An automatic separation and protection device and method for metallic foreign objects before iron ore crushing

Abstract

This invention belongs to the field of mining machinery and automation control technology, and relates to an automatic separation and protection device and method for metal foreign objects before iron ore crushing. It includes a conveyor belt, a head funnel located at the end of the conveyor belt to receive material thrown from the belt, and a separation storage hopper located in the head funnel and away from the end of the conveyor belt. The head funnel, metal detector, and separation flap assembly together achieve full metal detection of ferromagnetic and non-ferromagnetic metal foreign objects in the conveyed material, and protect the downstream cone crusher from excessive iron damage while ensuring the operational safety of equipment maintenance personnel.

Description

Technical Field

[0001] This invention belongs to the field of mining machinery and automation control technology, and relates to an automatic separation and protection device and method for metal foreign objects before iron ore crushing. Background Technology

[0002] In iron ore mining and crushing / screening processes, metallic foreign objects (such as high-manganese steel drill bits, shovel teeth, broken bolts, and wear-resistant alloy parts) mixed into the material conveyor belt are the core cause of failures in downstream cone crushers and conveying systems. In existing technologies, conventional iron separators mainly rely on magnetic adsorption, which is only effective against ferromagnetic materials. However, with the upgrading of mining equipment materials, a large number of foreign objects are non-magnetic or weakly magnetic non-ferrous metals such as high-manganese steel and wear-resistant alloys. These substances cannot be captured by conventional iron separators and thus penetrate the defenses to enter the fine crushing stage. Because the discharge port of the intermediate crusher is relatively large, iron leakage is generally not common; therefore, the problem of metallic foreign object iron leakage is concentrated in the fine crushing stage.

[0003] A key technical challenge in addressing the aforementioned operating conditions is that the fracture of the cone crusher's main shaft is not simply caused by a single large metal impact, but rather by the cumulative effect of metal fatigue resulting from multiple minor metal impacts. Each undetected metal impact causes impact damage to the crusher's main shaft, moving cone, and foundation structure, ultimately triggering a catastrophic fracture during a single metal impact. Furthermore, relying solely on metal detectors without reliable mechanical separation and safety interlocking mechanisms cannot fundamentally solve the equipment protection problem. Summary of the Invention

[0004] This invention provides an automatic separation and protection device and method for metallic foreign objects before iron ore crushing, which realizes full metal detection of ferromagnetic and non-ferromagnetic metallic foreign objects in the conveyed material, and protects the downstream cone crusher from damage caused by excessive iron while ensuring the operational safety of equipment maintenance personnel.

[0005] To achieve the above-mentioned technical objectives, the technical solution adopted in this application is an automatic separation and protection device for metallic foreign objects before iron ore crushing, comprising: A belt is driven by the first pulley of a belt conveyor at one end; the belt is used to transport materials; the materials are thrown off the belt when they are transported to one end of the first pulley of the belt conveyor; the end of the belt located at the first pulley of the belt conveyor is the belt end. A head funnel, located at the end of the belt, is used to catch material thrown off the belt; at the same time, the head funnel covers the end of the belt. A separate storage hopper is located in the head funnel and on the side of the head funnel away from the end of the belt; A metal detector is installed above the belt or at one end of the head funnel near the first pulley of the belt conveyor; A separating flap assembly includes a separating flap and a driving mechanism; the driving mechanism is mounted on the head funnel; the separating flap is mounted in the head funnel, with its distal end suspended and its proximal end driven to rotate by the driving mechanism, while the proximal end of the separating flap is adjacent to the separating storage hopper; the separating flap has a working position and a standby position during rotation; in the working position, the distal end of the separating flap is close to the belt and forms an inclined surface at the end of the belt to catch material thrown from the belt; in the standby position, the distal end of the separating flap is close to the inner wall of the separating storage hopper, and the material will fall directly into the head funnel without passing through the separating flap; during the rotation of the separating flap from the working position to the standby position, the material on the separating flap is thrown into the separating storage hopper; The drive mechanism operates based on the detection signal from the metal detector.

