An adaptive intelligent loading system

Abstract

This utility model discloses an adaptive intelligent loading system, comprising a belt conveyor, a buffer bin, a quantitative bin, and a loading chute connected in sequence. The buffer bin has four sets of gates at its bottom, which are electrically connected to a PID controller. The PID controller controls the opening and closing of the gates and can adjust the gate opening degree. The quantitative bin is equipped with a weighing sensor, a material level sensor, and a three-dimensional measuring instrument. This utility model uses the three-dimensional measuring instrument to calculate the material volume in the quantitative bin in real time, and combines this with the density data to dynamically adjust the gate opening degree. This achieves adaptive loading under changing material characteristics, solving the problem of difficulty in self-matching loading parameters due to changes in the loaded material. It effectively improves loading accuracy and significantly enhances the intelligence and work efficiency of the loading station.

Description

Technical Field

[0001] This utility model relates to an adaptive intelligent loading system, which is an adaptive intelligent loading system for loading bulk materials onto automated transport machinery. Background Technology

[0002] As new energy technologies mature, coal's role in the energy structure will diminish, but its coal-dominated energy pattern will remain unchanged for a considerable period. my country possesses abundant coal resources, but their distribution is extremely uneven, making coal transportation crucial for their allocation across different regions. Rapid, quantitative loading is a critical step in improving coal transportation efficiency. This primarily involves using batching and weighing equipment to quantitatively weigh materials and then quickly loading them into the loading wagons. The batching system control is key to the rapid, quantitative loading system control.

[0003] Existing loading methods have several shortcomings in practical applications: In terms of loading accuracy control, they rely on manual experience to set parameters. When the density, particle size, or other properties of the material change, operators struggle to adjust the gate opening accurately and promptly. Furthermore, the lack of real-time density monitoring and a linkage mechanism with the actuators leads to significant loading deviations, affecting the accuracy of subsequent transportation and measurement. The coordinated control of efficiency and safety is also weak. Extensive use of coarse-grained flow control fails to dynamically match the conveying rate based on material level. Due to the lag in safety thresholds, underloading can impact efficiency, while overloading can trigger rework. The level of automation in the process is insufficient for large-scale production. Key steps such as gate opening and closing and material quantity correction rely on manual operation, which not only increases loading time due to reaction delays but also inevitably introduces significant deviations during the batching process. These deviations greatly affect the accuracy and speed of material loading, reducing loading efficiency and coal transportation efficiency. Utility Model Content

[0004] In view of the deficiencies in the prior art, this utility model provides an adaptive intelligent loading system that adjusts the deviation of loading and batching parameters by real-time monitoring of material density, thereby improving the accuracy and speed of material loading and increasing loading efficiency.

[0005] The purpose of this utility model is achieved as follows:

[0006] An adaptive intelligent loading system includes a belt conveyor, a buffer bin, a metering bin, and a loading chute connected in sequence. The buffer bin has four sets of gates at its bottom, which are electrically connected to a PID controller. The PID controller controls the opening and closing of the gates and can adjust the gate opening degree. The metering bin is equipped with a weighing sensor, a material level sensor, and a three-dimensional measuring instrument. The material level sensor has four levels of material level monitoring points: the first level monitoring point is used for initial deceleration triggering, the second level monitoring point is used for flow grading control, the third level monitoring point is used for precise flow limiting at the end, and the fourth level monitoring point is used for ultimate volume limitation.

[0007] Furthermore, the material level height sensor is a lidar, a video camera, or a combination of lidar and a video camera.

[0008] Furthermore, the primary level monitoring point for monitoring the lowest material level in the aforementioned level height sensor includes a weighted level gauge.

[0009] Furthermore, the gate is equipped with a hydraulic cylinder for controlling the gate's movement and a displacement sensor for monitoring the displacement of the hydraulic cylinder piston rod.

[0010] Furthermore, the PID controller is electrically connected to the signal selector. The signal selector can directly output a switch signal to close the gate, or it can selectively output a PID controller signal to regulate the gate opening for precise control.

[0011] Furthermore, the 3D measuring instrument can be a 3D laser scanner, a Time-of-Flight (ToF) camera, or a laser ranging sensor array.

[0012] Furthermore, the quantitative bin is connected to the loading chute via a material distribution machine. A guide rail is provided at the lower end of the outlet of the quantitative bin. The material distribution machine is positioned at the outlet at the lower end of the quantitative bin and can move horizontally back and forth via the guide rail, thereby achieving uniform material distribution to the front and rear of the loaded vehicle.

[0013] Furthermore, the material distribution machine includes a storage box connected to the discharge port of the quantitative silo. The lower longitudinal end of the storage box is connected to a loading chute, which is a retractable chute. A scraper conveyor belt is provided in the storage box. The scraper conveyor belt is used to send the material discharged from the quantitative silo into the storage box to the loading chute, and then discharge it into the vehicle being loaded.

