An interlocking start / stop control system for grain conveying equipment based on infrared sensing

Abstract

This utility model discloses an interlocking start-stop control system for grain conveying equipment based on infrared sensing, belonging to the field of grain storage automation technology. It solves the problems of high energy consumption during idling, complex control systems, and poor adaptability of existing equipment. The system includes a remote control device, infrared sensors, a signal output conversion controller, and a power conversion device. A manual control switching module can also be added. The front-end conveying equipment is started via the remote control device, and the rear-end equipment uses dual-beam infrared sensors installed at the inlet / outlet to detect grain flow. The signal output conversion controller receives the signal and outputs interlocking start-stop commands. The handheld transmitter has an emergency stop button, and the infrared sensors adopt an IP67 dustproof design. This system requires no professional programming or equipment modification and is compatible with flatbed, aerial, and telescopic mobile conveyors. It reduces idling time for individual units, lowers energy consumption and equipment wear, and improves operational safety and flexibility. It is suitable for grain depot loading and unloading operations of various types.

Description

Technical Field

[0001] This utility model belongs to the field of automated control technology for grain storage equipment, specifically relating to an interlocking start-stop control system for grain conveying equipment based on infrared sensing, which is particularly suitable for the coordinated operation control of flat conveyors, aerial conveyors and telescopic conveyors. Background Technology

[0002] In grain loading and unloading operations, conveying equipment typically uses a stand-alone, independent start-stop control mode. Due to uneven grain inflow (such as the interval between vehicle unloading), the equipment often runs idle, leading to two major problems: first, increased energy consumption, as the motor continuously consumes electricity while idling, resulting in energy waste; second, accelerated equipment wear, as idling causes belts, rollers, and bearings to operate ineffectively, shortening equipment lifespan and increasing maintenance costs.

[0003] Existing solutions to the above problems have obvious shortcomings. For example, Chinese utility model patent CN212846472U discloses an intelligent control system for grain conveying equipment, proposing to use PLC to realize multi-device interlocking control: by collecting the operating status signals of each conveyor, the start and stop commands are output through PLC programming logic to realize the linkage between the preceding and following equipment; however, the control system based on traditional PLC requires professional programming, which is complex to operate and has high modification costs.

[0004] For example, Chinese utility model patent with publication number CN218825264U discloses a field wireless control system for grain storage machinery. It detects grain flow by installing a gravity sensor under the conveyor belt. When the sensor detects that the grain weight reaches a threshold, it triggers the equipment to start and automatically stops when there is no grain. However, the gravity sensor solution requires modification of the equipment support, has poor compatibility, and is difficult to deploy quickly at the grain depot site.

[0005] Therefore, there is an urgent need for a practical control system that is simple in structure, low in cost, and highly adaptable. Utility Model Content

[0006] This invention aims to solve the technical problems of high energy consumption during idling, rapid equipment wear, poor compatibility of control systems, and complex operation of existing grain conveying equipment. It proposes an interlocking start-stop control system for grain conveying equipment based on infrared sensing.

[0007] This invention proposes an interlocking start-stop control system for grain conveying equipment based on infrared sensing, comprising a remote control device, an infrared sensor, a signal output conversion controller, and a power conversion device. The remote control device is installed on the front-end conveying equipment to receive manual start commands. The infrared sensor is installed at the inlet or outlet of the rear-end conveying equipment to detect the presence or absence of grain flow. The signal output conversion controller is electrically connected to both the remote control device and the infrared sensor, and outputs interlocking start-stop commands to the front-end and rear-end conveying equipment. The power conversion device supplies power to all components in the system. This interlocking control, achieved through the coordinated operation of these four components, solves the problem of equipment idling, reduces energy consumption, and extends equipment lifespan.

[0008] Preferably, the remote control device includes a handheld transmitter and a fixed receiver, the effective control distance of the transmitter is not less than 100m, and the remote control device has a built-in anti-interference chip.

[0009] By adopting the above technical solutions, the 100m remote control combined with anti-interference design ensures stable signal in complex grain depot environments and improves operational response speed.

[0010] Preferably, the infrared sensor is configured as a dual-beam anti-interference type, the detection distance of the infrared sensor can be adjusted within the range of 0.1 to 1m, and it adopts an IP67 dustproof and waterproof design.

[0011] By adopting the above technical solutions, the dual-beam infrared sensor has strong anti-interference capabilities, an adjustable detection distance of 0.1 to 1m to adapt to different devices, and an IP67 design that reduces the failure rate in dusty environments.

