A coal leveler hopper positioner

Abstract

The utility model relates to the technical field of flat coal machine, specifically disclose a kind of flat coal machine hopper positioner, comprising: flat coal machine main body, flat coal machine main body both sides are equipped with pitch frame, pitch frame is fixedly connected with mounting bracket, mounting bracket is fixedly connected with collision detection component, collision detection component detects the safety distance of flat coal machine and carriage, pitch frame other end is equipped with limiting component, limiting component is positioned to the stroke of flat coal machine main body up and down pitch, by setting collision detection component, real-time accurate monitoring hopper and carriage distance, trigger fast evasion collision risk after, by setting limiting component, strictly limit pitch overtravel, completely solve the security loophole of traditional manual operation, substantially reduce the accident rate of equipment collision damage, bottom contact etc., overall mutual cooperation adapts different carriage and coal quantity, and safety, adaptability and economy are considered, the protection performance and practicality of core component are prominent.

Description

Technical Field

[0001] This utility model relates to the field of coal leveling machine technology, specifically to a coal leveling machine hopper limiter. Background Technology

[0002] In industrial scenarios such as coal loading, unloading, and transfer, coal leveling machines are key equipment for achieving uniform leveling of coal in train carriages and silos. Their hoppers or spiral coal leveling mechanisms need to adjust the working height through pitching motion and cover the working range through horizontal movement to meet the coal leveling needs of different carriage specifications and different coal quantities.

[0003] Traditional coal leveling machines lack automated safety features, relying entirely on the driver's visual judgment of safe distances between the hopper and the car walls, bottom, or top, as well as the hopper's vertical pitch limits. This method is susceptible to errors due to experience, coal dust obstruction, and fatigue, leading to hopper overtravel collisions or scrapes against the car. It can also cause coal spills, environmental pollution, forced work interruptions, and reduced transport efficiency. In severe cases, collisions can even cause equipment malfunctions, fires, or injuries, resulting in economic losses and safety hazards for the company. Therefore, we propose a coal leveling machine hopper limiter. Utility Model Content

[0004] The purpose of this invention is to provide a hopper limiter for a coal leveler, addressing the shortcomings of traditional coal levelers mentioned in the background art. These traditional methods lack automated safety measures and rely entirely on the driver's visual judgment of the safe distance between the hopper and the car wall, bottom, or top, as well as the hopper's vertical pitch limits. This approach is susceptible to limitations imposed by experience, coal dust obstruction, and fatigue, potentially leading to hopper overtravel and collisions with or scraping the car. It can also cause coal spillage, environmental pollution, forced work interruptions, and reduced transportation efficiency. In severe cases, collisions can even result in equipment malfunctions, fires, or personal injuries, causing economic losses and safety hazards for the company.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a hopper limiter for a coal leveler, comprising: a coal leveler body, pitching frames on both sides of the coal leveler body, mounting brackets fixedly connected to the pitching frames, a collision detection component fixedly connected to the mounting brackets, the collision detection component detecting the safe distance between the coal leveler and the car body, and a limiting component at the other end of the pitching frame, the limiting component limiting the vertical pitching stroke of the coal leveler body.

[0006] The collision detection component includes a rotating shaft fixedly connected to a mounting bracket, a detection frame rotatably connected to the rotating shaft, a groove on the detection frame, a fixing bolt slidably connected within the groove, a spring fixedly connected to the fixing bolt, and the other end of the spring fixedly connected to the mounting bracket; it also includes:

[0007] A fixed rod is fixedly connected to the detection frame. A piston cylinder is fixedly connected to the fixed rod. A magnetic sensor is installed on the piston cylinder. A sliding groove is opened on the mounting bracket, and the fixed rod can slide in the sliding groove.

[0008] A micro switch adjustment base, on which a micro switch is fixedly connected.

[0009] The limit assembly includes a limit switch adjusting seat, on which a limit switch is fixedly connected; it also includes:

[0010] A fixed base is fixedly connected to the pitch frame. A lever is fixedly connected to the fixed base, and the lever overlaps with the trigger part of the limit switch.

[0011] A switch cover is fixedly connected to the outside of the piston cylinder.

[0012] The micro switch adjustment seat and the limit switch adjustment seat are provided with adjustment holes.

[0013] The limiting components are provided in two sets, which are symmetrically arranged on the pitching frames on both sides of the main body of the coal leveler.

[0014] The magnetic sensor can be adjusted to a fixed position up and down along the piston cylinder.

[0015] The mounting bracket is fixedly connected to the side cleaning curtain.

