A real-time coal level detection system in a raw coal bin

Abstract

A real-time coal level detection system in a raw coal bunker includes multiple pressure sensing mechanisms spaced apart on the bunker wall. Each pressure sensing mechanism includes a support tube fixedly inserted into a perforation in the bunker wall and a pressure sensing element disposed within the support tube. All pressure sensing elements are signal-connected to a display. The base of each pressure sensing element is fixedly connected to the support tube. A push plate is located at the inner end of the support tube, corresponding to the sensing part of the pressure sensing element. The upper end of the push plate is hinged to the top of the tube opening, and a torsion spring is located at the hinge point. When there is no coal at the corresponding height in the raw coal bunker, the push plate, controlled by the torsion spring, maintains a gap with the sensing part of the pressure sensing element. When coal is present at the corresponding height in the raw coal bunker, the gravity of the coal compresses and overcomes the torsion force of the torsion spring, pressing against the sensing part of the pressure sensing element. This invention has a simple structure and high detection stability.

Description

Technical Field

[0001] This utility model relates to the field of detection and alarm technology for raw coal bunkers in underground coal mines, specifically a real-time coal level detection system in a raw coal bunker. Background Technology

[0002] In coal conveying systems, raw coal bunkers serve as crucial intermediate buffers and storage facilities, and their coal level directly impacts the continuity and stability of the entire production process. Low coal levels can lead to supply interruptions, affecting downstream equipment operation; high coal levels can cause bunker blockages, coal spills, and other safety hazards, even impacting overall mine production efficiency. With the continuous improvement of automation and intelligence in the coal industry, real-time and accurate monitoring of coal bunker storage, and coordinated control with underground conveyor belts, feeders, and other equipment, has become a vital link in ensuring safe and efficient coal mine production. Therefore, developing a reliable and stable coal bunker level detection and early warning system is of great significance for improving the level of automated management in coal mines.

[0003] To address this need, the applicant previously developed a coal level monitoring device based on 3D radar detection technology. This device can simulate the coal level morphology within the storage bin in real time and possesses intelligent analysis and alarm functions. However, this technology relies on complex image processing and signal simulation, and its stability and reliability still face significant challenges in harsh environments such as high dust, high humidity, and strong electromagnetic interference underground. Especially for some of the applicant's clients, who have high requirements for the mechanical reliability of equipment, the maturity of vision-based detection systems is not yet convincing enough for their complete acceptance. Therefore, the applicant urgently needs a real-time coal level detection system with a simple structure, high mechanical stability, and strong anti-interference capabilities as an important supplement or alternative to existing technologies. Utility Model Content

[0004] The present invention aims to provide a real-time coal level detection system in a raw coal bunker, which has a simple structure and high stability.

[0005] To solve the above technical problems, the specific solution adopted by this utility model is as follows: a real-time coal level detection system in a raw coal bunker, including multiple pressure sensing mechanisms spaced apart on the bunker wall. Each pressure sensing mechanism includes a bearing tube fixedly inserted into a perforation in the bunker wall and a pressure sensing element disposed in the bearing tube. All pressure sensing elements are signal-connected to a display. The base of the pressure sensing element is fixedly connected to the bearing tube. A push plate is provided at the inner end of the bearing tube corresponding to the sensing part of the pressure sensing element. The upper end of the push plate is hinged to the top of the pipe opening of the bearing tube, and a torsion spring is provided at the hinge position. When there is no coal at the corresponding height position in the raw coal bunker, the push plate can maintain a gap with the sensing part of the pressure sensing element under the control of the torsion spring. When there is coal at the corresponding height position in the raw coal bunker, the gravity of the coal can squeeze and overcome the torsion force of the torsion spring to press the sensing part of the pressure sensing element.

[0006] Preferably, the pressure sensing element is an S-type tension / compression sensor, with a base formed on one side and fixedly connected to the bearing tube, and a sensing part formed on the other side for the push plate to press.

