Coal flow detection device

Abstract

The utility model relates to the technical field of coal transportation measurement, and discloses a coal flow detection device which comprises a bottom plate and a line laser binocular stereo camera, a support is fixedly arranged at the upper end of the bottom plate, the line laser binocular stereo camera is fixed above a conveying belt through the support, and the installation direction of the line laser binocular stereo camera is parallel to the conveying belt. The upper end of the linear laser binocular stereo camera is fixedly provided with a linear laser, the laser emission direction is perpendicular to the conveying belt so that laser rays can be formed on the surface of the coal flow, and the side, away from the support, of the upper end of the bottom plate is further provided with a hard trigger interface module. The hard trigger interface module is connected with the camera through a hard trigger interface line and supports external trigger signal input, and an image processing instrument is installed at the upper end of the line laser and communicates with the camera through a gigabit network port so as to calculate the coal flow volume in real time and output a statistical result.

Description

Technical Field

[0001] This application belongs to the field of coal transportation measurement technology, specifically relating to a coal flow detection device. Background Technology

[0002] Currently, the common practice for measuring the amount of coal conveyed by a belt conveyor per unit time is to use a belt scale. A belt scale is an automatic weighing instrument that continuously weighs bulk materials on a conveyor belt without requiring subdivision of mass or interruption of the conveyor belt's movement. Belt scales are mainly classified by the load-bearing device: weighing platform type and conveyor type; and by belt speed: single-speed belt scales and variable-speed belt scales. Another method is to use an optical coal flow meter. Optical coal flow meters use an industrial camera and a line laser light source, and based on the triangulation principle, measure the cross-sectional area of ​​the coal being transported on the belt conveyor, then multiply this area by the belt's speed to obtain the amount of coal conveyed per unit time. Compared to electronic belt scales, optical coal flow meters have the advantages of smaller size, easier installation, and simpler maintenance.

[0003] In related technologies, the camera and laser source adopt an integrated structure, with the camera and laser source fixed inside the housing. In actual use, due to the complex installation environment, the actual field of view of the camera and laser source deviates significantly from the intended field of view, resulting in low applicability. Summary of the Invention

[0004] This application provides a coal flow detection device to solve the above-mentioned technical problems.

[0005] The technical solution adopted in this application is as follows:

[0006] A coal flow detection device includes a base plate with a bracket fixedly mounted on its upper end. It also includes a line laser binocular stereo camera, which is fixed above a conveyor belt via the bracket, with its installation direction parallel to the conveyor belt, to collect stereo point cloud data of the coal flow on the conveyor belt. A line laser is fixedly mounted on the upper end of the line laser binocular stereo camera, with the laser emission direction perpendicular to the conveyor belt, to form a laser line on the surface of the coal flow. A hard trigger interface module is also provided on the upper end of the base plate, away from the bracket. The hard trigger interface module is connected to the camera via a hard trigger interface cable, supporting external trigger signal input. An image processor is mounted on the upper end of the line laser, communicating with the camera via a gigabit Ethernet port to calculate the coal flow volume in real time and output statistical results.

[0007] Optionally, an adjustable universal joint is provided at one end of the bracket, which is used to adjust the camera's tilt angle.

[0008] Optionally, the base plate is a damping shock absorber base, which is fixed to the conveyor belt support by bolts and has a rubber buffer layer at the bottom.

[0009] Optionally, the emission angle of the line laser can be finely adjusted by rotating an adjustment dial to ensure that the laser stripe is strictly perpendicular to the surface of the conveyor belt.

[0010] Optionally, the hard trigger interface line includes a trigger input line, a trigger output line, and a grounding line. The trigger input line is connected to the pulse signal terminal of the external encoder, and the grounding line is connected to the zero potential terminal of the encoder to achieve dynamic synchronization between the coal flow velocity and the acquisition frequency.

[0011] Optionally, the device supports a multi-machine collaborative working mode, with several line laser binocular stereo cameras distributed at intervals along the length of the conveyor belt, and the detection range of each camera is set by software to provide continuous and seamless coverage.

[0012] Optionally, a cooling fan is mounted on the rear side of the bracket via a fixing clip. The cooling fan faces the line laser binocular stereo camera and the line laser to reduce the operating temperature of the equipment.

[0013] Optionally, a switch is fixedly installed on one side of the upper end of the base plate. The switch includes a manual start / stop button and a linkage control interface. The linkage control interface is connected to the data processing unit via a signal line, and the switch is connected to the main power input interface of the device via a three-core waterproof cable.

[0014] Optionally, the triggering methods for the line laser binocular stereo camera include constant speed mode, variable speed mode, and compatible mode.

