Intelligent control system for directly preparing concrete from coal gangue underground

Abstract

The utility model discloses a kind of intelligent control systems of coal gangue direct preparation concrete in underground, it is related to mine solid waste resource utilization technical field, and the intelligent control system of this coal gangue direct preparation concrete in underground includes integrated control center and distributed sensing and execution system.Integrated control center is mine intrinsic safety central processing unit, and each execution equipment is connected by signal cable or communication bus connection.Distributed sensing and execution system includes video monitoring system, safety environment monitoring system, material metering and conveying control module and stirring host control module, respectively through corresponding sensor and frequency converter realizes whole process monitoring and accurate control.The utility model provides reliable hardware system architecture for the whole-process intelligent operation from environmental perception, material proportioning, production scheduling to remote monitoring, significantly improves the intelligent level of underground concrete production, resource utilization efficiency and operation safety.

Description

Technical Field

[0001] This utility model belongs to the field of intelligent mining solid waste resource utilization technology, specifically relating to an intelligent control system for directly preparing concrete from coal gangue underground. Background Technology

[0002] my country's coal mines have achieved a high level of intelligent construction in their mining, transportation, and management systems, with over 180 pairs of intelligent coal mines already documented. Intelligent mining is a trend in the scientific development of coal mining. However, the intelligent construction of coal gangue resource utilization, especially the utilization of solid waste under conditions where coal gangue is not brought to the surface, is almost nonexistent.

[0003] The common method of disposing of coal gangue on the surface after it is brought to the mine is not only costly in terms of both bringing it up and bringing it down into the mine, but also puts pressure on the mine's main transportation capacity. Piping coal gangue down into the mine requires a long-distance, large-scale system, further increasing costs. Furthermore, storing coal gangue on the surface occupies land and can cause serious consequences such as dust pollution, soil contamination, and spontaneous combustion. Therefore, keeping coal gangue within the mine's surface has become an important option for coal mine gangue disposal in my country and a crucial component of the global strategy for the resource utilization of solid waste.

[0004] On the other hand, my country's smart mines primarily rely on rubber-tired transport, requiring the construction of paved roads. Simultaneously, underground roadways and equipment chambers require support, floor hardening, shotcreting, and face sealing and filling, all of which rely heavily on concrete. Currently, concrete used in my country's coal mines mainly comes from commercial concrete produced at surface mixing plants, requiring transport by wheelbarrows (or pipelines) after mixing, resulting in high costs, long distances, and complex processes. Existing systems for on-site underground concrete preparation generally employ single-mixer operations, lacking a complete hardware control network suitable for directly preparing high-performance concrete from underground coal gangue. This hinders the coordinated operation of gangue identification, accurate metering, intelligent proportioning, adaptive mixing, and production scheduling. Utility Model Content

[0005] This utility model provides an intelligent control system for the direct underground preparation of concrete from coal gangue, including a mixing host, a feeding conveyor, a mobile unloader, multiple sets of material silos, auxiliary material silos, hydraulic gate valves, a water pump, and a discharge conveyor, and also includes: The integrated control center is an intrinsically safe central processing unit for mining, installed in an explosion-proof control box underground, and connected to the feeding conveyor, the mobile unloader, the hydraulic gate valve, the water pump and the discharge conveyor via signal cables or communication buses; The distributed sensing and actuation system, connected to the integrated control center via signal cables or a communication bus, includes at least: The video surveillance system includes monitoring cameras installed at key workstations and hard disk recorders connected to the monitoring cameras; The safety and environmental monitoring system includes a local control console installed at the underground mixing plant site and an integrated underground monitoring unit installed on the local control console; The material metering and conveying control module includes a weighing sensor, a flow sensor, and a first frequency converter. The weighing sensor is installed on the support structure of the cement silo, the flow sensor is installed on the frame of the belt conveyor of the feeding conveyor and the discharging conveyor, and the first frequency converter is connected to the drive motor of the belt conveyor of the feeding conveyor and the discharging conveyor. The mixing host control module includes a current sensor and a second frequency converter. The current sensor is sleeved on the power supply cable of the motor of the mixing host, and the second frequency converter is connected to the motor of the mixing host.