[0006] As an improved technical solution of this application, the head funnel is provided with a separation storage hopper cleaning window on the side where the separation storage hopper is installed.

[0007] As an improved technical solution of this application, a safety protection device is also included, including a limit switch disposed at the cleaning window of the separation storage hopper; the limit switch is electrically interlocked with the drive mechanism, and the drive mechanism stops working when the cleaning window of the separation storage hopper is opened.

[0008] As an improved technical solution of this application, the metal detector adopts an electromagnetic induction device.

[0009] As an improved technical solution of this application, the separating storage hopper operating device includes a central rotating shaft, a support structure, and an operating handle; the central rotating shaft is supported at the bottom center of the separating storage hopper; the wall of the head funnel is provided with a support structure; both ends of the central rotating shaft are supported by the wall of the head funnel through the support structure; the central rotating shaft can rotate around the support structure; one end of the central rotating shaft penetrates the wall of the head funnel, and the operating handle is installed at this end of the central rotating shaft and located outside the head funnel.

[0010] Another technical objective of this application is to provide a method for automatic separation and protection of metallic foreign objects before iron ore crushing, which is implemented based on the aforementioned device and includes the following steps: Monitoring phase: Ore and any metal foreign objects that may be mixed in are thrown off at the end of the conveyor belt as it travels along the belt. Identification stage: As the material passes through the metal detector detection area on the conveyor belt, if no metal is detected, the metal detector does not output a signal, and the material flow naturally passes over the separation flap area and is directly thrown into the guide channel of the head funnel, where it is guided into the downstream crushing equipment; if metal is detected, the detector immediately outputs an electrical signal. Delay and trigger: The control system receives electrical signals and calculates the delay time based on the belt running speed. It determines when the delay time expires that the metal will have reached the end of the belt and be ready to be thrown off. Interception: The drive device pushes the separation flap to extend. When the delay time ends, the far end of the separation flap is adjacent to the end of the belt, and the metal falls directly from the belt onto the surface of the separation flap. Tilting and Resetting: After completing the interception action, the detachable flap immediately returns to the standby position; Safety interlock: If manual cleaning of the head funnel is required, the operator opens the cleaning window of the separation storage hopper. At this time, the limit switch of the safety protection device is activated, and the drive mechanism stops working. Material return: After manual cleaning and closing the cleaning window of the separation storage hopper, the operator drives the central shaft to rotate through the separation storage hopper operating device, flipping the separation storage hopper so that the remaining ore material in the hopper can be smoothly returned to the production process. Then the separation storage hopper is reset to the horizontal receiving position, waiting for the next separation operation. Beneficial effects

[0011] The device and method of this technology effectively overcome the problem of non-magnetic alloy detection and achieve all-metal protection: In response to the increasing number of non-magnetic or weakly magnetic foreign objects such as high-manganese steel and wear-resistant alloys in modern mining processes, this technology uses high-sensitivity metal detection technology to replace traditional magnetic separation for iron removal, completely solving the technical blind spot of conventional iron removers that "cannot see" non-ferrous metals, and achieving full coverage detection of various metal foreign objects.

[0012] It features an inherently safe interlocking protection mechanism: This method specifically designs a hard-wired interlocking logic between the cleaning window of the separation storage hopper and the actuator. When manually cleaning foreign objects, the system forcibly locks the separation flap, ensuring that the flap will not move even if the detector alarms again. This design fully considers the operational safety of maintenance personnel, eliminates mechanical pinching accidents, and meets the modern mine's production requirements of "people-oriented, safe and efficient."