[0015] Due to the adoption of the above technical solution, the beneficial effects achieved by this application are as follows:

[0016] 1. This device employs a line laser binocular stereo camera combined with the optical sectioning principle to acquire stereo point cloud data of coal flow, whereas traditional coal flow detection methods mainly rely on monocular cameras or ultrasonic measurements, resulting in low data accuracy. This device improves the ability to capture coal flow morphology through high-precision stereo measurement, ensuring data accuracy.

[0017] 2. The camera's pitch angle is adjusted via an adjustable universal joint, enabling precise alignment for different installation environments, improving measurement accuracy, and avoiding data deviations caused by improper camera installation angles. Furthermore, this structure can adapt to variations in conveyor belt height and tilt angle, enhancing the device's versatility.

[0018] 3. By setting a rotating adjustment disk, the emission angle of the laser is precisely adjusted to ensure that the laser stripe is strictly perpendicular to the surface of the conveyor belt, avoiding data errors caused by angular deviation, ensuring the accuracy of optical sectioning measurement, and improving the accuracy of volume calculation. Attached Figure Description

[0019] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings:

[0020] Figure 1 This is a front perspective view of a coal flow detection device according to this application;

[0021] Figure 2 This is a rear-view perspective view of a coal flow detection device according to this application;

[0022] Figure 3 This is a top perspective view of a coal flow detection device according to this application;

[0023] Figure 4 This is a side view of a coal flow detection device according to this application;

[0024] Figure 5 This is a front view of a coal flow detection device according to this application.

[0025] 1. Base plate; 2. Bracket; 3. Line laser binocular stereo camera; 4. Line laser; 5. Hard trigger interface module; 6. Image processor; 7. Universal joint; 8. Rotary adjustment disk; 9. Cooling fan; 10. Switch. Detailed Implementation

[0026] To more clearly illustrate the overall concept of this application, a detailed explanation is provided below with reference to the accompanying drawings.

[0027] Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application may also be implemented in other ways different from those described herein. Therefore, the scope of protection of this application is not limited to the specific embodiments disclosed below. It should be noted that, unless otherwise specified, the embodiments of this application and the features thereof can be combined with each other.

[0028] A coal flow detection device includes a base plate 1, a bracket 2 fixedly mounted on the upper end of the base plate 1, and a line laser binocular stereo camera 3. The line laser binocular stereo camera 3 is fixed above a conveyor belt via the bracket 2, with its installation direction parallel to the conveyor belt, to collect stereo point cloud data of the coal flow on the conveyor belt. A line laser 4 is fixedly mounted on the upper end of the line laser binocular stereo camera 3, with the laser emission direction perpendicular to the conveyor belt, to form a laser line on the surface of the coal flow. A hard trigger interface module 5 is also provided on the upper end of the base plate 1 away from the bracket 2. The hard trigger interface module 5 is connected to the camera via a hard trigger interface cable and supports external trigger signal input. An image processor 6 is mounted on the upper end of the line laser 4. The image processor 6 communicates with the camera via a gigabit network port to calculate the coal flow volume in real time and output statistical results.

[0029] In this embodiment, the coal flow detection device is based on a base plate 1. A bracket 2 is fixedly installed on the upper end of the base plate 1. The bracket 2 is installed above the conveyor belt to ensure that the acquisition device maintains a suitable distance from the coal flow. An online laser binocular stereo camera 3 is fixed on the bracket 2, with its installation direction parallel to the conveyor belt. It can acquire three-dimensional point cloud data of the coal flow on the conveyor belt in real time. A linear laser 4 is fixedly installed on the upper end of the camera. Its laser emission direction is perpendicular to the conveyor belt, forming bright laser stripes on the surface of the coal flow, which are used to calibrate the depth information of the point cloud data. At the same time, a hard trigger interface module 5 is set on the side of the upper end of the base plate 1 away from the bracket 2. It is connected to the camera through the hard trigger interface line and supports the input of pulse signals emitted by an external encoder to realize the dynamic synchronization of the coal flow speed and the data acquisition frequency. An image processor 6 is also installed on the upper end of the online laser 4. This instrument communicates with the camera through a gigabit network port, calculates and counts the coal flow volume in real time, and provides a basis for subsequent data analysis and production monitoring.

[0030] Furthermore, one end of the bracket 2 is equipped with an adjustable universal joint 7, which is used to adjust the camera's tilt angle.

[0031] In this embodiment, to adapt to the changes in the height and shape of the coal flow under different production conditions, one end of the support 2 is equipped with an adjustable universal joint 7 to adjust the pitch angle of the camera and ensure that the laser stripe always falls on the surface of the coal flow. At the same time, the base plate 1 adopts a damping and shock absorption design and is firmly connected to the conveyor belt support 2 by bolts. A rubber buffer layer is set at the bottom to reduce the interference caused by the vibration of the conveyor belt and ensure the stability of data acquisition.