[0007] Preferably, the outer end of the bearing tube is provided with a detachable end cap, and the base of the pressure sensing element is fixed on the end cap.

[0008] Preferably, the outer end of the bearing pipe is provided with flanges distributed circumferentially, and multiple studs are fixedly provided at intervals on the flanges. The end cover is provided with bolt holes corresponding to the studs one by one.

[0009] Preferably, the angle between the central axis of the bearing pipe and the horizontal plane is 0-45°.

[0010] Preferably, the cross-section of the bearing pipe is rectangular.

[0011] Preferably, the bottom of the bearing pipe opening is provided with a step for the lower end of the push plate to be engaged.

[0012] Preferably, all pressure sensing mechanisms are evenly spaced along the vertical direction.

[0013] Preferably, all pressure sensing mechanisms are evenly spaced along a spiral.

[0014] Beneficial effects

[0015] This invention employs a combination of purely mechanical triggering and sensors, resulting in a robust structure that is less susceptible to dust, humidity, electromagnetic interference, and other factors, making it particularly suitable for complex working conditions in underground coal mines. Furthermore, through the distributed arrangement of multiple pressure sensing mechanisms, this invention can perceive the state of coal seams at different heights in real time. The push plate directly triggers the sensors under the weight of the coal, resulting in a low false alarm rate and fast response speed.

[0016] In a preferred embodiment of this utility model, the sensing mechanism adopts a modular design, the bearing tube and the end cap are detachably connected, and the pressure sensing element is directly fixed on the end cap, which facilitates sensor debugging, replacement and internal cleaning, and reduces operation and maintenance costs. Attached Figure Description

[0017] Figure 1 This is a cross-sectional view of one of the pressure sensing mechanisms in Embodiment 1 of this utility model. There is no coal pile at the corresponding height position in the figure, and the push plate maintains a gap with the sensing part of the pressure sensing element under the action of the torsion spring.

[0018] Figure 2 for Figure 1 The diagram shows the state after coal is piled up at the indicated location. The coal's own weight presses the push plate to overcome the torsion spring's thrust and rotate, eventually touching the sensing part of the pressure sensor.

[0019] Figure 3 This is a cross-sectional view of one of the pressure sensing mechanisms in Embodiment 2 of the present invention, with the bearing tubes distributed at an angle.

[0020] The markings in the diagram are: 1. Pressure sensing mechanism, 2. Bin wall, 3. Hinge shaft, 4. Torsion spring, 5. Push plate, 6. Step, 7. Pressure sensing element, 701. Sensing part, 702. Base, 8. End cap, 9. Signal line, 10. Stud, 11. Flange, 12. Bearing pipe. Detailed Implementation

[0021] This utility model provides a real-time coal level detection system in a raw coal bunker, comprising multiple pressure sensing mechanisms 1, which are arranged at certain intervals on the bunker wall 2. Figure 1 , Figure 2 and Figure 3 As shown, each pressure sensing mechanism 1 includes a support tube 12 fixedly inserted into a perforation in the bin wall 2, and a pressure sensing element 7 disposed within the support tube. All pressure sensing elements 7 are connected to a display (not shown in the figure) via signal lines 9, thereby realizing real-time display and monitoring of the coal level.

[0022] The base 702 of the pressure sensor 7 is fixed to the bearing pipe 12, and a push plate 5 is provided at the opening of the bearing pipe 12 facing the inside of the coal bunker. The upper end of the push plate 5 is connected to the top of the opening of the bearing pipe 12 via a hinge shaft 3, and a torsion spring 4 is provided at the hinge. Figure 1 As shown, when there is no coal at this height, the push plate 5 maintains a certain gap with the sensing part 701 of the pressure sensor 7 under the action of the torsion spring 4; while when there is coal at this height, as... Figure 2 As shown, the weight of the coal presses against the pusher plate 5, causing it to rotate against the torque of the torsion spring 4, ultimately pressing against the sensing part 701 and triggering the sensor signal. The technical solution of this utility model is further illustrated below through three embodiments:

[0023] Example 1

[0024] refer to Figure 1 and Figure 2 In this embodiment, the support pipe 12 is arranged horizontally, that is, its central axis is parallel to the horizontal plane (with an included angle of 0°). The cross-section of the support pipe 12 is rectangular, which is simple in structure and easy to process, install and position. Multiple support pipes 12 are evenly spaced vertically.