[0013] Protecting core equipment: By implementing a pre-entry interception system, the entry of foreign metal objects into the cone crusher is completely prevented. This solves the problem of major accidents caused by excessive metal contamination, such as main shaft breakage, moving cone damage, and liner plate fracture. Statistics show that the number of times the fine crusher experiences excessive metal contamination has decreased from dozens of times per month before the modification to 3-5 times per month, fundamentally eliminating the risk of crusher shaft breakage due to accumulated metal fatigue. Attached Figure Description

[0014] Figure 1 A left sectional view illustrating the installation relationship between the head funnel and the separation flap assembly of this application; Figure 2 A front view showing the installation relationship between the head funnel and the separation flap assembly of this application; Figure 3 A top sectional view of the head funnel and separation flap assembly of this application is shown; Figure 4 A schematic diagram of the structure of the detachable flap in standby mode of this application is shown; Figure 5 A schematic diagram of the structure of the detachable flap in the working position is shown; Figure 6 A schematic diagram illustrating the process of the separation flap rotating from the working position to the standby position in this application; Figure 7 A schematic diagram illustrating the process of the separation flap rotating from the working position to the standby position in this application; Figure 8 A schematic diagram of the separation bucket tilting structure of this application is shown; In the diagram, 1. Belt; 2. Metal detector; 3. Head funnel; 4. Separation flap; 5. First pulley of belt conveyor; 6. Separation storage hopper; 7. Cleaning window of separation storage hopper; 8. Protective device; 9. Separation storage hopper operating device; 10. Drive mechanism. Detailed Implementation

[0015] This technology provides an automatic separation and protection device and method for metallic foreign objects before iron ore crushing. Its core purpose is to achieve full metal detection of ferromagnetic and non-ferromagnetic metallic foreign objects in the conveyed material, and to protect the downstream cone crusher from damage caused by excessive iron while ensuring the operational safety of equipment maintenance personnel.

[0016] To achieve the above objectives, the overall approach of the technical solution proposed in this paper is as follows: 1. High-sensitivity detection module: A metal detector 2 is installed in front of the conveyor head hopper 3. To address the interference of iron ore conductivity and quantity fluctuations on the detection signal, dynamic parameter adjustment and threshold optimization are used to accurately identify various metallic foreign objects (including but not limited to ironware, high-manganese steel, and alloy parts) mixed in the ore flow, effectively avoiding false alarms caused by the ore effect.

[0017] 2. Mechanical Separation Execution Module: A separation flap assembly is installed at the head of the belt conveyor. When the metal detector 2 detects a foreign object and sends a trigger signal, the drive mechanism quickly drives the separation flap 4 to rotate after a preset delay (calculated based on the speed of belt 1), changing the material's trajectory.

[0018] 3. Safety isolation and storage module: After the separation flap 4 is activated, it forms a narrow angle with the first pulley 5 of the belt conveyor, which peels off the metal foreign objects and guides them into the separation and storage hopper 6. The head funnel 3 is equipped with a separation and storage hopper cleaning window 7 and a safety protection device 8 to ensure that even if the metal detector 2 alarms again during manual cleaning, the separation flap 4 will not malfunction, thus preventing pinching accidents.

[0019] like Figure 1-8 As shown, an automatic metal foreign object separation and protection device before iron ore crushing is mainly installed at the head of the conveyor belt before the fine crushing process. Its core structure includes the following components: belt 1; metal detector 2; head funnel 3; separation flap 4; belt conveyor first wheel 5; separation storage hopper 6; separation storage hopper cleaning window 7; protection device 8; separation storage hopper operating device 9; drive mechanism 10.

[0020] The specific functions and connections of each component are as follows: Belt 1, driven at one end by the first pulley 5 of the conveyor belt; belt 1 is the main equipment for transporting materials, carrying and conveying ore materials; it transports upstream ore to the cone crusher, and also serves as a carrier for metal detection and separation. The material is dropped off by belt 1 when it is transported to one end of the first pulley 5 of the conveyor belt; the end of belt 1 located at the first pulley 5 of the conveyor belt is the end of belt 1. The head funnel 3, located at the end of the belt 1, is used to receive the material thrown from the belt 1 and guide it into the downstream crushing equipment; at the same time, it covers the belt 1 and the separation and storage funnel as a sealing cover to prevent dust generated during the material throwing process from overflowing.

[0021] The separation storage hopper 6 is located in the head funnel 3 and away from the end of the belt 1; it receives metal foreign objects and a small amount of associated ore that are dumped off by the separation flap 4 during the rapid reset process, and is used for temporary storage for subsequent manual sorting.