[0032] Furthermore, the base plate 1 is a damping shock absorber base, which is fixed to the conveyor belt support 2 by bolts, and has a rubber buffer layer at the bottom.

[0033] Furthermore, the emission angle of the line laser 4 is finely adjusted by rotating the adjustment disk 8 to ensure that the laser stripe is strictly perpendicular to the surface of the conveyor belt.

[0034] In this embodiment, in order to ensure that the laser stripe is strictly perpendicular to the surface of the conveyor belt, a rotating adjustment disk 8 is designed at the upper end of the laser. This disk can finely adjust the laser emission angle. When there are slight changes in the production environment or the angle of the conveyor belt, the laser direction can be corrected in time by adjusting the disk to ensure accurate positioning of the laser stripe and thus improve measurement accuracy.

[0035] Furthermore, the hard trigger interface line includes a trigger input line, a trigger output line, and a grounding line. The trigger input line is connected to the pulse signal terminal of the external encoder, and the grounding line is connected to the zero potential terminal of the encoder to achieve dynamic synchronization between the coal flow speed and the acquisition frequency.

[0036] In this embodiment, the hard trigger interface line includes a trigger input line, a trigger output line, and a ground line. The trigger input line is connected to the pulse signal terminal of the external encoder, and the ground line is connected to the zero potential terminal of the encoder. This design enables the camera acquisition frequency to be dynamically synchronized with the coal flow speed, ensuring that continuous and accurate data can be acquired at different coal flow speeds, thus meeting the production monitoring requirements.

[0037] Furthermore, the device supports a multi-machine collaborative working mode, with several line laser binocular stereo cameras 3 distributed at intervals along the length of the conveyor belt, and the detection range of each camera is set by software to provide continuous and seamless coverage.

[0038] In this embodiment, to cover a larger monitoring area, this embodiment supports a multi-machine collaborative working mode. Multiple line laser binocular stereo cameras 3 are evenly distributed along the length of the conveyor belt, and their detection range is set by software to provide continuous and seamless coverage, ensuring that the coal flow on the entire conveyor belt can be detected.

[0039] Furthermore, a cooling fan 9 is mounted on the rear side of the bracket 2 via a fixing clip. The cooling fan 9 faces the line laser binocular stereo camera 3 and the line laser 4 to reduce the operating temperature of the equipment.

[0040] By adopting the above technical solution, a cooling fan 9 is installed on the rear side of the bracket 2 by a fixing clip. The fan faces the camera and laser, which effectively reduces the heat generated when the equipment is working, extends the service life of the device, and ensures the stability of data acquisition.

[0041] Furthermore, a switch 10 is fixedly installed on one side of the upper end of the base plate 1. The switch 10 includes a manual start / stop button and a linkage control interface. The linkage control interface is connected to the data processing unit through a signal line, and the switch 10 is connected to the main power input interface of the device through a three-core waterproof cable.

[0042] Furthermore, the triggering methods of the line laser binocular stereo camera 3 include constant speed mode, variable speed mode, and compatible mode.

[0043] In this embodiment, a switch 10 is fixedly installed on one side of the upper end of the base plate 1. The switch 10 includes a manual start / stop button and a linkage control interface. The linkage control interface is connected to the data processing unit via a signal line, enabling linkage control with other equipment on the production line. The switch 10 is connected to the main power input interface of the device via a three-core waterproof cable, ensuring reliable electrical connection. Simultaneously, the line laser binocular stereo camera 3 supports multiple trigger modes, including constant speed mode, variable speed mode, and compatible mode, to adapt to the data acquisition requirements of different production scenarios.

[0044] Working principle:

[0045] As the coal flow passes through the sensing area, the line laser emits laser light that forms stripes or point clouds on the coal surface, acquiring real-time three-dimensional structural information of the coal flow. The data acquisition module works synchronously with the encoder on the conveyor belt via a hard-triggered interface, adjusting the data acquisition frequency according to the coal flow speed to ensure continuous and complete point cloud data in each sampling cycle. The acquired point cloud data is processed in real-time by the image processor 6, which calculates the coal flow volume using a pre-set algorithm. Simultaneously, when multiple sensors work collaboratively, their individual data are integrated by software to form a continuous and seamless coal flow volume statistical data, which is fed back to the production control system in real time. To cope with on-site vibration, temperature fluctuations, and dust intrusion, the equipment adopts a damped shock-absorbing base, rubber buffer layer, and protective cover design. The heat dissipation system ensures that the equipment temperature remains within a safe range under high-load operating conditions. Switch 10 and the linkage control interface enable linkage operation with other equipment on the production line, achieving a high degree of automation in coal flow detection and production scheduling.

