Intelligent analysis integrated device for flotation froth

Abstract

This invention provides an integrated intelligent flotation foam analysis device, belonging to the field of mineral processing equipment technology. A support frame is installed at the top of the flotation mechanism. The bottom of the main shaft mechanism extends into the flotation mechanism through the support frame. The drive mechanism is mounted above the support frame, and an industrial camera is installed above the support frame. The flotation mechanism incorporates an electromagnetic flowmeter, an infrared pH sensor, an ultrasonic analyzer, and a level gauge. The control system receives sensor data and image data in real time and regulates the flotation process. By integrating multiple sensing devices such as an industrial camera, infrared pH sensor, ultrasonic analyzer, and electromagnetic flowmeter, it can simultaneously collect various key parameters such as foam morphology and pulp density. Combined with the intelligent control system, it enables real-time online monitoring and analysis of flotation foam parameters, significantly improving the accuracy and stability of flotation process control and effectively reducing reagent consumption and manual intervention.

Description

Technical Field

[0001] This utility model belongs to the field of mineral processing equipment technology, and specifically relates to an integrated intelligent analysis device for flotation foam. Background Technology

[0002] Flotation is a core process in mineral processing, separating target minerals through the adsorption of flotation bubbles. The physical characteristics of flotation froth directly reflect the mineral grade and recovery rate. Traditional methods relying on manual observation suffer from high subjectivity, low efficiency, and difficulty in quantification.

[0003] From a production control perspective, traditional flotation machines heavily rely on operators visually observing the shape, color, and flowability of froth to determine flotation conditions. This manual observation method is not only limited by the operator's experience and subjective judgment but also makes it difficult to accurately capture the microstructure and dynamic changes of the froth. Meanwhile, the detection of key parameters such as the pH value, concentration, and particle size distribution of the pulp is typically done offline. The entire process, from sampling and delivery to laboratory testing, is time-consuming, resulting in the inability to promptly relay test results to the production control system. This control lag makes it difficult to precisely adjust the flotation process according to real-time conditions, easily leading to over-flotation or under-flotation, which in turn causes serious consequences such as decreased concentrate grade and reduced recovery of valuable minerals, severely impacting the company's economic benefits.

[0004] In terms of safety, the existing flotation machine's structural design has significant flaws. Its transmission components, such as motors, reducers, and couplings, are mostly directly exposed to slurry splashes and mechanical collisions. On the one hand, chemicals in the slurry can corrode the transmission components, shortening their service life; on the other hand, the high-speed operation of these components lacks effective protective measures, and any malfunction or component detachment could easily cause personal injury to on-site operators, posing a significant safety hazard. Furthermore, slurry pH, concentration, and other parameter monitoring equipment are typically scattered across different locations within the flotation machine, lacking an effective data integration and sharing mechanism between these monitoring points. This not only increases the difficulty and cost of equipment maintenance but also makes it difficult for operators to fully and accurately grasp the overall operating status of the flotation process, further affecting the timeliness and accuracy of production control. Simultaneously, the froth scraper, as a crucial component of the flotation machine, lacks integrated protective design with the transmission system. During flotation, the froth scraper continuously scrapes froth from the surface of the flotation cell, while the transmission system provides power for the scraper's operation. Due to the lack of effective isolation and protection between the two, slurry and foam can easily enter the transmission system, leading to increased wear and tear on transmission components and frequent malfunctions. This not only affects flotation efficiency but also increases the workload of equipment maintenance and downtime.

