Bucket wheel machine material height detection device suitable for multiple working conditions

Abstract

The utility model discloses a kind of bucket wheel machine material height detection devices suitable for multiple working conditions, it is related to material height detection device field, including turnover support, turnover support bottom end is hinged on the pivot of support, one side is provided with push rod assembly, top end one side is hung with material level meter, another side is connected with several steel wires;Steel wire is reeled on reel by passing through pulley assembly, encoder is equipped on reel, lower limit switch is equipped in turnover support bottom end one side, upper limit switch is equipped below push rod assembly, inclination detector is installed on turnover support. According to different stacking mode, automatically change detection position posture, significantly improve material height measurement accuracy;Best measurement angle can be maintained without manual intervention throughout, realizes stacking process automation.

Description

Technical Field

[0001] This utility model relates to the field of material height detection devices, and in particular to a material height detection device for bucket wheel excavators suitable for multiple working conditions. Background Technology

[0002] Existing material height detection devices primarily employ ultrasonic or radar technology, installed at the cantilever head of a bucket wheel excavator to vertically detect changes in the height of the material pile below. Because the material is transported to the cantilever head via a height conveyor belt and moves in a parabolic trajectory to the stacking point, the measured value from the material height detection device is some distance from the actual stacking point. In the reverse stacking mode (where the trolley's backward movement is opposite to the material flow direction), the measured value is the height of a point on the slope of the material pile. Using the parabolic motion principle and the angle of repose of the material pile, the relative positional relationship between the measured point and the stacking point can be obtained, thus providing the true height of the stacking point. However, in the forward stacking mode (where the trolley's forward movement is the same as the material flow direction), the measured value is the height of a point on the top of the already stacked material pile, failing to accurately reflect the height of the stacking point ahead. During automated stacking, the inability to obtain accurate material height data prevents the implementation of the forward stacking mode, hindering the realization of related stockpile processes.

[0003] Chinese Patent Publication No. CN213748654U, Publication Date: July 20, 2021, discloses a Chinese patent entitled "A Level Gauge with Adjustable Angle," which includes a level gauge body. A wiring port is provided on the side of the level gauge body, and an upper connecting seat is installed at the bottom of the level gauge body. A lower connecting seat is connected to the lower end of the upper connecting seat. A connecting post is provided on the side of the lower connecting seat, extending outward through a connecting plate. The connecting plate is fixedly connected to a support plate. A screw hole is provided at the upper end of the support plate, and the bottom end of the support plate is fixed to a flange. A through hole is provided at the center of the flange, and a protrusion is provided on the bottom surface of the flange. The protrusion is connected to an extrusion component via a spring. A rotating shaft is installed inside the screw hole, and the end of the rotating shaft enters a sliding groove. However, this patent cannot meet the requirements for accurate material height measurement under different stacking modes, especially the forward stacking mode, where accurate material height data cannot be obtained. Utility Model Content

[0004] This invention provides a material height detection device for bucket wheel excavators suitable for multiple working conditions. By automatically adjusting the position and orientation of the material height detection device according to different stacking modes, the accuracy of material height measurement is improved, and the stacking process is automated.

[0005] To achieve the above object, the utility model adopts the following technical solutions: A bucket wheel machine material height detection device suitable for multiple working conditions, including a flip bracket, the bottom end of the flip bracket is hinged on the rotating shaft of the support, a push rod assembly is arranged on one side, a level gauge is suspended on one side of the top end, and a plurality of steel wire ropes are connected on the other side; the steel wire ropes pass through the pulley assembly and are wound on the reel, an encoder is arranged on the reel, a lower limit switch is arranged on one side of the bottom end of the flip bracket, an upper limit switch is arranged below the push rod assembly, and an inclination detector is installed on the flip bracket.