[0046] Meanwhile, in actual working environments, when the detection system detects a skewed laser stripe through real-time image analysis, the operator can fine-tune the laser's installation angle by rotating the adjustment disc 8. This adjustment disc, acting as a physical support component, achieves small-amplitude, high-precision rotation via a threaded or gear mechanism, allowing for precise adjustment of the laser emission direction and ensuring the laser line remains strictly perpendicular to the conveyor belt surface. In situations where the conveyor belt operates at high speed or experiences significant vibration, the adjustment disc, in conjunction with mechanical fixing devices, can reduce angular deviations caused by vibration, thereby improving the stability of laser measurements.

[0047] The universal joint 7 incorporates multiple rotating axes, allowing the camera to adjust its pitch angle in both horizontal and vertical directions. When operators detect anomalies in the point cloud data (such as missing data or laser stripes deviating from the target area), they can adjust the universal joint 7 to match the camera's acquisition angle with the actual height of the coal flow and the conveyor belt angle, ensuring that the laser stripes accurately illuminate the coal flow surface. Under some highly dynamic operating conditions, the physical flexibility of the universal joint 7 allows the equipment to automatically compensate for angular deviations caused by vibration or changes in operating conditions within a certain range. Simultaneously, field maintenance personnel can also manually adjust the universal joint 7 to quickly restore the system to its optimal acquisition state, ensuring accurate real-time data. Any aspects not described in this application can be achieved by adopting or referencing existing technologies.

[0048] The various embodiments in this specification are described in a progressive manner. The same or similar parts between the various embodiments can be referred to each other. Each embodiment focuses on describing the differences from other embodiments.

[0049] The above description is merely an embodiment of this application and is not intended to limit the scope of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.

Claims

1. A coal flow detection device, comprising a base plate (1), a support (2) is fixedly arranged at the upper end of the base plate (1), characterized in that: Also include line laser binocular stereo camera (3), the line laser binocular stereo camera (3) is fixed above the conveyer belt through the support (2), its installation direction is parallel to the conveyer belt, to collect the stereo point cloud data of the coal flow on the conveyer belt, the line laser binocular stereo camera (3) is fixed with line laser (4) on the upper end, the laser emission direction of the line laser (4) is perpendicular to the conveyer belt, to form a laser line on the surface of the coal flow, the bottom plate (1) is also provided with a hard trigger interface module (5) on the upper end of the side away from the support (2), the hard trigger interface module (5) is connected with the camera through the hard trigger interface line, supports external trigger signal input, the line laser (4) is installed with image processing instrument (6) on the upper end, the image processing instrument (6) communicates with the camera through the gigabit network port, to calculate the volume of the coal flow in real time and output statistical results.

2. The coal flow detecting device according to claim 1, wherein: One end of the support (2) is provided with an adjustable universal joint (7), which is used to adjust the pitch angle of the camera.

3. The coal flow detecting device according to claim 1, wherein: The bottom plate (1) is a damping shock-absorbing base, which is fixed on the conveyer belt support (2) by bolts, and the bottom is provided with a rubber buffer layer.

4. The coal flow detecting device according to claim 1, wherein: The emission angle of the line laser (4) is fine-tuned by rotating the adjusting disc (8) to ensure that the laser stripe is strictly perpendicular to the surface of the conveyer belt.

5. The coal flow detecting device according to claim 1, wherein: The hard trigger interface line includes a trigger input line, a trigger output line and a ground line, the trigger input line is connected to the pulse signal end of the external encoder, and the ground line is connected to the zero potential end of the encoder, so that the coal flow speed and the acquisition frequency are dynamically synchronized.

6. The coal flow detecting device according to claim 1, wherein: The device supports multi-machine cooperative working mode, a plurality of line laser binocular stereo cameras (3) are distributed along the length direction of the conveyer belt, and the detection range of each camera is set as continuous seamless coverage by software.

7. The coal flow detecting device according to claim 1, wherein: The rear side of the support (2) is provided with a cooling fan (9) installed through a fixing clamp, the cooling fan (9) faces the line laser binocular stereo camera (3) and the line laser (4), which is used to reduce the working temperature of the equipment.

8. The coal flow detecting device according to claim 1, wherein: A switch (10) is fixed on one side of the upper end of the bottom plate (1), the switch (10) includes a manual start-stop button and a linkage control interface, the linkage control interface is connected with the data processing unit through a signal line, and the switch (10) is connected to the main power input interface of the device through a three-core waterproof cable.

9. The coal flow detecting device according to claim 1, wherein: The trigger mode of the line laser binocular stereo camera (3) includes uniform speed mode, variable speed mode and compatible mode.

Images