[0005] In view of the many problems existing in traditional flotation machines, in order to achieve efficient, accurate and safe operation of the flotation process, it is urgent to develop an integrated device that integrates intelligent sensing, multispectral imaging and multiple protections. Utility Model Content

[0006] The purpose of this invention is to overcome the problem of declining mineral processing grade caused by the lack of real-time detection devices in existing flotation machines, and to provide an integrated intelligent flotation foam analysis device.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: This utility model provides an integrated intelligent analysis device for flotation foam, including a main shaft mechanism, a drive mechanism and a flotation cell. A support frame is set on the top of the flotation cell. The bottom of the main shaft mechanism extends into the flotation cell through the support frame. The drive mechanism is installed above the support frame. An industrial camera is installed above the support frame. The flotation cell is equipped with an electromagnetic flow meter, an infrared pH sensor, an ultrasonic analyzer and a level gauge. It includes a control system that is simultaneously connected to an industrial camera, an infrared pH sensor, an ultrasonic analyzer, and an electromagnetic flowmeter to receive sensor data and image data in real time and to regulate the flotation process.

[0008] A ring-shaped multispectral light source is placed around the industrial camera.

[0009] The main shaft mechanism includes a drive shaft and an impeller located at its bottom.

[0010] The drive shaft is equipped with at least two branch pipes, which are used to introduce air and reagents into the flotation cell, respectively.

[0011] The drive mechanism includes a first motor and a second motor disposed above the support frame. The first motor drives the main shaft mechanism through a first belt; the second motor drives the transmission wheel through a second belt. The output shaft of the transmission wheel is connected to a horizontally disposed fixed rod, and multiple sets of scrapers are symmetrically disposed on both sides of the fixed rod.

[0012] The end of the fixed rod is provided with a scraper protective cover covering the transmission components on the outside of the scraper.

[0013] A main drive protective cover is installed on the outside of the drive unit of the main spindle mechanism.

[0014] A slurry pipe is inserted into one side of the bottom of the flotation cell, connecting the slurry outlet of the flotation cell to the external piping system.

[0015] The electromagnetic flowmeter is installed on the slurry pipe.

[0016] Lifting gates are installed between adjacent flotation cells.

[0017] Compared with the prior art, the present invention has the following beneficial effects: This invention provides an integrated intelligent flotation foam analysis device, comprising a main shaft mechanism, a drive mechanism, and a flotation mechanism. A support frame is mounted on top of the flotation mechanism, and the bottom of the main shaft mechanism extends into the flotation mechanism through the support frame. The drive mechanism is mounted above the support frame, and an industrial camera is mounted above the support frame. The flotation mechanism integrates an electromagnetic flowmeter, an infrared pH sensor, an ultrasonic analyzer, and a level gauge. The control system is simultaneously connected to the industrial camera, infrared pH sensor, ultrasonic analyzer, and electromagnetic flowmeter to receive sensor data and image data in real time and regulate the flotation process. By integrating multiple sensing devices such as the industrial camera, infrared pH sensor, ultrasonic analyzer, and electromagnetic flowmeter, it can simultaneously acquire various key parameters such as foam morphology and pulp density. Combined with the intelligent control system, it enables real-time online monitoring and analysis of flotation foam parameters, significantly improving the accuracy and stability of flotation process control, effectively reducing reagent consumption and manual intervention. The integrated structural design simplifies installation and maintenance processes, provides reliable data support for flotation process optimization, and ultimately achieves the technical effects of improving mineral recovery rate and grade while reducing production costs.

[0018] Furthermore, a ring-shaped multispectral light source is set around the industrial camera. The ring light source provides uniform and adjustable lighting conditions, which significantly improves the recognition accuracy of foam surface features. A wiper structure is set up to automatically remove attached water mist and mineral slurry splashes, ensuring that the camera window is clean for a long time.