[0006] Preferably, the push rod assembly is arranged on the limit bracket, and an upper limit switch is arranged below the limit bracket. The inclination detector is installed on the flip bracket and is used to detect the front and rear pitching angles and the left and right inclination angles of the flip bracket. The left and right inclination angles are used to detect the left and right balance, and after being fed back to the PLC, the left and right drive motors and the length of the steel wire rope are adjusted. The front and rear pitching angles are used to calculate the extended position of the detection height of the level gauge. The upper limit signal is immediately fed back to the PLC to achieve automatic shutdown, prevent the flip bracket from overshooting during return, ensure the safety of the equipment, and improve the operation reliability.

[0007] Preferably, the push rod assembly includes a push rod, one end of the push rod is provided with a push plate, the push plate abuts against the flip bracket in the initial state, and the other end of the push rod is connected to the driving member. The push rod is used to push the flip bracket in the vertical direction forward to make the flip bracket tilt. The push plate is in a "C" shape with one end open and fits the shape of the flip bracket. The "C" shaped push plate contacts the flip bracket surface, and the force is transmitted evenly, avoiding point contact fatigue; the linear drive of the push rod converts the flip torque, the action is stable, and the mechanical impact noise is reduced.

[0008] Preferably, one end of the limit bracket abuts against the flip bracket, and the other end is connected to the fixed bracket. The end of the limit bracket is also in a "C" shape with one end open.

[0009] Preferably, the top end of the fixed bracket fixes the pulley assembly, the pulley assembly includes a double pulley, and the steel wire rope passes through between the double pulleys. The double pulley is arranged in the pulley protection cover, and both ends of the pulley protection cover are open. An installation frame is arranged on the inner side of the top end of the flip bracket, and preferably two steel wire ropes are arranged, respectively arranged at both ends of the installation frame. The double pulley shares the tensile force of the steel wire rope and reduces wear; both ends of the protection cover are open, which is both dust-proof and convenient for observation and maintenance, and prolongs the service life of the pulley and the steel wire rope.

[0010] Preferably, both ends of the rotating shaft are fixedly connected to the bearing seats of the support, the bottom end of the flip bracket is provided with a hinge seat, and the hinge seat is hinged on the rotating shaft. A limit plate is arranged on the outer side of the hinge seat. The bearing seat reduces the friction resistance, and the hinge seat cooperates with the limit plate to limit the flip angle, prevent over-rotation, and ensure that the mechanism always operates within the safe range under multiple working conditions.

[0011] Preferably, a fixed beam is provided on the rear side of the rotating shaft, and the lower limit switch is mounted on the fixed beam. After the tilting bracket descends to its maximum extent, the tilting bracket triggers the lower limit switch, causing the PLC to control the wire rope reel to stop. The lower limit switch and the upper limit switch form a complete stroke protection system; the switch is triggered as soon as the lifting or lowering reaches its maximum position, and the PLC immediately stops the machine, preventing the wire rope from overwinding or becoming loose, thus improving system safety.

[0012] Preferably, several reels are mounted on a support, with one end of each reel connected to a drive motor and the other end connected to an encoder. The encoder detects the length of the wire rope travels; it is controlled in two groups, left and right, to maintain left-right balance when the tilting bracket is tilted. The encoder monitors the difference in wire rope length on both sides in real time, and the PLC synchronously adjusts the left and right motors to maintain the balance of the tilting bracket, prevent skewing, and ensure the accuracy of material height measurement.

[0013] Preferably, the top of the tilting bracket is equipped with a suspension rod, which is perpendicular to the tilting bracket and located on the outside of the tilting bracket. The outward extension of the suspension rod keeps the level gauge away from the bracket body, reduces structural obstruction, expands the measurement range, and adapts to various working conditions such as high stacks and slopes.

[0014] Preferably, the level gauge is connected to the end of the suspension rod via a chain. The level gauge can be either a radar level gauge or an ultrasonic level gauge, with radar level gauges being preferred. The flexible chain connection buffers mechanical vibrations while ensuring the level gauge remains vertically downward during detection; the radar beam has strong dust penetration capabilities, resulting in small measurement errors and enabling high-precision, all-weather level gauge detection.