[0022] Metal detector 2 is installed above belt 1 or near one end of head funnel 3 near the first pulley 5 of the belt conveyor; it mainly uses an electromagnetic induction device, which is the core detection unit, used to monitor the material flow through belt 1 in real time, and identify and distinguish ferromagnetic metals (such as ordinary iron blocks) and non-ferromagnetic metals (such as high manganese steel and alloy parts). Through parameter adjustment, it has the ability to resist ore interference.

[0023] The separating flap assembly includes a separating flap 4 and a driving mechanism 10. The driving mechanism 10 is mounted on the head funnel 3; the separating flap 4 is mounted in the head funnel 3. The distal end of the separating flap 4 is suspended, and the proximal end of the separating flap 4 is driven to rotate by the driving mechanism. Simultaneously, the proximal end of the separating flap 4 is adjacent to the separating storage hopper 6. The separating flap 4 has a working position and a standby position during rotation. The electric drive (driving mechanism 10) drives the separating flap 4, which is normally in a retracted state against the wall of the separating storage hopper 6, and extends downwards during operation. Specifically, in the working position, the distal end of the separating flap 4 is close to the belt 1 and forms an inclined surface at the end of the belt 1 to catch the material thrown from the belt 1. That is, its distal end cooperates with the surface of the first pulley 5 of the belt conveyor to form an acute interception angle (V-shaped angle) to peel metal foreign objects off the belt 1. In the standby position, the far end of the separating flap 4 is close to the inner wall of the separating storage hopper 6, and the material will fall directly into the head funnel 3 without passing through the separating flap 4. The drive mechanism operates based on the detection signal of the metal detector 2; after receiving the trigger signal from the metal detector 2, the control system dynamically calculates and executes a precise delay triggering mechanism based on the real-time running speed of the belt 1 and the physical distance from the detection point to the interception point (i.e., the working position of the separating flap 4), ensuring that when the separating flap 4 extends to the working position, the detected metal object is exactly running into the "V"-shaped angle interception zone, achieving precise interception. In actual industrial applications, this action sequence has clear quantitative indicators: from the metal detector 2 detecting iron and outputting a signal to the separating flap 4 starting to extend, the system-set precise delay time is 5.8 seconds; the entire process of the flap completing the interception action, returning to its original position, and restoring to the standby state takes only 0.6 seconds. This efficient action logic ensures the accuracy of interception while avoiding obstruction of subsequent normal material flow.

[0024] As an improved technical solution of this application, the head funnel 3 is provided with a separation storage hopper cleaning window 7 on the side where the separation storage hopper 6 is installed, which can be opened by the operator to pick out the metal foreign objects in the head funnel 3.

[0025] As an improved technical solution of this application, a safety protection device 8 is also included, comprising a limit switch installed at the cleaning window 7 of the separation storage hopper; the limit switch forms an electrical interlock with the drive mechanism, and the drive mechanism stops working when the cleaning window 7 of the separation storage hopper is opened. Specifically, it includes a limit switch and an electrical control interlock circuit installed on the cleaning window 7 of the separation storage hopper, and its safety logic is as follows: when the cleaning window 7 of the separation storage hopper is opened, the limit switch is triggered, forcibly cutting off the drive power (or control signal) of the separation flap 4, putting it in a mechanically locked state. Even if the metal detector 2 alarms again at this time, the separation flap 4 will not move, thereby protecting the safety of the cleaning personnel.

[0026] As an improved technical solution of this application, the metal detector 2 adopts an electromagnetic induction device.