[0019] Furthermore, by installing protective covers on the outside of the main shaft mechanism and scraper drive components, operators are prevented from accidentally touching them and impurities in the slurry are prevented from entering the transmission system and causing damage, thus protecting the safety of operators and extending the service life of the equipment. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a schematic diagram of the structure of this utility model from the left side; The following are the reference numerals in the figure: 1. Main shaft mechanism; 11. Drive shaft; 12. Impeller; 2. Drive mechanism; 21. First motor; 22. Second motor; 23. First belt; 24. Second belt; 25. Drive wheel; 26. Fixed rod; 27. Scraper; 28. Scraper guard; 3. Flotation cell; 31. Support frame; 32. Slurry pipe; 33. Electromagnetic flowmeter; 34. Infrared pH sensor; 35. Lifting gate; 36. Ultrasonic analyzer; 4. Industrial camera; 5. Ring multispectral light source. Detailed Implementation

[0021] To further understand the present invention, the following detailed description is provided in conjunction with the accompanying drawings and specific embodiments. It should be understood that the embodiments are merely illustrative and not intended to limit the scope of the invention.

[0022] Example 1 like Figures 1-2 As shown, an integrated intelligent analysis device for flotation foam includes a main shaft mechanism 1, a drive mechanism 2, and a flotation cell 3. A support frame 31 is mounted on the top of the flotation cell 3, and the main shaft mechanism 1 passes through the support frame 31, with its bottom extending into the flotation cell 3. The drive mechanism 2 is mounted above the support frame 31. An industrial camera 4 is mounted above the support frame 31, with its acquisition end facing the foam layer area of ​​the flotation cell 3 to acquire images of the foam layer during the flotation process. Its position clearly captures the morphology, color, thickness, and other characteristic information of the foam. The camera itself has high resolution and good image capture capabilities, and can adapt to the lighting and environmental conditions of the flotation workshop, providing a basis for subsequent image analysis and flotation process control.

[0023] Furthermore, a ring-shaped multispectral light source 5 is arranged around the industrial camera 4 to provide multispectral illumination for the industrial camera 4, making the acquired foam images clearer and more accurate. The light source of different wavelengths can highlight the different characteristics of the foam. At the same time, a wiper is set on the surface of the industrial camera 4 to prevent dust, mineral particles and other contaminants from adhering to the lens surface, ensuring that the imaging quality of the camera is not affected. Its compact structure works closely with the industrial camera 4 to ensure good lighting and cleaning effects.

[0024] Furthermore, an infrared pH sensor 34 is installed on the inner wall of the flotation cell 3 near the pulp surface to monitor the pH of the pulp in real time during the flotation process. Its probe directly contacts the pulp, enabling rapid and accurate sensing of pH changes. The infrared pH sensor 34 has good sealing and corrosion resistance to adapt to the complex environment of the flotation pulp. An ultrasonic analyzer 36 is installed on the side of the flotation cell 3, pointing towards the pulp area inside. It utilizes the reflection and propagation characteristics of ultrasonic waves to detect parameters such as pulp concentration and particle size distribution. Its probe can emit and receive ultrasonic signals, converting the received signals into electrical signals. After analysis and processing, relevant pulp characteristic data are obtained, providing a reference for the optimized control of the flotation process.

[0025] The main shaft mechanism 1 includes a drive shaft 11 and an impeller 12. The drive shaft 11 is vertically installed through the support frame 31, and the impeller 12 is installed at the bottom of the drive shaft 11. At least two branch pipes are provided on the main shaft mechanism 1, and air and reagents are introduced into the flotation cell 3 through the branch pipes respectively.

[0026] The drive mechanism 2 includes a first motor 21 and a second motor 22 arranged in parallel front and rear. The first motor 21 and the second motor 22 are mounted above the support frame 31. The output shaft of the first motor 21 drives the main shaft mechanism 1 to work under the action of the first belt 23. The output shaft of the second motor 22 drives the second transmission wheel 25 to work through the second belt 24. The second transmission wheel 25 is fixedly connected to the fixing rod 26. Several sets of scrapers 27 are symmetrically arranged on both sides of the fixing rod 26. The end of the fixing rod 26 is provided with a scraper protective cover 28 on the outside of the scraper 27.