[0015] Beneficial effects: This utility model can automatically change the material level detection posture according to different stacking modes, which significantly improves the accuracy of material height measurement; the optimal measurement angle can be maintained without manual intervention throughout the process, realizing the automation of the stacking process, reducing labor intensity, and improving work efficiency and system reliability. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of one structure of the present utility model.

[0017] Figure 2 for Figure 1 Enlarged view of point A.

[0018] Figure 3 for Figure 1 Enlarged view at point B.

[0019] Reference numerals: 101. Drive motor; 102. Reel; 103. Encoder; 104. Support; 105. Wire rope; 106. Pulley guard; 107. Pulley assembly; 108. Chain; 109. Level gauge; 110. Tilting bracket; 111. Inclination detector; 112. Push rod; 113. Limit bracket; 114. Upper limit switch; 115. Bearing seat; 116. Limit plate; 117. Lower limit switch; 118. Hinge seat; 119. Fixed beam. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0021] Bucket wheel stacker-reclaimers (referred to as "bucket wheel stackers") are key equipment for bulk material stacking and reclaiming in coal-fired power plants and bulk cargo terminal yards. Currently, some power plants and terminals are undergoing automation upgrades to remotely control fully automatic bucket wheel stackers and enable unattended on-site operation. Bucket wheel stackers employ two stacking methods: traveling stacking and rotating stacking. Traveling stacking relies primarily on the movement of the trolley to change the stacking point, while rotating stacking relies primarily on the rotation of the cantilever arm. During stacking, the system needs to monitor the height of the stacked material in real time. Once the detected height reaches a predetermined level, the system moves to a different stacking point to continue stacking.

[0022] The accuracy of material height detection for bucket wheel excavators directly affects stacking efficiency and operational safety. This invention provides a multi-condition material height detection device for bucket wheel excavators, which effectively solves the problem of poor adaptability of traditional detection devices by flexibly adjusting the detection posture to adapt to different stacking modes.

[0023] like Figure 1As shown, the device uses a tilting bracket 110 as its core load-bearing structure. The bottom end of the tilting bracket 110 is hinged to the rotating shaft of the support 104. This hinged design gives the tilting bracket 110 the ability to rotate flexibly around the rotating shaft, providing a basis for subsequent attitude adjustments. A push rod 112 assembly is provided on one side of the tilting bracket 110. In the initial state, the push rod assembly abuts against the tilting bracket. When the lowering is initiated, the push rod 112 pushes the tilting bracket 110 out, and the tilting bracket 110 descends under gravity, while the push rod 112 automatically stops and returns to its original position. A level gauge 109 is suspended on one side of the top. The level gauge 109 serves as the core detection component and can monitor the height of the material pile in real time. Several steel wire ropes 105 are connected to the other side. The steel wire ropes 105 pass through the pulley assembly 107 and are wound onto the reel 102. The encoder 103 on the reel 102 can accurately record the length of the steel wire ropes 105, assisting in calculating the tilt angle of the tilting bracket 110 and the extension position of the level gauge 109. The lower limit switch 117 on one side of the bottom of the flip bracket 110 and the upper limit switch 114 below the push rod 112 assembly constitute a dual safety protection mechanism to prevent the flip bracket 110 from being damaged due to excessive rotation; the tilt detector 111 installed on the flip bracket 110 captures the bracket's attitude parameters in real time to provide data support for precise adjustment.