[0012] Preferably, the signal output conversion controller is configured to: enter a standby state after receiving the start signal from the remote control device, and output a start command to the back-end conveying equipment when the infrared sensor detects a signal of grain flow.

[0013] By adopting the above technical solutions, the controller's standby state design avoids accidental activation, and the grain flow trigger start response time is ≤0.5 seconds, thereby improving operational efficiency.

[0014] More preferably, the signal output conversion controller is further configured to: when the signal interruption of the grain flow of the infrared sensor lasts for 25 to 35 seconds, output a shutdown command to the conveying equipment of the entire system.

[0015] By adopting the above technical solution, a 25-35 second delay shutdown setting is used to avoid accidental shutdowns due to short-term food shortages, reduce the number of ineffective start-stop cycles, and extend equipment life.

[0016] More preferably, the power conversion device is configured as a DC / AC conversion module with an input voltage of AC220V and an output voltage of DC24V, adapting to the power supply requirements of each component in the system.

[0017] By adopting the above technical solutions, the AC220V to DC24V power module can be adapted to multiple devices, improve power supply stability, and reduce failures caused by voltage fluctuations.

[0018] Preferably, the handheld transmitter is also equipped with an emergency stop button, which, when pressed, can directly send a stop signal to the signal output conversion controller to forcibly cut off the power supply to the entire system.

[0019] By adopting the above technical solutions, instantaneous shutdown response (response time ≤ 0.3 seconds) can be achieved in emergency situations, bypassing conventional control logic to directly cut off the power supply, ensuring that all system equipment shuts down synchronously, greatly reducing the risk of safety accidents such as grain spillage and equipment collisions, and further improving operational safety.

[0020] Preferably, the infrared sensor is fixedly mounted on the support of the conveying equipment, and the vertical distance between the installation position of the infrared sensor and the inlet or outlet is 10-20cm.

[0021] By adopting the above technical solution, an installation distance of 10-20cm ensures accurate grain flow detection with a detection error of ≤5%, avoiding missed or false detections.

[0022] Preferably, the signal output conversion controller is further provided with three status indicator lights, including a power indicator light, a running indicator light, and a fault indicator light, which correspond to the power supply status, working status, and abnormal status of the system, respectively.

[0023] By adopting the above technical solution, the three-color indicator light can intuitively display the system status, shortening the troubleshooting time to within a few minutes and improving maintenance efficiency.

[0024] Preferably, it further includes: a manual control switching module, which is electrically connected to the signal output conversion controller and is used to switch between automatic interlocking control and single-machine manual control modes.

[0025] By adopting the above technical solutions, the manual / automatic switching function can adapt to special operating scenarios, improve operational flexibility, and is compatible with traditional operating modes.

[0026] Preferably, the system is also adapted to several types of mobile grain conveyors, including flatbed conveyors, aerial conveyors, and telescopic conveyors. The flatbed conveyor can be used as a front-end conveying device or a rear-end conveying device, and the aerial conveyor and telescopic conveyor can be used as rear-end conveying devices.

[0027] By adopting the above technical solutions, the system can be adapted to various types of mobile conveyors. The dual-role design of the flatbed conveyor expands the system's applicability to most grain depot operation scenarios.

[0028] Compared with the prior art, the beneficial results of this utility model are as follows:

[0029] (1) Energy saving and emission reduction: The actual measurement shows that when 5,500 tons of grain are put into a single warehouse, each piece of equipment reduces idling time by 36 hours, resulting in significant energy savings.

[0030] (2) Equipment protection: Idle time is reduced by more than 60%, extending the life of belts and motors.

[0031] (3) Easy deployment: All components are plug-and-play, installation and disassembly do not require professional tools, and it is compatible with a variety of grain conveyors.

[0032] (4) Safe and reliable: Hardware interlocking avoids misoperation, and the infrared sensor dustproof design (IP67) is suitable for grain dust environment. Attached Figure Description

[0033] The accompanying drawings are included to provide a further understanding of the embodiments and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments and, together with the description, serve to explain the principles of the present invention. Other embodiments and many anticipated advantages of the embodiments will be readily recognized as they become better understood through reference to the following detailed description. Elements in the drawings are not necessarily to scale. The same reference numerals refer to corresponding similar parts.

[0034] Figure 1 A schematic diagram of the interlocking start-stop control system for grain conveying equipment based on infrared sensing, according to an embodiment of the present invention, is shown.