[0027] Preferably, a main drive protective cover is provided on the outside of the drive device of the main spindle mechanism 1. The main drive protective cover and the scraper protective cover 28 serve a protective function, preventing operators from accidentally touching the transmission components and preventing foreign objects from entering the transmission system. They are usually shell structures made of metal plates or engineering plastics. Through reasonable opening and sealing design, the protective function is ensured while facilitating the observation and maintenance of the transmission device.

[0028] A slurry pipe 32 is introduced into one side of the bottom of the flotation cell 3, connecting the slurry outlet of the flotation cell 3 to the external pipeline system. An electromagnetic flow meter 33 is installed on the slurry pipe 32 to accurately measure the flow rate of the slurry, so as to monitor and control the slurry flow rate in real time during the flotation process. When the slurry flows through, an induced electromotive force is generated by the principle of electromagnetic induction, thereby measuring the flow rate and transmitting the signal to the control system for corresponding operation adjustments.

[0029] Preferably, a level gauge is installed inside the flotation cell 3 to monitor the level of the slurry.

[0030] Preferably, it includes a control system that receives monitoring data from each sensor in real time and combines it with image data acquired by the industrial camera 4 to control the operation of the flotation device.

[0031] Preferably, the diameter of the slurry pipe 32 is designed according to the processing capacity of the flotation machine, and the inner wall is relatively smooth to reduce the resistance during the flow of slurry and ensure that the slurry can be discharged smoothly. At the same time, the connection of the slurry pipe 32 is well sealed to prevent slurry leakage.

[0032] Furthermore, lifting gates 35 and slurry pipes 32 are installed between adjacent flotation cells 3 to control the flow direction, flow rate, and system pressure of the slurry. By controlling the height of the lifting gates 35, the cross-section of the slurry pipes 32 between the front and rear cells is changed, thereby controlling the speed at which the slurry flows from the front cell into the rear cell and maintaining the stability of the liquid level in the front cell. The structure is determined according to different functions and working conditions. Through the opening, closing, and adjustment of valves, the slurry feeding and discharging of the flotation machine and its connection with other equipment can be flexibly managed to ensure the stable operation of the entire flotation process.

[0033] Example 2 An integrated intelligent analysis device for flotation foam, the working method of which is as follows: The first motor 21 drives the main shaft mechanism 1 to rotate via the first belt 23, which in turn drives the impeller 12 to stir the slurry in the flotation cell 3. Simultaneously, air and reagents are introduced into the cell through the branch pipe. The second motor 22 drives the scraper 27 to scrape the foam generated during flotation out of the flotation cell 3. The scraped foam flows into a dedicated foam tank, where it can be further processed according to process requirements, such as dewatering and filtration, to obtain the final concentrate product. The tailings at the bottom of the flotation cell 3 are discharged from the flotation machine through the lifting gate 35 and the slurry pipe 32, entering the next stage flotation cell 3. The electromagnetic flowmeter 33 on the slurry pipe 32 can monitor the tailings flow rate in real time. Based on the flow data, the tailings discharge during the flotation process can be controlled to ensure the material balance of the entire flotation system.

[0034] The infrared pH sensor 34, ultrasonic analyzer 36 and other detection instruments can monitor parameters such as pulp pH, pulp concentration and mineral particle size distribution in real time during the flotation process, and transmit the monitored parameters to the control system. The control system can adjust the flotation process parameters in a timely manner, such as pulp level, reagent addition, aeration rate and impeller speed, based on these monitoring data and the quality indicators of the flotation products, so as to ensure the stable operation of the flotation process and the quality of the products.

[0035] An infrared pH sensor 34 monitors the slurry's acidity and alkalinity in real time, feeding the data back to the control system. If the pH value deviates from the set range (e.g., insufficient alkalinity), the system automatically adjusts the reagent dosage. An ultrasonic analyzer 36 monitors the slurry's concentration and particle distribution in real time. If the particles are too coarse or the concentration is too high, the control system adjusts the stirring intensity or water replenishment. An electromagnetic flowmeter 33 monitors the slurry flow rate; if the flow rate is abnormal, the gate 35 is activated to adjust its opening. Data from the level gauge and pH sensor are integrated to ensure the slurry level matches the acidity and alkalinity; acid addition is paused if the level is low.