[0025] The push plate 5 is mounted on the upper part of the inner opening of the bearing tube 12 via a hinge shaft 3. A torsion spring 4 is sleeved on the hinge shaft 3, with one end fixed to the inner wall of the bearing tube 12 and the other end acting on the push plate 5 to provide it with a reset torque. A step 6 is provided at the bottom of the opening of the bearing tube 12. This structure can limit the swing range of the push plate 5 and provide support during reset. Figure 2 After the pusher plate 5 shown is squeezed by coal, the lower end of the pusher plate 5 enters the step 6 to prevent coal from entering the bearing pipe.

[0026] The pressure sensor 7 is an S-type tension / compression sensor, with its base 702 on the left side fixed to the end cap 8 by screws. The end cap 8 is bolted to the flange 11, which is welded to the outer end of the bearing pipe 12. Multiple studs 10 are evenly distributed circumferentially on the flange 11, and the end cap 8 has corresponding bolt holes. The end cap is detachably installed by tightening nuts, facilitating sensor debugging and maintenance. In this embodiment, both the flange 11 and the end cap 8 are rectangular, thus facilitating the installation and positioning of the pressure sensor 7.

[0027] This horizontal arrangement is structurally stable and easy to install, suitable for working environments where the coal flow in the coal bunker is relatively stable and coal accumulation is not likely. During system operation, multiple pressure sensing mechanisms 1 are installed at different heights on the coal bunker wall 2 at certain intervals according to monitoring requirements.

[0028] When the coal level is lower than the height of a certain sensor, the push plate 5 at that location remains in an outward-facing state under the action of the torsion spring 4, and there is a gap between it and the sensing part 701 of the pressure sensor 7 (e.g., Figure 1 As shown in the figure, the sensor outputs a no-coal signal.

[0029] When the coal level rises to this height, the weight of the coal acts on the outside of the push plate 5, pushing it to rotate inward around the hinge shaft 3, overcoming the torque of the torsion spring 4, and then pressing against the sensing part 701 (e.g., Figure 2 As shown in the figure, the sensor then outputs a signal indicating the presence of coal.

[0030] All signals generated by the pressure sensors 7 are transmitted to the display via the signal line 9. Personnel can determine the current coal level by identifying the location distribution of the triggered sensors, and can further set high and low level alarm thresholds to achieve real-time monitoring and safety warning of coal storage materials.

[0031] Example 2

[0032] like Figure 3 As shown, the difference between this embodiment and Embodiment 1 is that the support pipe 12 is installed at an angle, with its central axis forming a certain angle (e.g., 30°) with the horizontal plane. The structure and connection relationship of the other components of the support pipe 12 are the same as in Embodiment 1.

[0033] The main advantage of the inclined arrangement is that when a small amount of coal particles accidentally enters the bearing pipe 12, they can automatically slide out along the inclined pipe wall under their own gravity after the coal falls and the push plate 5 resets. This effectively avoids interference from coal particle accumulation on the movement of the push plate 5 or the sensor signal, significantly improving the reliability and accuracy of the detection results. This arrangement is particularly suitable for applications where the coal is wet, prone to sticking, or where the raw coal bunker experiences significant vibration, reducing maintenance requirements and extending equipment lifespan.