[0024] like Figure 2 As shown, the push rod 112 assembly is mounted on the limit bracket 113, and the upper limit switch 114 located below the limit bracket 113 is a key safety component. When the drive motor 101 pulls the tilting bracket 110 to rotate via the reel 102 and the wire rope 105, the tilting bracket 110 contacts the upper limit switch 114, triggering the upper limit switch 114 to operate. The switch signal is immediately fed back to the PLC control system, achieving automatic shutdown and preventing overshoot of the tilting bracket 110, thus significantly improving the reliability of equipment operation. The tilt meter 111 is particularly important because it can simultaneously detect the front-to-back pitch angle and the left-to-right tilt angle of the tilting bracket 110. The left-to-right tilt angle is used to determine whether the bracket is balanced. After the detection data is fed back to the PLC, the system can automatically adjust the running status of the left and right drive motors 101 and the length of the wire ropes 105 on both sides to ensure that the bracket is horizontal. The front-to-back pitch angle is used to accurately calculate the extension position of the level gauge 109 to detect the height. Combined with the length of the wire rope 105 recorded by the encoder 103 of the reel 102, the level gauge 109 detection point is accurately positioned to ensure the accuracy of the material height measurement.

[0025] like Figure 1As shown, the structural design of the push rod 112 assembly takes into account both the force transmission efficiency and the running stability. The push rod 112 assembly includes a push rod 112, a push plate, and a driving member. One end of the push rod 112 is connected to the push plate, which is in contact with the flipping bracket 110 in the initial state, and the other end is connected to the driving member. The power provided by the driving member is transmitted to the push plate through the push rod 112, pushing the flipping bracket 110 to tilt around the rotating shaft and then separating. The flipping bracket 110 continues to tilt by itself relying on gravity, realizing the conversion from the vertical state to the tilted state. The push plate adopts a "U" - shaped design with one end open, and its shape precisely fits the surface contour of the flipping bracket 110. This surface contact method evenly distributes the thrust on the flipping bracket 110, avoiding the problems of local stress concentration and fatigue damage caused by traditional point contact. The linear driving mode of the push rod 112 converts the power into a flipping torque, with a smooth and impact - free action process, effectively reducing the noise during mechanical operation and extending the service life of the components. The limiting bracket 113, as an auxiliary support component, is in contact with the flipping bracket 110 at one end and fixed to the fixed frame at the other end, and its end also adopts a "U" - shaped design with one end open.

[0026] This structural design enables the device to flexibly adapt to different stacking conditions. Through the precise coordination of each component, it not only ensures the detection accuracy but also improves the running safety and reliability, providing strong support for the efficient and automated operation of the bucket wheel stacker - reclaimer, and having significant practical value in the industrial stacking field.

[0027] Working principle: Before the bucket wheel stacker - reclaimer starts stacking coal, the detection position of the material height detection device, that is, the front - back pitching angle of the flipping bracket 110, is determined according to the operation mode requirements. After determination, the driving motor 101 drives the wire rope 105 reel 102 to make the wire rope 105 in a slack state; at the same time, the push rod 112 pushes the lifting bracket forward, making the flipping bracket 110 tilt, and the flipping bracket 110 continues to tilt downward under the action of gravity. The left and right two sets of wire ropes 105 are controlled by the encoder 103 and the PLC, and the lengths released on both sides are kept the same, so that the flipping bracket 110 remains balanced left and right. The inclination detector 111 detects the left - right inclination angle and the pitching angle. After the pitching angle reaches the set value, the driving motor 101 is stopped. The lower limit switch 117 prevents the flipping bracket 110 from tilting too much downward. After the coal stacking is completed, the left and right driving motors 101 drive the reel 102 to pull the wire rope 105, and the flipping bracket 110 rises and returns to the vertical state. After the upper limit switch 114 is triggered, the PLC stops the left and right driving motors 101 to prevent the flipping bracket 110 from being pulled backward continuously.

[0028] As Figure 1As shown, in the structural design of the bucket wheel mill material height detection device, the coordinated operation of each component is the core of achieving multi-condition adaptability. The pulley assembly 107 fixed at the top of the fixed bracket adopts a double pulley design, with the wire rope 105 passing between the two pulleys. This structure can effectively distribute the tension of the wire rope 105, making the tension evenly distributed on the two pulleys, reducing wear caused by excessive force on a single pulley, and extending the service life of the wire rope 105 and the pulleys. The double pulleys are enclosed in a pulley protective cover 106. The protective cover has openings at both ends, which can prevent dust and debris generated during the material stacking process from entering the pulley gap, avoiding jamming failures, and also allows operators to easily observe the operating status of the pulleys and wire rope 105, facilitating daily maintenance. The top inner side of the flipping bracket 110 is equipped with a mounting frame, and two steel wire ropes 105 are respectively connected to the two ends of the mounting frame. This symmetrical layout ensures that the tension of the steel wire ropes 105 on the flipping bracket 110 is balanced, avoiding the bracket tilt caused by unilateral force, and providing stable tension support for posture adjustment.