[0036] Under the illumination of a ring-shaped multispectral light source, industrial camera 4 continuously captures images of the foam, determining its size, distribution uniformity, and mineral enrichment based on its color intensity. The thickness of the foam layer indicates its stability. The industrial camera 4 sends the captured images to the control system, which identifies the foam thickness and bursting speed and compares them with embedded thresholds. The system dynamically adjusts the foaming agent addition rate via the branch pipe chemical valve. It also determines the mineral content of the foam based on its color intensity and adjusts the speed of the second motor 22 to optimize the scraper 27's rotation speed. If the foam color intensity is too high compared to the embedded threshold of the control system, and the slurry concentration detected by the ultrasonic analyzer is higher than the threshold, the system automatically reduces the impeller 12's rotation speed and increases the injection of dilution water.

[0037] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and not to limit it. Although the utility model has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of this utility model. Any modifications or equivalent substitutions that do not depart from the spirit and scope of this utility model should be covered within the protection scope of the claims of this utility model.

Claims

1. An integrated intelligent analysis device for flotation foam, characterized in that, It includes a spindle mechanism (1), a drive mechanism (2) and a flotation cell (3). A support frame (31) is set on the top of the flotation cell (3). The bottom of the spindle mechanism (1) extends into the flotation cell (3) through the support frame (31). The drive mechanism (2) is installed above the support frame (31). An industrial camera (4) is installed above the support frame (31). The flotation cell (3) has a built-in electromagnetic flowmeter (33), an infrared pH sensor (34), an ultrasonic analyzer (36) and a level gauge. The system includes a control system that is simultaneously connected to an industrial camera (4), an infrared pH sensor (34), an ultrasonic analyzer (36), and an electromagnetic flowmeter (33) to receive sensor data and image data in real time and to regulate the flotation process.

2. The integrated intelligent flotation foam analysis device according to claim 1, characterized in that, A ring-shaped multispectral light source (5) is set around the industrial camera (4).

3. The integrated intelligent flotation foam analysis device according to claim 1, characterized in that, The main shaft mechanism (1) includes a drive shaft (11) and an impeller (12) located at its bottom.

4. The integrated intelligent flotation foam analysis device according to claim 3, characterized in that, The drive shaft (11) is provided with at least two branch pipes, which are used to introduce air and reagents into the flotation cell (3) respectively.

5. The integrated intelligent flotation foam analysis device according to claim 1, characterized in that, The drive mechanism (2) includes a first motor (21) and a second motor (22) disposed above the support frame (31). The first motor (21) drives the main shaft mechanism (1) through the first belt (23); the second motor (22) drives the transmission wheel (25) through the second belt (24). The output shaft of the transmission wheel (25) is connected to a horizontally disposed fixed rod (26). Multiple sets of scrapers (27) are symmetrically disposed on both sides of the fixed rod (26).

6. The integrated intelligent flotation foam analysis device according to claim 5, characterized in that, The end of the fixed rod (26) is provided with a scraper guard (28) covering the transmission components on the outside of the scraper (27).

7. The integrated intelligent flotation foam analysis device according to claim 5, characterized in that, A main drive protective cover is provided on the outside of the drive device of the main spindle mechanism (1).

8. The integrated intelligent flotation foam analysis device according to claim 1, characterized in that, A slurry pipe (32) is introduced into one side of the bottom of the flotation cell (3) to connect the slurry outlet of the flotation cell (3) to the external pipeline system.

9. The integrated intelligent flotation foam analysis device according to claim 8, characterized in that, The electromagnetic flowmeter (33) is installed on the slurry pipe (32).

10. The integrated intelligent flotation foam analysis device according to claim 7, characterized in that, A lifting gate (35) is installed between adjacent flotation cells (3).

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