[0035] Figure 2 A schematic diagram of the structure of a conveying device according to an embodiment of the present invention is shown;

[0036] Figure 3 A circuit logic diagram of an interlocking start-stop control system for a grain conveying device based on infrared sensing, according to an embodiment of the present invention, is shown.

[0037] The meanings of the numbers in the diagram are as follows: 1. Remote control device; 2. Infrared sensor; 3. Signal output conversion controller; 4. Power conversion device; 5. Manual control switching module; 6. Front-end conveying equipment; 7. Back-end conveying equipment. Detailed Implementation

[0038] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the relevant utility model and not intended to limit the scope of the utility model. Furthermore, it should be noted that, for ease of description, only the parts relevant to the utility model are shown in the accompanying drawings.

[0039] It should be noted that, where there is no conflict, the embodiments and features in the embodiments of this utility model can be combined with each other. The present utility model will now be described in detail with reference to the accompanying drawings and embodiments.

[0040] This utility model relates to automated control technology for grain storage equipment, specifically an interlocking start-stop control system for mobile grain conveying equipment (such as flatbed conveyors and aerial conveyors), which solves the problem of equipment idling through infrared sensing and remote control technology.

[0041] This utility model proposes an interlocking start-stop control system for grain conveying equipment based on infrared sensing, such as... Figure 1 , Figure 2 and Figure 3 As shown, the interlocking start-stop control system includes a remote control device 1, an infrared sensor 2, a signal output conversion controller 3, and a power conversion device 4. The remote control device 1 is installed on the front-end conveying equipment to receive manual start commands. The infrared sensor 2 is installed at the inlet or outlet of the rear-end conveying equipment 7 to detect the presence of grain flow. The signal output conversion controller 3 is electrically connected to both the remote control device 1 and the infrared sensor 2, and outputs interlocking start-stop commands to both the front-end conveying equipment 6 and the rear-end conveying equipment 7. The power conversion device 4 supplies power to all components in the system. Through the coordinated operation of these four components, interlocking control is achieved, solving the problem of equipment idling, reducing energy consumption, and extending equipment lifespan.

[0042] In this embodiment, the specific selection and parameters of each component of the interlocking start-stop control system are as follows:

[0043] Remote control device 1 adopts an industrial-grade wireless remote control module such as HFS-433. Remote control device 1 includes a handheld transmitter and a fixed receiver. The handheld transmitter has a start button and an emergency stop button. The fixed receiver is integrated into the front-end equipment control box. The effective control distance is 100m. It has a built-in SAW filter anti-interference chip, a communication frequency of 433MHz, and a standby current of ≤10mA.

[0044] Infrared sensor 2, selected is E3JK-R2M1 dual-beam anti-interference type, detection distance is continuously adjustable from 0.1-1m, outputs NPN normally open signal, response time ≤10ms, IP67 protection level, operating temperature -25℃~+55℃.

[0045] The signal output conversion controller 3 is based on the MY2N-J relay logic circuit design. The input interface is compatible with dry contact signals, and the output can drive AC220V / 380V contactor coils. It has a built-in 25-35 second adjustable time delay relay, and the panel is equipped with red (fault), green (run), and yellow (power) three-color LED indicator lights.

[0046] Specifically, the signal output conversion controller 3 is configured to: enter a standby state after receiving the start signal from the remote control device 1; when the infrared sensor 2 detects a signal indicating grain flow, output a start command to the back-end conveying device 7; and when the grain flow signal from the infrared sensor 2 is interrupted for 25 to 35 seconds, output a stop command to the conveying device of the entire system.

[0047] The signal output conversion controller 3 is equipped with three status indicator lights: a power indicator, a running indicator, and a fault indicator. These three indicator lights correspond to the system's power supply status, operating status, and abnormal status, respectively. The three-color indicator lights clearly display the system status, reducing troubleshooting time to within a few minutes and improving maintenance efficiency.

[0048] The power conversion device 4 adopts a DC / AC conversion module such as the S-35-24, with an input of AC220V±10% and an output of DC24V / 1.5A. It is compatible with motors from 4 to 10.5kW, has an efficiency of ≥85%, and has overcurrent and short-circuit protection functions.

[0049] Manual control switching module 5: adopts a KN3 series rotary switch, with 3-position switching (automatic / stop / manual), contact capacity 10A / AC250V, and connected in series with the controller input terminal.

[0050] The manual control switching module 5 is electrically connected to the signal output conversion controller 3, and is used to switch between automatic interlock control and stand-alone manual control modes. The manual / automatic switching function adapts to special operating scenarios, improves operational flexibility, and is compatible with traditional operating modes.