[0006] In one embodiment of the present invention, the distributed sensing and execution system further includes a concrete quality monitoring module for acquiring physical signals related to concrete consistency.

[0007] In one embodiment of the present invention, the concrete quality monitoring module includes at least one of a vibration sensor, an acoustic sensor, and a microwave moisture content sensor installed on the inner wall of the mixing host.

[0008] In one embodiment of the present invention, the distributed sensing and execution system further includes an environmental sensing module, which includes at least one of a temperature sensor, a humidity sensor, a dust sensor, a gas sensor, and a harmful gas concentration sensor installed on the walls of the roadway surrounding the underground mixing station.

[0009] In one embodiment of this utility model, a dust control system is also included. The dust control system is connected to the integrated control center via a communication cable. The dust control system includes a dust control spray network installed around the underground mixing station.

[0010] In one embodiment of this utility model, an equipment safety monitoring system is also included. The equipment safety monitoring system is connected to the integrated control center via a communication cable. The equipment safety monitoring system includes an audible and visual alarm installed at the underground mixing station site.

[0011] In one embodiment of this utility model, a remote monitoring system is also included, which is connected to an Ethernet communication module integrated inside the integrated control center via an industrial network device. The remote monitoring system includes a remote control console and a central control computer located in the wellhead dispatch room.

[0012] In one embodiment of this utility model, the integrated control center integrates a gangue production monitoring interface and a production planning and scheduling module, wherein the gangue production monitoring interface is connected to an underground gangue identification and production monitoring instrument.

[0013] In one embodiment of this utility model, the safety environment monitoring system further includes a mining intrinsically safe touch screen installed on the local operating platform for on-site human-machine interaction.

[0014] In one embodiment of this utility model, the integrated control center integrates a data storage and optimization module for recording historical production, environmental and equipment operation data.

[0015] Compared with the prior art, the beneficial effects of this utility model are as follows: 1. This utility model discloses an intelligent control system for directly preparing concrete from coal gangue underground. Using a mining-grade intrinsically safe integrated control center as its core, multiple functional modules are connected, forming a reliable hardware system architecture. This architecture utilizes weighing and flow sensors to collect material data in real time. The integrated control center adjusts the feeding speed by controlling the first frequency converter, achieving precise proportions of cement, aggregate, and crushed gangue, thus ensuring the quality of concrete preparation from the hardware perspective. A current sensor monitors the motor load in real time, and a second frequency converter controls the mixing speed and torque, preventing overload operation and ensuring equipment safety, while also ensuring the uniformity and efficiency of the mixing process.

[0016] 2. The intelligent control system for direct underground concrete preparation from coal gangue of this utility model provides reliable operation and monitoring nodes for the underground site through a safety and environmental monitoring system, which facilitates debugging, emergency intervention and local management. The video monitoring system provides visual monitoring of key work positions and links with local and remote monitoring systems, providing operators with an intuitive picture of the production site and assisting in fault diagnosis and remote scheduling.

[0017] The above description is merely an overview of the technical solution of this utility model. In order to better understand the technical means of this utility model and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this utility model more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0018] Figure 1 This is a block diagram of the overall structure of an intelligent control system for the direct underground preparation of concrete from coal gangue, provided in an embodiment of this utility model. Detailed Implementation

[0019] To further illustrate the technical means and effects adopted by this utility model to achieve its intended purpose, the following describes in detail, with reference to the accompanying drawings and specific embodiments, an intelligent control system for direct underground concrete preparation from coal gangue proposed according to this utility model.