[0016] This utility model has at least the following beneficial effects:

[0017] When in use, this utility model uses a collision detection component to monitor the distance between the hopper and the car in real time and accurately. After being triggered, it can quickly avoid the risk of collision. By setting a limit component, it strictly limits the pitch overtravel, completely solving the safety loopholes of traditional manual operation and greatly reducing the accident rate of equipment damage and bottoming out. The whole system is well-matched to different cars and coal volumes, taking into account safety, adaptability and economy. The protective performance and practicality of the core components are outstanding. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0019] Figure 2 This is a slanted view of the overall structure of this utility model;

[0020] Figure 3 This is a schematic diagram of the interior of the switch cover of this utility model;

[0021] Figure 4 This is a schematic diagram of the collision detection component of this utility model;

[0022] Figure 5 This is an enlarged schematic diagram of area A of this utility model;

[0023] Figure 6 This is a partial schematic diagram of the limiting component of this utility model.

[0024] In the diagram: 1. Main body of the coal leveler; 2. Pitching frame; 3. Mounting bracket; 4. Collision detection assembly; 41. Rotating shaft; 42. Detection frame; 43. Groove; 44. Fixing bolt; 45. Spring; 46. Fixing rod; 47. Piston cylinder; 48. Magnetic sensor; 49. Sliding groove; 410. Microswitch adjustment seat; 411. Microswitch; 5. Limit assembly; 51. Limit switch adjustment seat; 52. Limit switch; 53. Fixing seat; 54. Toggle lever; 6. Switch cover; 7. Adjustment hole; 8. Side cleaning curtain. Detailed Implementation

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0026] Example 1

[0027] Please see Figures 1 to 6 This utility model provides a technical solution: a coal leveler hopper limiter, comprising: a coal leveler body 1, with pitching frames 2 on both sides of the coal leveler body 1, mounting brackets 3 fixedly connected to the pitching frames 2, and collision detection components 4 fixedly connected to the mounting brackets 3. The collision detection components 4 detect the safe distance between the coal leveler and the train car, and a limiting component 5 is provided at the other end of the pitching frame 2, which limits the vertical pitching stroke of the coal leveler body 1. The pitching frames 2 are made of alloy steel and driven by a hydraulic cylinder or gear transmission mechanism, possessing precise angle adjustment capability to adapt to different working height requirements. The mounting brackets 3 are hot-dip galvanized for corrosion protection, with a thickness of not less than 5mm, which can resist the erosion of the high dust, humidity and corrosive environment of the coal working site, extending their service life. The collision detection components 4 can capture the distance change between the coal leveler hopper and the train car side wall or end in real time when the distance is less than the preset safety threshold, and promptly output a trigger signal to the coal leveler control system, fundamentally preventing rigid scraping or collision between the hopper and the car. The limiting component 5 monitors the rotation angle or linear displacement of the pitching frame 2 to strictly limit the maximum stroke of the hopper driven by the main body 1 of the coal leveler. This prevents the hopper from being raised too much and colliding with the top of the car or the frame of the coal leveler itself, and also avoids excessive descent that could damage the hopper, the spiral coal leveling mechanism and other core components, thus ensuring the safety and controllability of the equipment's pitching action.

[0028] The collision detection assembly 4 includes a rotating shaft 41 fixedly connected to the mounting bracket 3, a detection frame 42 rotatably connected to the rotating shaft 41, a groove 43 on the detection frame 42, a fixing bolt 44 slidably connected in the groove 43, a spring 45 fixedly connected to the fixing bolt 44, and the other end of the spring 45 fixedly connected to the mounting bracket 3; it also includes a fixing rod 46 fixedly connected to the detection frame 42, a piston cylinder 47 fixedly connected to the fixing rod 46, a magnetic sensor 48 on the piston cylinder 47, a sliding groove 49 on the mounting bracket 3, and the fixing rod 46 sliding within the sliding groove 49; and a micro switch adjustment seat 410 fixedly connected to a micro switch 411. In use, initially, the detection frame 42 maintains a preset posture under the tension of the spring 45 and the limiting action of the fixing bolt 44, the fixing rod 46 is in the initial position of the sliding groove 49 of the mounting bracket 3, the magnetic sensor 48 does not detect a magnetic head signal, and the micro switch 411 is in an untriggered state. When the coal leveler hopper approaches the car body, the side wall of the car body first contacts the front end of the detection frame 42, pushing the detection frame 42 to rotate around the shaft 41. At this time, the fixing bolt 44 slides along the groove 43 of the detection frame 42, and the spring 45 is stretched and stored. Simultaneously, the detection frame 42 drives the fixing rod 46 to slide synchronously along the sliding groove 49, thereby driving the piston cylinder 47 to move accordingly. When the piston cylinder 47 moves and causes the magnetic sensor 48 to move into the sensing range of the micro switch 411, the micro switch 411 synchronously outputs an on / off signal, which is transmitted to the coal leveler control system. The system immediately executes protective actions, such as controlling the hopper to lift or stopping horizontal movement. After the hopper moves away from the car body, the spring 45 releases its elastic force and pulls the detection frame 42 to rotate in the opposite direction around the shaft 41 to reset. The fixing rod 46 slides back to the initial position with the detection frame 42, and the magnetic sensor 48 on the piston cylinder 47 moves away from the micro switch 411. The assembly returns to its initial state, waiting for the next detection.