[0051] In a specific embodiment, the installation steps of the interlocking start-stop control system specifically include:

[0052] Front-end equipment deployment: The fixed receiver of remote control device 1 is installed in the electrical control box of the flat conveyor via a DIN rail. The receiver output terminal is connected to the "start signal" input terminal of the signal output conversion controller 3. The wiring uses RVV2×0.75mm. 2 Shielded cable.

[0053] Infrared sensor installation: Fix the infrared sensor 2 on the feed inlet bracket of the overhead conveyor or telescopic conveyor with M8 bolts, ensuring that the detection surface is vertically aligned with the grain flow path. The installation height is 10-20cm from the feed inlet. Connect the sensor output line to the "grain flow detection" input terminal of the controller.

[0054] Controller and power supply connection: The signal output conversion controller 3 is installed in the rainproof control cabinet next to the equipment. The input terminal of the power conversion device 4 is connected to the AC220V main power supply, and the output terminals are for powering the controller, sensor and remote control receiver respectively. The controller output terminals are connected in series to the main circuit of the flat conveyor, the aerial conveyor and the telescopic conveyor through the KM1-KM3 contactor coils respectively.

[0055] Mode switching module installation: The manual control switching module 5 is embedded in the control cabinet panel, and its contacts are connected in series with the mode control loop of the controller to realize automatic / manual mode switching.

[0056] Taking a typical grain conveyor line (front-end flatbed conveyor + rear-end aerial work platform conveyor) as an example, the specific workflow includes:

[0057] Automatic interlock mode: The operator presses the start button via a handheld transmitter, and the receiver transmits the signal to the controller, which then enters standby mode (green running light flashes). When the grain flow enters the feed inlet of the back-end equipment, the infrared sensor detects the grain flow and outputs a signal to the controller. The controller immediately outputs a start command, and the back-end equipment starts (green running light stays on). After the grain flow is interrupted, the sensor output signal disappears, and the controller outputs a stop command after a delay of 25-35 seconds (default 30 seconds), shutting down all equipment in the system (indicator lights turn off).

[0058] Emergency stop procedure: Press the emergency stop button on the transmitter. The signal directly triggers the power-off protection circuit inside the controller, forcibly cutting off all outputs. All system equipment will immediately stop (red fault light flashes). Manual reset and restart are required.

[0059] Manual mode operation: Rotate the switch module to the "manual" position, the controller will de-interlock, and individual machines can be started and stopped via the independent buttons of each device, which is suitable for equipment maintenance or special grain supply scenarios.

[0060] In one specific embodiment, the process is simplified as follows: the operator remotely starts the front-end flatbed machine -- the controller receives the signal but does not start the back-end equipment; the grain flow reaches the back-end feed inlet -- the infrared sensor detects the material and outputs a high-level signal to the controller; the controller closes the contactor of the back-end equipment -- the aerial work platform machine starts automatically; the grain unloading ends and the grain flow is interrupted for 30 seconds -- the infrared sensor outputs a low level, the controller opens the contactor, and the entire line stops.

[0061] The interlocking start-stop control system disclosed in this embodiment is adapted to several types of mobile grain conveyors, including flat conveyors, aerial conveyors and telescopic conveyors. Flat conveyors can be used as front-end conveying equipment 6 or rear-end conveying equipment 7, while aerial conveyors and telescopic conveyors can be used as rear-end conveying equipment 7.

[0062] When a flatbed conveyor is used as a front-end device, it directly receives a remote start signal. When used as a back-end device, an infrared sensor is installed at its feed inlet to receive grain flow signals from the preceding device. Aerial conveyors or telescopic conveyors, used only as back-end devices, detect grain flow from preceding devices (flatbed conveyors or other conveyors) using infrared sensors to achieve interlocked start and stop.

[0063] This system achieves intelligent interlocking control of mobile grain conveying equipment through modular design. It features low cost (material cost of a single system ≤ 1500 yuan), fast installation (installation time ≤ 2 hours), strong compatibility (compatible with over 90% of mainstream models), can reduce equipment idling time by more than 60%, saves approximately 800 kWh of electricity per unit per year, and significantly reduces grain depot operating costs.

