A coal leveling mechanism for the top of a coal car

Abstract

The utility model discloses a coal flat-falling mechanism for the top of the carriage of coal rail car belongs to coal transportation technical field, including rail car, the carriage of setting in the upper rail car, install in the rear end of carriage and can open or close's compartment door and set up in the storage space of carriage, still include by the motor of installing on the right carriage, by the motor drive rotation and located above the agitator shaft of storage space and the agitator blade of connecting in the agitator shaft and axial array jointly constitute's material flat-falling mechanism, the front section area of storage space, middle section area and rear section area in each at least set up a group of material flat-falling mechanism, and the rotating speed of each section area in agitator shaft is different. Through setting sectional speed change's material flat-falling mechanism, in the coal filling process, real-time automatic flatness of the coal that piles up, eliminates " mountain package " -like convex, makes the coal thickness in storage space even, thereby reduces the discharge residue and the risk of scattering in the transportation process.

Description

Technical Field

[0001] This utility model relates to the field of coal transportation technology, specifically to a coal leveling mechanism for the top of a coal transport railcar. Background Technology

[0002] Coal railcars are the core tool for long-distance coal transportation. When loading coal into their carriages, it is typically done by directly tipping it over from the top opening. Due to the uneven size of coal particles, the unstable tipping angle, and the vibrations during railcar operation, the coal tends to naturally accumulate in the carriage's storage space under gravity, forming a "mound" shape that is higher in the middle and lower on the sides. (See attached image.) Figure 1 As shown. This uneven accumulation leads to two prominent problems:

[0003] Unloading residue: During unloading, the coal at the top of the "hill" is difficult to completely slide off, and residue is easily formed, especially in the corners or edges of the car, which reduces loading efficiency.

[0004] Coal spillage during transport: The high center of gravity of the "hill" makes it easy for the center of gravity to shift when the railcar starts, brakes, or passes through curved tracks, causing coal to spill from the top or side panel gaps of the car, which not only pollutes the environment but may also cause safety hazards (such as track slippage, signal interference, etc.).

[0005] Traditional solutions often rely on manual hand-held rakes or simple mechanical leveling devices. However, manual operation needs to be carried out simultaneously during the loading process, which is labor-intensive and inefficient. Simple mechanical devices have problems such as a small stirring range (only covering a local area) and non-adjustable speed (unable to adapt to different loading volumes), which cannot fundamentally solve the problem of "hill" accumulation and spillage. Utility Model Content

[0006] The technical problem to be solved by this utility model is to provide a coal leveling mechanism for the top of a coal railcar. By setting a segmented speed-changing material leveling mechanism, the accumulated coal is automatically leveled in real time during the coal loading process, eliminating "hill"-shaped protrusions and making the coal thickness in the storage space uniform, thereby reducing unloading residue and the risk of spillage during transportation.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] A coal leveling mechanism for the top of a coal railcar includes a railcar, a car body positioned above the railcar, a door installed at the rear of the car body that can be opened or closed, and a storage space inside the car body. It also includes a material leveling mechanism composed of a motor installed on the right side of the car body, a stirring shaft driven by the motor and located above the storage space, and stirring blades connected to the stirring shaft and arranged axially. At least one set of material leveling mechanisms is provided in each of the front, middle, and rear sections of the storage space, and the rotational speed of the stirring shaft decreases sequentially from the middle section to the front and rear sections (i.e., middle section speed > front section speed > rear section speed).

[0009] By adopting the above scheme and setting up a segmented speed-controlled material leveling mechanism, the coal is stirred during the coal filling process to make it fluid, thereby automatically leveling the piled coal in real time to eliminate "hill"-like protrusions and make the coal thickness in the storage space uniform, thus reducing the risk of unloading residue and spillage during transportation.

[0010] In a preferred embodiment of a coal leveling mechanism for the top of a coal railcar, a set of material leveling mechanisms is arranged at intervals along the length of the front section of the storage space, two sets are arranged at intervals in the middle section, and a set is arranged at intervals in the rear section. Since the middle section is more prone to accumulation, an additional set of material leveling mechanisms is arranged in the middle section. The stirring shaft of each set of material leveling mechanisms is arranged horizontally along the width of the storage space, and the distance between two adjacent sets of stirring shafts in different sections is 1 / 4 to 1 / 2 of the length of the storage space, which satisfies the control range of the material leveling mechanism, so that the coal in the entire storage space is in dynamic flow.