[0029] The limit assembly 5 includes a limit switch adjustment seat 51, on which a limit switch 52 is fixedly connected; it also includes a fixed seat 53, which is fixedly connected to the pitching frame 2, and a lever 54 is fixedly connected to the fixed seat 53. The lever 54 overlaps with the trigger part of the limit switch 52. The fixed seat 53 is used to fix the lever 54 and ensure that the lever 54 moves synchronously with the pitching frame 2. The limit switch 52 is a mechanical roller plunger type with a protection rating of IP65 or higher and a triggering force of 5-10N, which can withstand the vibration and impact during the operation of the coal leveler and avoid false triggering. The overlap distance is accurately calculated based on the limit stroke of the pitching frame 2 to ensure that when the pitching frame 2 drives the hopper to the preset limit position, the lever 54 can accurately and timely touch the trigger part of the limit switch 52. In use, when the pitching frame 2 drives the hopper to move up or down to the maximum allowable stroke, the lever 54 rotates or moves synchronously with the pitching frame 2, contacts the trigger part of the limit switch 52 and applies pressure, causing the internal contacts of the limit switch 52 to activate, the normally closed contact to open or the normally open contact to close, and outputs a limit signal to the coal leveling machine control system. The control system immediately cuts off the power of the pitching drive motor or hydraulic cylinder to achieve an emergency stop of the pitching action and prevent overtravel damage to the equipment.

[0030] A switch cover 6 is fixedly connected to the outside of the piston cylinder 47. The switch cover 6 is made of stainless steel plate or high-strength engineering plastic and its shape is adapted to the piston cylinder 47 and the magnetic sensor 48, completely covering the connection part of the two and the body of the magnetic sensor 48. The switch cover 6 can effectively prevent coal dust and coal powder from entering the interior of the piston cylinder 47, avoiding sliding jamming between the piston and the cylinder wall due to dust accumulation. At the same time, it can prevent the sensing surface of the magnetic sensor 48 from being covered by dust, ensuring accurate magnetic signal detection. In addition, the switch cover 6 can also isolate moisture and water droplets in the field, preventing rust inside the piston cylinder 47 or short circuit of the magnetic sensor 48 due to moisture, significantly extending the service life of the magnetic sensor 48 and the piston cylinder 47, and reducing the frequency and cost of equipment maintenance.

[0031] The microswitch adjusting seat 410 and the limit switch adjusting seat 51 are equipped with adjusting holes 7. The adjusting hole 7 of the microswitch adjusting seat 410 is an elongated hole, and the adjusting hole 7 of the limit switch adjusting seat 51 is a combination of an elongated hole and an arc-shaped hole. By flexibly adjusting the height and horizontal position of the microswitch 411, as well as the installation angle and distance from the limit switch 52 to the lever 54, the position of the microswitch 411 can be adjusted to change the response stroke of the collision detection component 4, and the position of the limit switch 52 can be adjusted to change the maximum lifting or lowering height of the hopper. Ultimately, this allows the limit switch to adapt to different specifications of train carriages and different coal leveling operation scenarios, improving the equipment's adaptability and flexibility.

[0032] Two sets of limit components 5 are symmetrically arranged on the pitching frames 2 on both sides of the main body 1 of the coal leveler. The two sets of limit components 5 have identical structures, dimensions, and parameters, and their installation positions are symmetrical about the central axis of the main body 1 of the coal leveler, forming a "dual-sided redundancy, mutual backup" limit protection logic. During the operation of the coal leveler, the pitching frames 2 on both sides synchronously drive the hopper to pitch. The two sets of limit components 5 simultaneously monitor the stroke status. If one set of limit components 5 fails to work properly due to contact wear, mechanical jamming, circuit fault, etc., the other set of limit components 5 can still accurately capture the extreme position of the pitching frame 2 and output a limit signal to the control system in a timely manner, controlling the equipment to stop the pitching action. This design completely avoids the risk of pitch overtravel caused by the failure of a single limit component 5, significantly improving the safety and reliability of the coal leveler's hopper pitching action.

[0033] The magnetic sensor 48 can be adjusted vertically along the piston cylinder 47 to maintain a fixed position. By changing the installation height of the magnetic sensor 48 on the piston cylinder 47, the trigger position can be flexibly set, allowing the piston to be detected after moving a shorter distance. This increases the safety distance threshold for collision detection, making it suitable for scenarios with smaller coal volumes and requiring a greater safety distance. Adjusting the magnetic sensor 48 downwards allows the piston to move a longer distance before being detected, decreasing the safety distance threshold for collision detection. This is suitable for scenarios with larger coal volumes and requiring the hopper to be close to the car body. This adjustable design allows the limit switch to flexibly set the sensitivity and safety threshold for collision detection according to different car body materials and coal qualities, further improving the adaptability and practicality of the equipment.