[0020] The foregoing and other technical contents, features, and effects of this utility model will be clearly presented in the following detailed description of the specific embodiments with reference to the accompanying drawings. Through the description of the specific embodiments, a more in-depth and specific understanding can be gained of the technical means and effects adopted by this utility model to achieve the intended purpose. However, the accompanying drawings are only provided for reference and illustration and are not intended to limit the technical solution of this utility model.

[0021] Please see Figure 1 , Figure 1 This is a general structural block diagram of an intelligent control system for directly preparing concrete from coal gangue underground, provided by an embodiment of this utility model. For the direct preparation of concrete from coal gangue underground, the preparation device includes a mixing host, a feeding conveyor for conveying materials, a mobile unloader positioned above the feeding conveyor, multiple sets of silos for storing materials, auxiliary material silos for storing water and additives, hydraulic gate valves positioned at the bottom of each silo, water pumps positioned on the auxiliary material silos, and a discharge conveyor for transferring materials from the bottom of the silos.

[0022] like Figure 1 As shown in the figure, the intelligent control system for direct underground concrete preparation from coal gangue according to this utility model includes an integrated control center and a distributed sensing and execution system.

[0023] The intelligent control system in this embodiment is centered on an integrated control center. This integrated control center employs a mining-grade intrinsically safe central processing unit, installed in an explosion-proof control box underground to ensure safe and stable operation in the harsh underground environment. The integrated control center is connected to actuators such as the feeding conveyor, mobile unloader, hydraulic gate valve, water pump, and discharge conveyor via signal cables or communication buses, enabling centralized control and scheduling. The distributed sensing and execution system is connected to the integrated control center via signal cables or communication buses, responsible for collecting various data from the site and executing control commands. All modules work collaboratively to achieve intelligent monitoring and precise control of the entire concrete preparation process.

[0024] In this embodiment, the integrated control center serves as the system's control core, employing a high-performance intrinsically safe mining processor with multiple communication interfaces, capable of simultaneously processing data from multiple sensors and issuing control commands. Internally, it integrates a data storage and optimization module for real-time recording of historical production data, environmental parameters, and equipment operating status. By analyzing this data, the system can optimize mix design and equipment operating parameters, improving concrete quality and production efficiency. Furthermore, the integrated control center also features a gangue production monitoring interface, directly connecting to underground gangue identification and production monitoring instruments to acquire real-time gangue production data. This data, combined with the production planning and scheduling module, dynamically adjusts production tasks, achieving efficient utilization of gangue resources.

[0025] In this embodiment, the distributed sensing and execution system includes at least: a video surveillance system, a safety and environmental monitoring system, a material metering and conveying control module, a mixing host control module, and a concrete quality monitoring module.

[0026] The video surveillance system installs intrinsically safe mining cameras at key workstations and stores the video data via hard disk recorders. This system provides operators with real-time visual monitoring, facilitating timely detection of anomalies and improving production safety and management efficiency. The safety and environmental monitoring system includes a local control panel and an integrated underground monitoring unit located at the underground mixing plant. In this embodiment, the local control panel is equipped with an intrinsically safe mining touchscreen, providing a human-machine interface for convenient parameter setting, manual operation, and status inquiry by on-site personnel. The safety and environmental monitoring system ensures a rapid switch to manual mode in case of automatic control failure, guaranteeing reliable system operation.

[0027] The material metering and conveying control module includes a weighing sensor, a flow sensor, and a first frequency converter. The weighing sensor is mounted on the support structure of the cement silo, and the flow sensor is mounted on the frame of the belt conveyors for both the feeding and discharging conveyors. The first frequency converter is connected to the drive motors of the belt conveyors for both the feeding and discharging conveyors. The module monitors the cement weight in real time using the weighing sensor, monitors the material flow rate using the flow sensor, and adjusts the speed of the drive motors for the feeding and discharging conveyors using the first frequency converter. This module achieves precise metering and speed matching of material conveying, avoiding material waste or blockages and ensuring accurate proportioning.