[0029] like Figure 3 As shown, the rotating shaft serves as the rotational core of the tilting bracket 110. Both ends are fixed to the support 104 via bearing seats 115. The hinge seat 118 at the bottom of the tilting bracket 110 is connected to the rotating shaft. The limiting plate 116 on the outer side of the hinge seat 118 plays a crucial limiting role. The limiting plate 116 and the lower limit switch 117 work together to generate a limit switch signal, which is sent to the PLC. When the tilting bracket 110 rotates around the rotating shaft to its lowest point, the limiting plate 116 contacts the lower limit switch 117, stopping the tilting bracket 110 from tilting further downwards. This prevents structural deformation or component damage due to excessive rotation, ensuring that the entire mechanism operates within a safe range under various working conditions.

[0030] like Figure 2 and Figure 3 As shown, a lower limit switch 117 is installed on the fixed beam 119 on the rear side of the rotating shaft, forming a complete stroke protection system with the upper limit switch 114 below the push rod assembly. When the tilting bracket 110 rises or falls to its maximum position, the corresponding limit switch is triggered: when it rises to the maximum position, the tilting bracket 110 triggers the upper limit switch 114; when it falls to the maximum position, it triggers the lower limit switch 117. The switch signal is transmitted to the PLC control system in real time. After receiving the signal, the control system immediately controls the drive components to stop, avoiding over-rush phenomena such as over-winding or over-tightening of the wire rope 105. This ensures equipment safety from both mechanical and electrical perspectives and significantly improves the reliability of system operation.

[0031] Several reels 102 mounted on the support 104 are connected at one end to a drive motor 101 and at the other end to an encoder 103. The drive motor 101 provides power for the winding and unwinding of the wire rope 105, while the encoder 103 detects the travel length of the wire rope 105 in real time and converts the length data into an electrical signal to be fed back to the PLC. The reels 102 adopt a left and right independent control design. When the tilt detector 111 detects that the tilting bracket 110 is tilted to the left or right, the PLC will precisely adjust the operating status of the left and right drive motors 101 according to the length difference of the wire rope 105 on both sides fed back by the encoder 103. By adjusting the length of the wire rope 105 through winding and unwinding, the tilting bracket 110 is restored to horizontal balance, preventing measurement errors of the level gauge 109 caused by tilting and ensuring the accuracy of material height detection.

[0032] The suspension rod at the top of the tilting bracket 110 is vertically mounted on the outside of the bracket. This extended layout allows the level gauge 109 to be positioned away from the body of the tilting bracket 110, reducing the obstruction of the level gauge 109's detection signal by the bracket structure. During the stacking process, whether on a steep slope with high stacking or a gentle area with low stacking, the level gauge 109 can be aligned with the detection point of the stack without obstruction, effectively expanding the measurement range and adapting to the working conditions of different stacking patterns. The end of the suspension rod is connected to the level gauge 109 via a chain 108. The flexibility of the chain 108 can buffer the mechanical vibration generated during the operation of the bucket wheel excavator, avoiding the vibration of the level gauge 109 caused by rigid connection, ensuring stable detection signal. At the same time, the chain 108 ensures that the measurement direction of the level gauge 109 is always vertically downward, unaffected by the posture of other mechanisms. The level gauge 109 is preferably a radar level gauge 109 or an ultrasonic level gauge 109. The radar level gauge 109, with its strong dust penetration capability, can accurately transmit and receive radar waves even in dusty material storage environments, reducing measurement errors and achieving high-precision material level detection in all weather conditions. The tilt detector 111 monitors the forward and backward pitch angles and left and right tilt angles of the tilting bracket 110 in real time: the forward and backward pitch angle data is used by the PLC to calculate the extension position of the level gauge 109, and combined with the length data of the steel wire rope 105 from the encoder 103, accurately locates the detection point; the left and right tilt angle data is fed back to the PLC, and balance control is achieved by adjusting the left and right reel motors 102. This closed-loop control of real-time monitoring and dynamic adjustment allows the device to automatically optimize the detection posture according to the material storage mode, ensuring that the level gauge 109 is always at the optimal measurement angle.