[0034] Before operation, the collision detection threshold and pitch limit travel are set according to the car body specifications by adjusting the adjustment holes 7 of the microswitch adjustment seat 410 and the limit switch adjustment seat 51. The car side cleaning curtain 8 is positioned with the mounting bracket 3, and all components are in the preset ready-to-work state. After the coal leveler is started, the hopper adjusts its height and moves horizontally to level the coal with the pitch adjustment frame 2. During the process, the car side cleaning curtain 8 simultaneously scrapes away the coal accumulated on the side wall of the car body to avoid affecting the detection accuracy. If the hopper gets close to the car body, the detection frame 42 of the collision detection component 4 is triggered to rotate, driving the fixed rod 46 and piston to move. The magnetic sensor 48 or microswitch 411 outputs a signal, and the control system immediately controls the hopper to lift and stop horizontal movement. If the hopper pitches close to the limit travel, the levers 54 of the limit components 5 on both sides touch the limit switch 52, and the output signal forces the pitching action to stop. Once the danger has passed and the hopper is away from the car or the pitch angle has been adjusted, the collision detection component 4 will reset under the action of the spring 45, and the limit component 5 will move in the opposite direction with the pitch frame 2 to disengage from the trigger state. The overall structure will return to its initial setting and enter the next round of coal leveling operation cycle.

[0035] Example 2

[0036] In this second embodiment, the other structures remain unchanged. The difference from the first embodiment is that a side cleaning curtain 8 is fixedly connected to the mounting bracket 3. During coal leveling machine operation, the hopper drives the mounting bracket 3 to move along the length of the car body. The side cleaning curtain 8 moves synchronously with the mounting bracket 3, its bottom tightly fitting against the side wall of the car body to scrape away coal dust and lumps adhering to the side wall. This design, on the one hand, prevents coal dust from accumulating on the side wall of the car body, preventing accumulated coal dust from obstructing the detection frame 42 or magnetic sensor 48 of the collision detection component 4, ensuring that the collision detection accuracy is not affected. On the other hand, it reduces coal dust shedding and scattering during operation, lowers the on-site coal dust concentration, improves the working environment for operators, reduces coal waste, and improves operational efficiency.

[0037] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0038] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A limit switch for a coal leveling machine hopper, comprising: The main body of the coal leveling machine is characterized in that: the main body of the coal leveling machine is provided with pitching frames on both sides, the pitching frames are fixedly connected with mounting brackets, the mounting brackets are fixedly connected with collision detection components, the collision detection components detect the safe distance between the coal leveling machine and the car body, and the other end of the pitching frame is provided with a limiting component, the limiting component limits the vertical pitching stroke of the main body of the coal leveling machine.

2. The coal leveler hopper limiter according to claim 1, characterized in that: The collision detection assembly includes a rotating shaft fixedly connected to a mounting bracket, a detection frame rotatably connected to the rotating shaft, a groove provided on the detection frame, a fixing bolt slidably connected in the groove, a spring fixedly connected to the fixing bolt, and the other end of the spring fixedly connected to the mounting bracket. It also includes: a fixing rod, which is fixedly connected to the detection frame, a piston cylinder is fixedly connected to the fixing rod, a magnetic sensor is provided on the piston cylinder, and a sliding groove is provided on the mounting bracket, so that the fixing rod can slide in the sliding groove; A micro switch adjustment base, on which a micro switch is fixedly connected.

3. The coal leveler hopper limiter according to claim 1, characterized in that: The limiting component includes a limit switch adjusting seat, on which a limit switch is fixedly connected; It also includes: a fixed base, which is fixedly connected to the pitch frame, and a lever is fixedly connected to the fixed base, the lever overlapping with the trigger part of the limit switch.

4. The coal leveler hopper limiter according to claim 2, characterized in that: A switch cover is fixedly connected to the outside of the piston cylinder.

5. The coal leveler hopper limiter according to claim 2, characterized in that: The micro switch adjustment base and the limit switch adjustment base are provided with adjustment holes.

6. The coal leveler hopper limiter according to claim 1, characterized in that: The limiting components are provided in two sets, which are symmetrically arranged on the pitching frames on both sides of the main body of the coal leveler.

7. The coal leveler hopper limiter according to claim 2, characterized in that: The magnetic sensor can be adjusted to a fixed position up and down along the piston cylinder.

8. The coal leveler hopper limiter according to claim 1, characterized in that: A side cleaning curtain is fixedly connected to the mounting bracket.

Images