[0011] In a preferred embodiment of a coal leveling mechanism for the top of a coal-carrying railcar, all motors are equipped with frequency converters, and each frequency converter is electrically connected to the central control system of the railcar to achieve synchronous speed adjustment. The speed of the stirring shaft in the front section is 25-35 rpm, in the middle section it is 35-45 rpm, and in the rear section it is 15-25 rpm. The middle section has the highest speed (to push the coal piled up in the middle to flow forward and backward), the front section is second highest (to help level the coal at the front), and the rear section has the lowest speed (to prevent coal from piling up at the rear and reduce the impact on the car door). The three sections work together to achieve uniform distribution across the entire width and length.

[0012] In a preferred embodiment of a coal leveling mechanism for the top of a coal-carrying railcar, the motor is fixed to the right side wall of the right side car via a mounting bracket, and the output shaft of the motor is coaxially arranged with the agitator shaft and rigidly connected by a flexible coupling. A shock-absorbing pad is provided at the connection between the mounting bracket and the right side car. The shock-absorbing pad can absorb the vibration (frequency 5-20Hz) during the operation of the railcar and prevent the vibration from being transmitted to the agitator shaft, which could cause wear on the agitator blades or overload of the motor.

[0013] In a preferred embodiment of a coal leveling mechanism for the top of a coal railcar, the agitator blades are spiral-shaped arc blades. The outer edge of the arc blades is inclined at a 30-45° angle to the horizontal plane at the top of the storage space, and the circumferential angle between two adjacent arc blades on the agitator shaft is 60°. The arc blades gradually increase in size from the middle of the agitator shaft to both sides. The larger the arc blade, the greater its agitation range, and the smaller the arc blade, the smaller its agitation range. This ensures that the coal is evenly spread to both sides.

[0014] The beneficial effects of this utility model are:

[0015] 1. Automatic real-time leveling: The stirring blades driven by the motor rotate synchronously during the coal filling process, and the accumulated coal can be spread out in all directions without manual intervention, thus avoiding the formation of "hills" from the source.

[0016] 2. Segmented speed optimization: The middle section has the highest speed (propelling the coal piled up in the middle to flow forward and backward), the front section has the second highest speed (assisting in leveling the coal at the front end), and the rear section has the lowest speed (preventing coal from piling up at the rear end). The three sections work together to achieve uniform distribution across the entire width and length.

[0017] 3. Anti-spillage design: After the coal is evenly distributed, the center of gravity of the storage space is stable, and the center of gravity is not easily shifted due to bumps when the railcar is running, which significantly reduces the risk of spillage during transportation.

[0018] 4. Highly adaptable parameter matching: By adjusting the speed through the frequency converter, it can adapt to the leveling requirements under different loads (such as no load, half load, and full load), taking into account both efficiency and energy consumption. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 The background image shows a three-dimensional structure of coal in a coal transport railcar arranged in a "hill" shape.

[0021] Figure 2 This is a three-dimensional structural diagram of the present invention applied to a coal transport railcar;

[0022] Figure 3 To showcase Figure 2 A three-dimensional structural diagram of the internal structure;

[0023] Figure 4 for Figure 3 Three-dimensional structural diagram of the medium-arc blade;

[0024] The markings in the diagram are: 1-rail car; 2-carriage; 3-carriage door; 4-storage space; 5-motor; 6-stirring shaft; 7-mounting bracket; 8-arc blade. Detailed Implementation