[0014] The beneficial effects of this utility model are: high loading accuracy; the three-dimensional measuring instrument of the quantitative silo calculates the material volume in real time, and dynamically obtains the density by combining the data of the weighing sensor; the system adjusts the opening of the buffer silo gate accordingly, and can cope with the differences in material properties without manual intervention, solving the deviation problem of traditional manual adjustment; balancing efficiency and safety; the four-level monitoring points of the material level sensor have clear division of labor, and together with the four sets of gates for separate control, it can speed up the loading speed through flow regulation and avoid overloading, achieving a balance between the two; improving overall operating efficiency; the PID controller automatically controls the gate, and the program automatically executes processes such as batching parameter retrieval and deviation adjustment, reducing the lag and error caused by manual intervention, and realizing continuous autonomous operation of loading;

[0015] Enhanced stability and adaptability, multiple sensors provide multi-dimensional data, and the PID controller and program logic respond in real time, enabling the system to flexibly adapt to complex environments, maintain stable loading quality, and reduce equipment wear and failure risks.

[0016] It enables adaptive loading under changing material properties, solves the problem of difficulty in self-matching loading parameters due to changes in loaded materials, effectively improves loading accuracy, and significantly enhances the intelligence and work efficiency of loading stations.

[0017] The present invention will be further explained in detail below with reference to the accompanying drawings and specific embodiments. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the intelligent loading system of this utility model.

[0019] In the diagram: 1-Belt conveyor, 2-Buffer bin, 3-Gate, 4-Quantitative bin, 5-Loading chute, 6-Weighing sensor, 7-Material level sensor, 8-3D measuring instrument, 9-Concrete placing machine, 10-Hydraulic cylinder, 11-Displacement sensor, 12-Loaded vehicle, 13-Guide rail, 91-Storage bin, 92-Scraper conveyor belt. Detailed Implementation

[0020] An adaptive intelligent loading system, such as Figure 1 As shown, the structure includes a steel frame that serves as the load-bearing foundation. From top to bottom, the steel frame is equipped with a belt conveyor 1, a buffer bin 2, and a metering bin 4. The output end of the belt conveyor 1 corresponds to the feed inlet of the buffer bin 2.

[0021] Four sets of gates 3 are installed at the bottom of the buffer chamber 2, namely gates A, B, C and D. The gates 3 are connected to the metering chamber 4 below. The gates 3 are equipped with hydraulic cylinders 10 to control their operation and displacement sensors 11 to monitor the displacement of the hydraulic cylinder piston rod.

[0022] Figure 1It is a simplified structural diagram, which omits the steel frame and only shows the belt conveyor 1, buffer bin 2, quantitative bin 4, loading chute 5, etc., as well as the positional relationship of each sensor.

[0023] The quantitative silo 4 is equipped with a weighing sensor 6 at the bottom or support structure, and a material level height sensor 7 with four monitoring points. It includes a plumb bob level gauge for detecting the lowest material level and can be combined with a radar sensor, video camera, and ultrasonic sensor. The quantitative silo 4 is also equipped with a three-dimensional measuring instrument 8. The three-dimensional measuring instrument 8 obtains the three-dimensional coordinates of the material surface by actively emitting a laser beam and receiving the reflected signal, and calculates the real-time volume.

[0024] The control system includes a central control system, a signal selector, a PID controller, and a hydraulic system. The hydraulic system supplies pressurized hydraulic oil to the hydraulic cylinder 10 via a hydraulic pump. The central control system is electrically connected to the three-dimensional measuring instrument 8, the weighing sensor 6, the material level sensor 7, the signal selector, and the discharge gate of the metering hopper 4. The signal selector is electrically connected to the PID controller and can select the output signal according to the material state of the metering hopper 4 to automatically adjust the opening of the gate 3, or output a closing signal to directly control the gate 3 to close.

[0025] The PID controller is electrically connected to the hydraulic system. According to the set signal, it outputs control commands to the hydraulic system to adjust the flow rate and pressure of the hydraulic oil output by the hydraulic pump, thereby driving the piston rod of the hydraulic cylinder 10 to extend and retract. The displacement sensor 11 monitors the displacement of the piston rod of the hydraulic cylinder 10 in real time and feeds the signal back to the PID controller. The PID controller compares the actual displacement value with the preset value, adjusts the control signal output to the hydraulic system, controls the action amplitude of the hydraulic cylinder 10, and regulates the opening degree of the gate 3.

[0026] In operation of the intelligent loading system: Belt conveyor 1 transports materials to buffer bin 2, and buffer bin 2 feeds materials to quantitative bin 4 through gate 3. Because material density fluctuates due to factors such as humidity and particle size, real-time density is used as the core control basis. Three-dimensional measuring instrument 8 transmits the three-dimensional coordinates of the material surface to the central control system, which calculates the real-time volume, receives real-time weight data from weighing sensor 6, calculates the real-time material density, and dynamically compensates for the impact of density fluctuations on the loading volume. The central control system, combined with the four-level material level monitoring data from the material level height sensor 7 (level 1 for initial deceleration triggering, level 2 for flow grading control, level 3 for precise flow limiting at the end, and level 4 for ultimate volume limitation), controls the opening and closing of gates A, B, C, and D according to a preset program. It can also transmit relevant data to the PID controller and signal selector. The signal selector selects the output signal based on the weighing and volume data and material level status of quantitative bin 4 to regulate or close the opening of gate 3.

