is restored, ensuring no data loss. In addition, it supports remote control command issuance, enabling remote operations such as starting, stopping, and resetting the vibrating device.

[0051] A method for detecting and controlling blockage in the chute of a belt conveyor in high-altitude and cold regions includes the following steps:

[0052] S1: Equipment Deployment. Two sets of blockage sensors are installed at the bottom one-third and two-thirds of the chute, respectively, ensuring the sensors are not directly impacted by material and are evenly distributed to avoid blind spots. The ambient temperature sensor is installed near the chute, away from heat sources and areas affected by material impact. The data acquisition module and signal processing module are installed in a nearby control box, which is explosion-proof and dustproof with a protection level of at least IP65. The alarm module is installed outside the control box for easy observation and hearing of alarm signals.

[0053] S2: Signal Acquisition. The data acquisition module acquires the pressure signal from the blockage sensor and the temperature signal from the ambient temperature sensor in real time, at a frequency of 0.5 times / second. When material accumulates in the chute, it exerts pressure on the chute sidewall, pushing the movable gate of the blockage sensor to deflect, and the sensor outputs a corresponding pressure signal. The ambient temperature sensor acquires the on-site temperature in real time, providing data for temperature compensation.

[0054] S3: Signal Processing. The signal processing module performs Kalman filtering on the acquired pressure signal to remove signal interference caused by coal dust and vibration; it automatically adjusts the detection threshold of the blockage sensor according to the ambient temperature using a temperature compensation algorithm (for example, appropriately increasing the detection threshold in low-temperature environments to avoid false triggering due to decreased sensor sensitivity at low temperatures); and it analyzes the processed pressure signal to determine whether the blockage threshold has been reached.

[0055] S4: Blockage Identification and Graded Handling. When the pressure signal detected by the first set of blockage sensors exceeds the mild blockage threshold, it is determined to be a mild blockage. The signal processing module outputs a control signal to activate the rapping linkage module and the alarm module: the rapping device begins rapping to clear the material accumulation in the chute; the alarm module emits a yellow audible and visual alarm to alert the operator. When the pressure signal detected by the second set of blockage sensors exceeds the severe blockage threshold, it is determined to be a severe blockage. The signal processing module outputs a control signal to activate the shutdown linkage module and the alarm module: the belt conveyor immediately stops to prevent continued material conveying from worsening the blockage; the alarm module emits a red audible and visual alarm to alert the operator for emergency handling. After the blockage is cleared, the movable door of the blockage sensor automatically resets under the action of the spring, the signal processing module stops outputting control signals, the rapping device stops working, the alarm signal is cleared, and the operator can manually reset it through the remote monitoring platform to restore the operation of the belt conveyor.

[0056] S5: Data Transmission and Monitoring. The remote communication module transmits the chute blockage status (normal, light blockage, heavy blockage), alarm information, and ambient temperature data to the unattended monitoring platform for the belt conveyor in real time. The platform displays the blockage location, blockage level, and ambient temperature in real time, and records alarm logs (including alarm time, blockage location, and handling status). Operators can remotely view the detection data and issue control commands such as rapping start and shutdown reset through the platform to achieve remote monitoring and handling.

[0057] It is understood that the above embodiments are merely exemplary implementations used to illustrate the principles of the present invention, and the present invention is not limited thereto. For those skilled in the art, various modifications and improvements can be made without departing from the spirit and essence of the present invention, and these modifications and improvements are also considered to be within the scope of protection of the present invention.

Claims

1. A blockage detection and control system for belt conveyor chutes in high-altitude and cold regions, characterized in that, include: The first set of blockage sensors (1) is installed at the bottom of the vertical sidewall of the chute at the first height position to detect mild blockage; The second set of blockage sensors (2) is installed at the bottom of the vertical sidewall of the chute at the second height position to detect severe blockage, wherein the second height is greater than the first height; An ambient temperature sensor (3) is installed near the chute to collect ambient temperature data. The data acquisition module (4) is used to synchronously acquire the pressure signals and ambient temperature signals of each group of blockage sensors; The adaptive signal processing module (5) has a built-in temperature compensation algorithm, which dynamically adjusts the blockage judgment threshold of the first group and / or the second group of blockage sensors according to the ambient temperature, and outputs a mild blockage control signal or a severe blockage control signal. The graded execution module (6) includes a vibration linkage unit (61) and a shutdown linkage unit (62). The vibration linkage unit (61) starts the chute vibration device (611) in response to a mild blockage control signal, and the shutdown linkage unit (62) triggers the belt conveyor (621) to stop in response to a severe blockage control signal. The remote communication module (7) is used to upload the blockage status and ambient temperature data to the unattended monitoring platform (8) and receive remote control commands.

2. The chute blockage detection and control system for belt conveyors in high-altitude and cold regions according to claim 1, characterized in that: The adaptive signal processing module (5) also includes a Kalman filter unit for filtering the pressure signal to suppress noise interference caused by coal dust and vibration.

3. The chute blockage detection and control system for belt conveyors in high-altitude and cold regions according to claim 1, characterized in that: The first set of blockage sensors (1) is installed at one-third of the height of the bottom of the chute, and the second set of blockage sensors (2) is installed at two-thirds of the height of the bottom of the chute; each set of blockage sensors includes at least 4 sensors, which are evenly distributed or staggered around the chute.

4. The chute blockage detection and control system for belt conveyors in high-altitude and cold regions according to claim 3, characterized in that: The blockage sensor includes a movable detection gate, a reset elastic element, and a micro switch; The active detection door is hinged to the sensor housing, with one end extending into the chute, and is used to rotate around the hinge axis when pushed by the material. The reset elastic element applies a restoring force to the active detection gate, keeping it in its initial position; The micro switch is located on the rotation path of the active detection gate. When the active detection gate is pushed to the trigger position by the material, the micro switch outputs a blockage signal.

5. The chute blockage detection and control system for belt conveyors in high-altitude and cold regions according to claim 4, characterized in that: The angle of motion required for the active detection gate to rotate from its initial position to the trigger position is no greater than 5°, and the maximum allowable rotation limit angle of the active detection gate is no greater than 10°.

6. The method for detecting and controlling chute blockage in a belt conveyor in high-altitude and cold regions according to claim 1, characterized in that: Includes the following steps: S1: Collect pressure signals and ambient temperature signals from sensors at different blockage heights; S2: Filter the pressure signal and dynamically adjust the blockage determination threshold according to the ambient temperature; S3: When the pressure signal at the first height position exceeds the minor blockage threshold, it is determined to be a minor blockage, and a rapping clearing is performed and a yellow alarm is issued; S4: When the pressure signal at the second height position exceeds the severe blockage threshold, it is determined to be a severe blockage, triggering the belt conveyor to stop and issuing a red alarm; S5: Uploads the congestion level, alarm information, and ambient temperature to the remote monitoring platform in real time, and records the alarm log.

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