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

[0026] like Figures 2 to 3 As shown, a coal leveling mechanism for the top of a coal-carrying railcar is provided for automatic leveling during coal filling. Specifically, it includes a railcar 1 (standard coal-carrying railcar), a car body 2 (a rectangular structure with an open top, length L = 8m, width W = 2.8m, and height H = 2.2m) positioned above the railcar 1, a door 3 installed at the rear of the car body 2 that can be opened or closed, and a storage space 4 within the car body 2. It also includes a material leveling mechanism composed of a motor 5 installed on the right side of the car body 2, a stirring shaft 6 driven by the motor 5 and located above the storage space 4, and stirring blades connected to the stirring shaft 6 and arranged axially. At least one set of material leveling mechanisms is provided in each of the front, middle, and rear sections of the storage space 4, and the rotational speed of the stirring shaft 6 decreases sequentially in the middle, front, and rear sections (i.e., middle section speed > front section speed > rear section speed). By setting up a segmented speed-controlled material leveling mechanism, the coal is stirred during the coal filling process to make it fluid, thereby automatically leveling the piled coal in real time to eliminate "hill"-shaped protrusions and make the coal thickness in the storage space 4 uniform, thus reducing the risk of unloading residue and spillage during transportation.

[0027] like Figure 2As shown, in the front section of the storage space 4 (near the front end of the railcar, length L3 = 2.5m), a set of material leveling mechanisms is arranged at intervals along the length direction. In the middle section (middle area, length L2 = 3m), two sets are arranged at intervals. In the rear section (near the door end, length L1 = 2.5m), a set is arranged at intervals. Since the middle section is more prone to accumulation, an extra set of material leveling mechanisms is set in the middle section. The stirring shaft 6 of each set of material leveling mechanisms is arranged horizontally along the width direction of the storage space 4, and the distance between two adjacent sets of stirring shafts 6 in different sections is 1 / 4 to 1 / 2 of the length of the storage space 4 (1 / 3 in this embodiment, i.e., the distance is about 2.7m), which meets the control range of the material leveling mechanism, so that the coal in the entire storage space 4 is in dynamic flow.

[0028] Continue as Figure 2 As shown, all motors 5 (waterproof three-phase asynchronous motors, model: Y2-160L-4, power 11kW) are equipped with frequency converters (model: ABB ACS580). Each frequency converter is electrically connected to the central control system (PLC) of the railcar 1 to achieve synchronous speed adjustment. The speed of the stirring shaft 6 in the front section is 25-35 rpm (30 rpm in this embodiment), in the middle section it is 35-45 rpm (40 rpm in this embodiment), and in the rear section it is 15-25 rpm (20 rpm in this embodiment). The middle section has the highest speed (to push the coal piled up in the middle to flow forward and backward), the front section is second (to help level the coal at the front), and the rear section has the lowest speed (to prevent the coal at the rear from piling up and reduce the impact on the door). The three sections work together to achieve uniform distribution across the entire width and length.

[0029] like Figure 3 As shown, motor 5 is connected to the side wall of carriage 2 via M16 bolts through mounting bracket 7 (welded from Q235 steel plate). The output shaft of motor 5 is coaxially set with agitator shaft 6 and rigidly connected through a flexible coupling (model: HL5 flexible pin coupling), made of 45# steel with a diameter of Φ100mm. Nitrile rubber shock-absorbing pads (8mm thick) are provided at the connection between mounting bracket 7 and right carriage 2. The shock-absorbing pads can absorb the vibration (frequency 5-20Hz) of railcar 1 during operation, preventing the vibration from being transmitted to agitator shaft 6, which could cause blade wear or motor 5 overload.

[0030] like Figure 4As shown, the stirring blades are spiral arc-shaped blades 8 (each group of mechanisms has 10 blades with a spacing of 180mm). The outer edge of the arc-shaped blades 8 is inclined at a 30-45° angle to the horizontal plane at the top of the storage space 4 (to balance the stirring coverage and resistance). In this embodiment, the inclination angle is 40°, and the circumferential angle between two adjacent arc-shaped blades 8 on the stirring shaft 6 is 60° (to ensure no dead angles in the stirring). The arc-shaped blades 8 gradually increase in size from the middle of the stirring shaft 6 to both sides. The arc-shaped blades 8 with larger areas have a larger stirring range, while the arc-shaped blades 8 with smaller areas have a relatively smaller stirring range. In this way, it can ensure that the coal is evenly spread to both sides.