[0034] Example 3

[0035] This embodiment provides a real-time coal level detection system in a raw coal bunker, whose basic structure is the same as that of embodiments 1 and 2, including multiple pressure sensing mechanisms 1 installed on the bunker wall 2. Each pressure sensing mechanism 1 includes core components such as a bearing pipe 12, a pressure sensing element 7, a push plate 5, and a torsion spring 4.

[0036] The unique feature of this embodiment is that all pressure sensing mechanisms 1 are evenly spaced along a spiral path on the wall 2 of the raw coal bunker (no diagram is provided in this embodiment due to the simplicity of the arrangement). This distribution is not a simple vertical straight line arrangement, but rather a spiral arrangement that rises or falls along the bunker wall. This spiral distribution allows for simultaneous monitoring of coal levels at multiple locations along the circumference of the bunker, rather than just a single point on a vertical line. This is crucial for detecting uneven coal level patterns such as surface inclination, central depression, or coal adhering to the perimeter, significantly reducing blind spots and avoiding false alarms. Within the same height of the bunker, the spiral distribution achieves more comprehensive coverage of the surrounding walls with fewer sensors, or provides higher spatial resolution with the same number of sensors, improving the system's economy and monitoring efficiency.

Claims

1. A real-time coal level detection system in a raw coal bunker, characterized in that: The system includes multiple pressure sensing mechanisms (1) spaced apart on the wall (2) of the raw coal bunker. Each pressure sensing mechanism (1) includes a support tube (12) fixedly inserted into a perforation in the wall (2) and a pressure sensing element (7) disposed in the support tube (12). All pressure sensing elements (7) are connected to a display. The base (702) of the pressure sensing element (7) is fixedly connected to the support tube (12), and the sensing part of the pressure sensing element (7) is located at the inner end of the support tube (12). A push plate (5) is provided at position (701). The upper end of the push plate (5) is hinged to the top of the pipe opening of the bearing pipe (12), and a torsion spring (4) is provided at the hinge position. When there is no coal at the corresponding height position in the raw coal bunker, the push plate (5) can be controlled by the torsion spring (4) to maintain a gap with the sensing part (701) of the pressure sensor (7). When there is coal at the corresponding height position in the raw coal bunker, the gravity of the coal can squeeze and overcome the torsion of the torsion spring (4) to press the sensing part (701) of the pressure sensor (7).

2. The real-time coal level detection system in a raw coal bunker as described in claim 1, characterized in that: The pressure sensor (7) is an S-type tension and compression sensor. One side forms a base (702) and is fixedly connected to the bearing tube (12). The other side forms a sensing part (701) and is pressed by the push plate (5).

3. The real-time coal level detection system in a raw coal bunker as described in claim 1, characterized in that: The outer end of the bearing tube (12) is provided with a detachable end cap (8), and the base (702) of the pressure sensor (7) is fixed on the end cap (8).

4. The real-time coal level detection system in a raw coal bunker as described in claim 3, characterized in that: The outer end of the bearing pipe (12) is provided with a flange (11) distributed circumferentially. Multiple studs (10) are fixedly provided on the flange (11) at intervals. The end cover (8) is provided with bolt holes corresponding to the studs (10).

5. The real-time coal level detection system in a raw coal bunker as described in claim 1, characterized in that: The angle between the central axis of the bearing pipe (12) and the horizontal plane is 0-45°.

6. The real-time coal level detection system in a raw coal bunker as described in claim 1, characterized in that: The cross-section of the bearing tube (12) is rectangular.

7. The real-time coal level detection system in a raw coal bunker as described in claim 1, characterized in that: The bottom of the port of the bearing pipe (12) is provided with a step (6) for the lower end of the push plate (5) to be inserted.

8. The real-time coal level detection system in a raw coal bunker as described in claim 1, characterized in that: All pressure sensing mechanisms (1) are evenly spaced along the vertical direction.

9. The real-time coal level detection system in a raw coal bunker as described in claim 1, characterized in that: All pressure sensing mechanisms (1) are evenly spaced along a spiral.

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