[0027] As an improved technical solution of this application, the separating storage hopper operating device 9 includes a central rotating shaft, a support structure, and an operating handle. The central rotating shaft is supported at the bottom center of the separating storage hopper 6. The wall of the head funnel 3 is provided with a support structure. Both ends of the central rotating shaft are supported by the wall of the head funnel 3 through the support structure. The central rotating shaft can rotate around the support structure. The support structure is specifically a bearing seat. The bearing seat is fixedly installed on the side wall of the head funnel 3 by bolts or other fasteners. Both ends of the central rotating shaft are respectively installed in the bearing seat through bearings, so that the central rotating shaft can rotate smoothly around the support structure and drive the separating storage hopper 6 to rotate. One end of the central rotating shaft penetrates the wall of the head funnel 3. The operating handle is installed at the end of the central rotating shaft and is located outside the head funnel 3. Specifically: the separation and storage hopper 6 is hinged to the support structure via a horizontally arranged central pivot, allowing it to rotate around the central pivot; the separation and storage hopper operating device 9 includes an operating handle fixed to the end of the central pivot; by rotating the operating handle, the central pivot can be driven to rotate, thereby causing the separation and storage hopper 6 to flip around the axis to dump the internal material. This allows the operator to remove any metal foreign objects from the head funnel 3, and then rotate the head funnel 3 using the separation and storage hopper operating device 9 to return the remaining ore material in the hopper to the production process.

[0028] Another technical objective of this application is to provide a method for automatic separation and protection of metallic foreign objects before iron ore crushing, implemented using the aforementioned device, which follows a closed-loop logic of "detection-judgment-interception-dumping". Specifically, it includes the following steps: Monitoring phase: The ore and any metal foreign objects that may be mixed in are thrown off at the end of belt 1 as it travels along belt 1; Identification stage: When the material passes through the detection area of ​​the metal detector 2 on the belt 1, if there is no metal, the metal detector 2 will not output a signal, and the material flow will naturally pass through the separation flap 4 area and be thrown directly into the guide channel of the head funnel 3, and then be guided into the downstream crushing equipment; if metal is detected, the detector will immediately output an electrical signal. Delay and trigger: The control system receives an electrical signal and calculates the delay time based on the running speed of belt 1. It determines when the delay time expires that the metal will run to the end of belt 1 and be ready to be thrown off. Interception: The drive device pushes the separation flap 4 to extend. When the delay time ends, the far end of the separation flap 4 is adjacent to the end of the belt 1, and the metal falls directly from the belt 1 onto the surface of the separation flap 4. Pour and reset: After completing the interception action, the separation flap 4 immediately returns to the standby position; during the reset process, the flap "scoops up" the intercepted metal foreign objects and a small amount of ore and pours them into the separation storage hopper 6 below, and then the flap returns to the initial standby position; Safety interlock: If manual cleaning of the head funnel 3 is required, the operator opens the cleaning window 7 of the separation storage hopper. At this time, the limit switch of the safety protection device 8 is activated, and the drive mechanism stops working. Material return: After manual cleaning is completed and the cleaning window 7 of the separation storage hopper is closed, the operator drives the central shaft to rotate through the separation storage hopper operating device, flipping the separation storage hopper 6 so that the remaining ore material in the hopper can be smoothly returned to the production process. Then the separation storage hopper 6 is reset to the horizontal receiving position, waiting for the next separation operation.

[0029] Practical Application Effects: 1. Protecting Core Equipment: Through pre-interception, the entry of metal foreign objects into the cone crusher is completely prevented. This solves major accidents such as main shaft breakage, moving cone damage, and liner breakage caused by excessive metal. Statistics show that the number of times the fine crusher experiences excessive metal has decreased from dozens of times per month before the modification to 3-5 times per month, fundamentally eliminating the risk of crusher shaft breakage due to metal fatigue accumulation. 2. Ensuring Conveying System Safety: Effectively prevents sharp metal objects from piercing or tearing the conveyor belt, avoiding expensive belt replacement and long-term downtime for maintenance. 3. High Reliability and Anti-interference Capability: The metal detector 2, with optimized parameters, can accurately distinguish between ore and metal, significantly reducing the false alarm rate and ensuring the continuity of the production process. 4. Intrinsically Safe Design: The unique protection device logic (locking the actuator when the separation storage hopper cleaning window 7 is opened) ensures the safety of equipment operation and the personal safety of maintenance personnel, meeting modern mine safety production standards.