[0033] This device achieves automatic posture adjustment under different stacking conditions through designs such as uniform force transmission via double pulleys, safety protection via limit switches, balanced control via encoder 103 and PLC, and optimized measurement of suspension rods and chains 108. The entire process requires no manual intervention, ensuring both accurate material height measurement and full automation of the stacking process. During stacking, appropriate control parameters can be set according to different stacking modes, and the device can monitor the material height in real time to ensure it meets the target height. This effectively reduces labor intensity, improves operational efficiency and system reliability, and provides a strong guarantee for the efficient and safe operation of the bucket wheel excavator.

[0034] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the protection scope of this utility model.

Claims

1. A bucket wheel excavator material height detection device suitable for multiple working conditions, characterized in that, It includes a tilting bracket, the bottom of which is hinged to the pivot of the support. A push rod assembly is provided on one side, a level gauge is suspended on one side of the top, and several steel wire ropes are connected to the other side. The wire rope passes through the pulley assembly and is wound onto the reel. The reel is equipped with an encoder. A lower limit switch is located on one side of the bottom of the tilting bracket, and an upper limit switch is located below the push rod assembly. An inclination detector is installed on the tilting bracket.

2. The bucket wheel excavator material height detection device suitable for multiple working conditions according to claim 1, characterized in that, The push rod assembly is mounted on the limit bracket, and an upper limit switch is located below the limit bracket.

3. A bucket wheel excavator material height detection device suitable for multiple working conditions according to claim 1 or 2, characterized in that, The push rod assembly includes a push rod, one end of which is provided with a push plate. In the initial state, the push plate abuts against the flipping bracket, and the other end of the push rod is connected to the drive component.

4. The bucket wheel excavator material height detection device suitable for multiple working conditions according to claim 3, characterized in that, One end of the limiting bracket abuts against the flipping bracket, and the other end is connected to the fixed bracket.

5. A bucket wheel excavator material height detection device suitable for multiple working conditions according to claim 4, characterized in that, A pulley assembly is fixed at the top of the fixed bracket. The pulley assembly includes two pulleys, and a steel wire rope passes between the two pulleys.

6. A bucket wheel excavator material height detection device suitable for multiple working conditions according to claim 1, characterized in that, The two ends of the rotating shaft are fixedly connected to the bearing seats of the support, and the bottom of the flipping bracket is provided with a hinge seat, which is hinged to the rotating shaft.

7. A bucket wheel excavator material height detection device suitable for multiple working conditions according to claim 1 or 6, characterized in that, A fixed beam is provided on the rear side of the rotating shaft, and the lower limit switch is located on the fixed beam.

8. A bucket wheel excavator material height detection device suitable for multiple working conditions according to claim 1, characterized in that, Several reels are mounted on the support, with one end of the reel connected to the drive motor and the other end connected to the encoder.

9. A bucket wheel excavator material height detection device suitable for multiple working conditions according to claim 4, characterized in that, The top of the flipping bracket is equipped with a suspension rod, which is perpendicular to the flipping bracket and is located on the outside of the flipping bracket.

10. A bucket wheel excavator material height detection device suitable for multiple working conditions according to claim 9, characterized in that, The level gauge is connected to the end of the suspension rod via a chain.

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