[0064] The interlocking start-stop control system disclosed in this embodiment includes a remote control device 1, a power conversion device 4, an infrared sensor 2, and a signal output conversion controller 3. The front-end unloading flatbed conveyor is manually triggered by the remote start-stop device, while the rear-end conveying equipment 7 detects the presence or absence of grain flow through the infrared sensor 2, achieving automatic start-stop interlocking control. When grain arrives, the system automatically starts the entire line of equipment; when there is no grain or a malfunction occurs, it automatically stops, effectively reducing equipment idling time, energy consumption, and equipment wear. It achieves automatic equipment start-up when grain arrives and automatic shutdown when there is no grain; reduces energy consumption and equipment wear; is compatible with existing conveying equipment without large-scale modifications; has a simple structure and is easy to install; is suitable for various types of mobile grain conveyors; and can reduce idling time by 36 hours / 5500 tons of storage capacity per unit, demonstrating significant energy-saving effects.

[0065] The specific embodiments of this utility model have been described above, but the scope of protection of this utility model is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the scope of protection of this utility model. Therefore, the scope of protection of this utility model should be determined by the scope of the claims.

[0066] In the description of this utility model, it should be understood that the terms "upper," "lower," "inner," "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. The word "comprising" does not exclude the presence of elements or steps not listed in the claims. The word "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. The simple fact that certain measures are recited in mutually different dependent claims does not indicate that combinations of these measures cannot be used for improvement. Any reference signs in the claims should not be construed as limiting the scope.

Claims

1. An infrared induction-based interlocking start-stop control system for a grain conveying device, characterized by, Includes a remote control device, an infrared sensor, a signal output conversion controller, and a power conversion device; The remote control device is installed on the front-end conveying equipment and is used to receive manual start commands; The infrared sensor is installed at the inlet or outlet of the rear conveying equipment to detect whether there is grain flow at the inlet or outlet. The signal output conversion controller is electrically connected to the remote control device and the infrared sensor respectively, and is used to output interlocking start and stop commands to the front-end conveying equipment and the back-end conveying equipment. The power conversion device is used to supply power to the various components in the system.

2. The infrared induction based on grain conveying equipment interlock start-stop control system according to claim 1, characterized in that, The remote control device includes a handheld transmitter and a fixed receiver. The effective control distance of the transmitter is not less than 100m, and the remote control device has a built-in anti-interference chip.

3. The infrared induction based onstop control system for grain conveying equipment interlock according to claim 1, characterized in that, The infrared sensor is configured as a dual-beam anti-interference type, and the detection distance of the infrared sensor can be adjusted within the range of 0.1 to 1m. It also adopts an IP67 dustproof and waterproof design.

4. The infrared sensor-based on-off control system for grain conveying equipment interlock according to claim 1, characterized in that, The signal output conversion controller is configured as follows: After receiving the start signal from the remote control device, it enters the standby state. When the infrared sensor detects a signal of grain flow, it outputs a start command to the back-end conveying equipment.

5. The infrared induction based on grain conveying equipment interlock start-stop control system according to claim 4, characterized in that, The signal output conversion controller is also configured to: When the signal of grain flow from the infrared sensor is interrupted for 25 to 35 seconds, a shutdown command is output to the conveying equipment of the entire system.

6. The infrared induction based onstop control system for grain conveying equipment interlock according to claim 2, characterized in that, The power conversion device is configured as a DC / AC conversion module with an input voltage of AC220V and an output voltage of DC24V, adapting to the power supply requirements of each component in the system.

7. The infrared sensor based on / off control system for grain conveying equipment according to claim 1, characterized in that, The infrared sensor is fixedly mounted on the support of the conveying equipment, and the vertical distance between the installation position of the infrared sensor and the inlet or outlet is 10-20cm.

8. The infrared sensor-based on-off control system for grain conveying equipment according to claim 1, characterized in that, The signal output conversion controller is also equipped with three types of status indicator lights, including a power indicator light, a running indicator light, and a fault indicator light, which correspond to the power supply status, working status, and abnormal status of the system, respectively.

9. The infrared induction based onstop control system for grain conveying equipment interlock according to claim 1, characterized in that, Also includes: A manual control switching module is electrically connected to the signal output conversion controller and is used to switch between automatic interlocking control and single-machine manual control modes.

10. The infrared sensor-based on-off control system for grain conveying equipment according to any one of claims 1-9, characterized in that, The system is adapted to several types of mobile grain conveyors, including flatbed conveyors, aerial conveyors, and telescopic conveyors. The flatbed conveyor can be used as a front-end conveying device or a rear-end conveying device, while the aerial conveyor and telescopic conveyor are used as rear-end conveying devices.

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