[0028] The mixer control module includes a current sensor and a second frequency converter. The current sensor is mounted on the power supply cable of the mixer motor, and the second frequency converter is connected to the motor. The mixer control module monitors the motor load through the current sensor and adjusts the motor speed through the second frequency converter. This control module can automatically adjust the mixing intensity and time according to load changes, ensuring uniform concrete mixing, while also providing overload protection and extending equipment life.

[0029] The concrete quality monitoring module is used to collect physical signals related to concrete consistency. In one optional embodiment, the concrete quality monitoring module collects physical signals related to concrete consistency, uniformity, and / or moisture content in real time through vibration sensors, acoustic sensors, and / or microwave moisture content sensors installed on the inner wall of the mixing unit. The integrated control center dynamically adjusts the water-cement ratio based on this data to ensure that the concrete consistency meets the requirements, significantly improving product quality consistency.

[0030] In one possible embodiment, the distributed sensing and actuation system further includes an environmental sensing module. Optionally, the environmental sensing module includes at least one of a temperature sensor, humidity sensor, dust sensor, gas sensor, and hazardous gas concentration sensor installed on the walls of the roadway surrounding the underground mixing station. The environmental sensing module monitors environmental parameters in real time by installing multiple sensors on the walls of the roadway surrounding the underground mixing station. When environmental data exceeds a safety threshold, the system automatically triggers an alarm or adjusts the equipment operating mode, effectively preventing safety accidents and protecting the health of underground workers.

[0031] In an optional embodiment, the intelligent control system also includes a dust suppression system and an equipment safety monitoring system. The dust suppression system, connected to the integrated control center via a communication cable, includes a dust suppression spray network installed around the underground mixing station. When dust sensors detect excessive dust concentrations, the integrated control center automatically activates the spray system to reduce dust, significantly improving the working environment and reducing occupational health risks. The equipment safety monitoring system, also connected to the integrated control center via a communication cable, includes audible and visual alarms installed at the underground mixing station. When equipment malfunctions or environmental parameters exceed limits, the integrated control center triggers the audible and visual alarms, promptly alerting personnel to take action and enhancing system safety.

[0032] In an optional embodiment, the intelligent control system further includes a remote monitoring system. This remote monitoring system is connected to an Ethernet communication module within the integrated control center via industrial network equipment, and includes a remote control console and a central control computer located in the surface dispatch room. This remote monitoring system enables real-time monitoring and remote intervention of the underground production process from the surface, supports remote querying and analysis of production data, and improves management efficiency and emergency response capabilities.

[0033] The working process of the intelligent control system in this embodiment is as follows: After the system is powered on, the integrated control center performs a self-test and initializes all sensors and actuators. Operators set production parameters through a local or remote control console. According to the production plan, the integrated control center controls the hydraulic gate valve to open the designated silo and starts the feeding conveyor. The material metering and conveying control module monitors the material flow rate in real time and adjusts the conveying speed through the first frequency converter to ensure accurate feeding according to the mixing ratio requirements. After the material enters the mixing host, the mixing host control module monitors the motor load, and the second frequency converter adjusts the mixing speed and time according to the preset program. At the same time, the concrete quality monitoring module collects relevant data in real time, and the integrated control center dynamically adjusts the mixing parameters and water-cement ratio. The environmental sensing module monitors environmental parameters in real time, and the dust suppression system automatically sprays dust according to the dust concentration. The equipment safety monitoring system triggers audible and visual alarms in abnormal situations. The video monitoring system records the key workstations throughout the process. After mixing is completed, the integrated control center controls the discharge conveyor to start and transport the concrete to the designated location. The mobile unloader adjusts the unloading position according to instructions. The data storage and optimization module of the integrated control center records the data of the entire process and optimizes the production parameters based on historical data. The surface control room monitors the underground production status in real time through a remote monitoring system and can intervene remotely when necessary. The production planning and scheduling module dynamically adjusts production tasks based on gangue production data.