[0031] The working principle of this utility model:

[0032] When railcar 1 begins loading coal, the coal is poured into storage space 4 through the opening at the top of car 2. As the loading increases, coal gradually accumulates at the top, at which point the central control system starts motor 5 based on real-time signals from the loading sensor.

[0033] The agitator 6, rotating at high speed (40 rpm) in the middle section, pushes the coal piled up in the middle to flow forward and backward (forward to the front section area, and backward to the rear section area);

[0034] The front-end medium-speed rotating (30rpm) stirring shaft 6 helps to spread the coal at the front end towards the door 3 (to prevent the front end from being too high);

[0035] The agitator 6, rotating at a low speed (20 rpm) in the rear section, slowly pushes the coal at the rear end back towards the middle (to prevent accumulation at the rear end);

[0036] During rotation, the spiral arc blade 8, through an outer edge tilt angle of 40° and a circumferential distribution of 60°, pushes the coal to both sides and in the front and back directions, ultimately ensuring that the coal thickness deviation in the storage space 4 is ≤50mm (relative to the average thickness).

[0037] Through the synergistic effect of this segmented speed change, the coal is automatically leveled into a layered structure of uniform thickness during the loading process, eliminating "hill-like" protrusions. During transportation, due to the stable center of gravity and flat surface, even if the railcar 1 experiences bumps or sudden stops, the coal is less likely to spill from the top or side panel gaps of the carriage 2, significantly improving transportation safety and unloading efficiency (residual amount reduced by more than 80%).

[0038] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model shall be included within the protection scope of the present utility model.

Claims

1. A coal leveling mechanism for the top of a coal railcar, comprising a railcar, a car body disposed above the railcar, a door installed at the rear of the car body that can be opened or closed, and a storage space disposed inside the car body. Its features are: It also includes a material leveling mechanism consisting of a motor installed on the right side of the carriage, a stirring shaft driven by the motor and located above the storage space, and stirring blades connected to the stirring shaft and arranged in an axial array. At least one set of material leveling mechanisms is provided in the front section, middle section and rear section of the storage space, and the rotational speed of the stirring shaft decreases sequentially in the middle section, front section and rear section.

2. The coal leveling mechanism for the top of a coal-carrying railcar according to claim 1, characterized in that: The storage space has a set of material leveling mechanisms spaced at intervals along its length in the front section, two sets spaced at intervals in the middle section, and a set spaced at intervals in the rear section.

3. The coal leveling mechanism for the top of a coal-carrying railcar according to claim 1, characterized in that: The stirring shafts of each material leveling mechanism are arranged horizontally along the width of the storage space, and the distance between two adjacent stirring shafts in different sections is 1 / 4 to 1 / 2 of the length of the storage space.

4. The coal leveling mechanism for the top of a coal-carrying railcar according to claim 1, characterized in that, All motors are equipped with frequency converters, and each frequency converter is electrically connected to the central control system of the railcar.

5. The coal leveling mechanism for the top of a coal-carrying railcar according to claim 1, characterized in that, The rotational speed of the agitator shaft is 25-35 rpm in the front section, 35-45 rpm in the middle section, and 15-25 rpm in the rear section.

6. The coal leveling mechanism for the top of a coal-carrying railcar according to claim 1, characterized in that, The motor is fixed to the right side wall of the right side compartment by a mounting bracket, and the output shaft of the motor is coaxial with the agitator shaft and rigidly connected by a flexible coupling. A shock-absorbing pad is provided at the connection between the mounting bracket and the right side compartment.

7. The coal leveling mechanism for the top of a coal-carrying railcar according to any one of claims 1-6, characterized in that, The stirring blades are spiral arc-shaped blades, with the outer edge of the arc-shaped blades inclined at a 30-45° angle to the horizontal plane at the top of the storage space, and the circumferential angle between two adjacent arc-shaped blades on the stirring shaft is 60°.

8. The coal leveling mechanism for the top of a coal-carrying railcar according to claim 7, characterized in that: The arc-shaped blades gradually increase in size from the center of the agitation shaft to both sides of the agitation shaft.

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