[0027] Material from quantitative silo 4 is discharged through the lower discharge port to the loaded vehicle 12.

[0028] The material placing machine 9 is a material transfer device that connects to the lower outlet of the quantitative silo 4. It is driven by a motor to move horizontally back and forth along the guide rail 13 below the lower outlet of the quantitative silo 4 via rollers at its bottom. The material placing machine 9 includes a storage bin 91 connected to the outlet of the quantitative silo 4, a scraper conveyor belt 92 inside the storage bin 91, and a loading chute 5 on one side of the lower longitudinal end of the storage bin 91. The loading chute 5 is a telescopic structure with at least two sleeves nested together, driven by a cylinder for extension and retraction. The outlet of the quantitative silo 4 is connected to the storage bin 91, and the output end of the scraper conveyor belt 92 corresponds to the inlet of the loading chute 5. The loading process is as follows: After the material in the quantitative bin 4 enters the storage box 91, it is sent to the loading chute 5 by the scraper conveyor belt 92. First, the outlet of the loading chute 5 is lowered into the bottom of the car body, and the chute gate is opened to unload the material. As the material is unloaded, it is gradually raised until the outlet is at the same height as the car body plate. Then, the motor drives the placing machine 9 to move horizontally backward along the guide rail 13, keeping the chute gate open until the loading is completed.

[0029] The 3D measuring instrument 8 can select a 3D laser scanner, a ToF time-of-flight camera, or a laser rangefinder sensor array depending on the scenario.

[0030] Finally, it should be noted that the above is only used to illustrate the technical solution of this utility model and not to limit it. Although this utility model has been described in detail with reference to the preferred arrangement, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solution of this utility model without departing from the spirit and scope of the technical solution of this utility model.

Claims

1. An adaptive intelligent loading system, comprising a belt conveyor (1), a buffer bin (2), a metering bin (4) and a loading chute (5) connected in sequence, characterized in that, The buffer chamber (2) is equipped with four sets of gates (3) at the bottom. The gates (3) are connected to the PID controller via electrical control. The PID controller controls the opening and closing of the gates (3) and can adjust the opening degree of the gates (3). The quantitative chamber (4) is equipped with a weighing sensor (6), a material level sensor (7) and a three-dimensional measuring instrument (8). The material level sensor (7) is equipped with four levels of material level monitoring points. The first level monitoring point is used for initial deceleration triggering, the second level monitoring point is used for flow graded regulation, the third level monitoring point is used for precise flow restriction at the end, and the fourth level monitoring point is used for ultimate volume restriction.

2. The adaptive smart loading system of claim 1, wherein, The material level sensor (7) is a lidar or a video camera or a combination of lidar and video camera.

3. The adaptive smart carloading system of claim 1, wherein, The first-level material level monitoring point for monitoring the lowest material level in the material level height sensor (7) includes a weighted level gauge.

4. The adaptive smart carloading system of claim 1, wherein, The gate (3) is equipped with a hydraulic cylinder (10) for controlling the gate's movement and a displacement sensor (11) for monitoring the displacement of the hydraulic cylinder piston rod.

5. The adaptive smart carloading system of claim 1, wherein, The PID controller is electrically connected to the signal selector. The signal selector can directly output a switch signal to close the gate (3), or it can select to output a PID controller signal to adjust the opening degree of the gate (3) for precise control.

6. The adaptive smart carloading system of claim 1, wherein, The three-dimensional measuring instrument (8) can be a three-dimensional laser scanner, a ToF time-of-flight camera, or a laser ranging sensor array.

7. The adaptive smart carloading system of claim 1, wherein, The quantitative bin (4) is connected to the loading chute (5) via the material distribution machine (9). A guide rail (13) is provided at the lower end of the discharge port of the quantitative bin (4). The material distribution machine (9) is located at the discharge port at the lower end of the quantitative bin (4) and can move horizontally back and forth via the guide rail (13) to achieve uniform material distribution to the loaded vehicle (12).

8. The adaptive smart carloading system of claim 7, wherein, The material distribution machine (9) includes a storage box (91) connected to the discharge port of the quantitative silo (4). The lower longitudinal end of the storage box (91) is connected to the loading chute (5). The loading chute (5) is a retractable chute. A scraper conveyor belt (92) is provided in the storage box (91). The scraper conveyor belt (92) is used to send the material discharged from the quantitative silo (4) into the storage box (91) to the loading chute (5) and discharged from the chute into the loaded vehicle (12).

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