Claims

1. An automatic separation and protection device for metallic foreign objects before iron ore crushing, characterized in that, include A belt is driven by the first pulley of a belt conveyor at one end; the belt is used to transport materials; the materials are thrown off the belt when they are transported to one end of the first pulley of the belt conveyor; the end of the belt located at the first pulley of the belt conveyor is the belt end. A head funnel, located at the end of the belt, is used to catch material thrown off the belt; at the same time, the head funnel covers the end of the belt. A separate storage hopper is located in the head funnel and on the side of the head funnel away from the end of the belt; A metal detector is installed above the belt or at one end of the head funnel near the first pulley of the belt conveyor; A separating flap assembly includes a separating flap and a driving mechanism; the driving mechanism is mounted on the head funnel; the separating flap is mounted in the head funnel, with the distal end of the separating flap suspended in the air, and the proximal end of the separating flap being driven to rotate by the driving mechanism, while the proximal end of the separating flap is adjacent to the separating storage hopper; the separating flap has a working position and a standby position during rotation; When in the working position, the far end of the separating flap is close to the belt and forms an inclined surface at the end of the belt to catch the material thrown off the belt; When in the standby position, the far end of the separating flap is close to the inner wall of the separating storage hopper, and the material will fall directly into the head funnel without passing through the separating flap; as the separating flap rotates from the working position to the standby position, the material on the separating flap is thrown into the separating storage hopper. The drive mechanism operates based on the detection signal from the metal detector.

2. The automatic separation and protection device for metallic foreign objects before iron ore crushing according to claim 1, characterized in that, The head funnel has a separation storage hopper cleaning window on the side where the separation storage hopper is installed.

3. The automatic separation and protection device for metallic foreign objects before iron ore crushing according to claim 2, characterized in that, It also includes a safety protection device, including a limit switch located at the cleaning window of the separation storage hopper; the limit switch is electrically interlocked with the drive mechanism, and the drive mechanism stops working when the cleaning window of the separation storage hopper is opened.

4. The automatic separation and protection device for metallic foreign objects before iron ore crushing according to claim 1, characterized in that, The metal detector uses an electromagnetic induction device.

5. The automatic separation and protection device for metallic foreign objects before iron ore crushing according to claim 1, characterized in that, A separation storage hopper operating device includes a central rotating shaft, a support structure, and an operating handle. The central rotating shaft is supported at the bottom center of the separation storage hopper. The wall of the head funnel is provided with a support structure. Both ends of the central rotating shaft are supported by the wall of the head funnel through the support structure. The central rotating shaft is rotatable around the support structure. One end of the central rotating shaft penetrates the wall of the head funnel, and the operating handle is installed at this end of the central rotating shaft and located outside the head funnel.

6. A method for automatic separation and protection of metallic foreign objects before iron ore crushing, characterized in that, The device according to any one of claims 1-5 is implemented by comprising the following steps: Monitoring phase: The ore and any metal foreign objects that may be mixed in are thrown off at the end of the conveyor belt as it travels along the belt. Identification stage: As the material passes through the metal detector detection area on the conveyor belt, if there is no metal, the metal detector will not output a signal. The material flow will then pass through the separation flap area and be directly thrown into the guide channel of the head funnel, where it will be guided into the downstream crushing equipment. If metal is detected, the detector immediately outputs an electrical signal; Delay and trigger: The control system receives electrical signals and calculates the delay time based on the belt running speed. It determines when the delay time expires that the metal will have reached the end of the belt and be ready to be thrown off. Interception: The drive mechanism pushes the separation flap to extend. When the delay time ends, the far end of the separation flap is adjacent to the end of the belt, and the metal falls directly from the belt onto the surface of the separation flap. Tilting and Resetting: After completing the interception action, the detachable flap immediately returns to the standby position; Safety interlock: If manual cleaning of the head funnel is required, the operator opens the cleaning window of the separation storage hopper. At this time, the limit switch of the safety protection device is activated, and the drive mechanism stops working. Material return: After manual cleaning and closing the cleaning window of the separation storage hopper, the operator drives the central shaft to rotate through the separation storage hopper operating device, flipping the separation storage hopper so that the remaining ore material in the hopper can be smoothly returned to the production process. Then the separation storage hopper is reset to the horizontal receiving position, waiting for the next separation operation.

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