[0034] This invention relates to an intelligent control system for the direct underground preparation of concrete from coal gangue. Centered on a mine-grade intrinsically safe integrated control center, it connects multiple functional modules to form a reliable hardware system architecture. Utilizing this architecture, material data is collected in real-time by weighing and flow sensors. The integrated control center regulates the feeding speed via a first frequency converter, achieving precise proportions of cement, aggregate, and crushed gangue, thus ensuring the quality of concrete preparation from the hardware perspective. A current sensor monitors the motor load in real-time, and a second frequency converter controls the mixing speed and torque, preventing overload operation and ensuring equipment safety, while also guaranteeing the uniformity and efficiency of the mixing process.

[0035] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations are intended to cover non-exclusive inclusion, such that an article or device comprising a list of elements includes not only those elements but also other elements not expressly listed. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the article or device comprising said element. Terms such as "connected" or "linked" are not limited to physical or mechanical connections but can include electrical connections, whether direct or indirect. The orientations or positional relationships indicated by terms such as "upper," "lower," "left," and "right" are based on the orientations or positional relationships shown in the accompanying drawings and are used only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention.

[0036] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features or characteristics described may be combined in any suitable manner in one or more embodiments or examples. In addition, those skilled in the art can combine and integrate the different embodiments or examples described in this specification.

[0037] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention. It should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the concept of the present invention, and all such modifications and substitutions should be considered within the protection scope of the present invention.

Claims

1. An intelligent control system for underground direct preparation of concrete from coal gangue, comprising a mixing main machine, a feeding conveyor, a mobile unloader, multiple groups of material bins, an auxiliary material bin, a hydraulic gate valve, a water pump, and a discharge conveyor, characterized in that, Also includes: The integrated control center is an intrinsically safe central processing unit for mining, installed in an explosion-proof control box underground, and connected to the feeding conveyor, the mobile unloader, the hydraulic gate valve, the water pump and the discharge conveyor via signal cables or communication buses; The distributed sensing and actuation system, connected to the integrated control center via signal cables or a communication bus, includes at least: The video surveillance system includes monitoring cameras installed at key workstations and hard disk recorders connected to the monitoring cameras; The safety and environmental monitoring system includes a local control console installed at the underground mixing plant site and an integrated underground monitoring unit installed on the local control console; The material metering and conveying control module includes a weighing sensor, a flow sensor, and a first frequency converter. The weighing sensor is installed on the support structure of the cement silo, the flow sensor is installed on the frame of the belt conveyor of the feeding conveyor and the discharging conveyor, and the first frequency converter is connected to the drive motor of the belt conveyor of the feeding conveyor and the discharging conveyor. The mixing host control module includes a current sensor and a second frequency converter. The current sensor is sleeved on the power supply cable of the motor of the mixing host, and the second frequency converter is connected to the motor of the mixing host.

2. The intelligent control system for underground direct preparation of concrete from coal refuse according to claim 1, characterized in that, The distributed sensing and execution system also includes a concrete quality monitoring module for acquiring physical signals related to concrete consistency.

3. The intelligent control system for underground direct preparation of concrete from coal refuse according to claim 2, characterized in that, The concrete quality monitoring module includes at least one of a vibration sensor, an acoustic sensor, and a microwave moisture content sensor installed on the inner wall of the mixing host.

4. The intelligent control system for underground direct preparation of concrete from coal refuse according to claim 1, characterized in that, The distributed sensing and execution system also includes an environmental sensing module, which includes at least one of a temperature sensor, a humidity sensor, a dust sensor, a gas sensor, and a harmful gas concentration sensor installed on the walls of the roadways surrounding the underground mixing station.

5. The intelligent control system for direct preparation of concrete from coal refuse underground according to claim 1, wherein, It also includes a dust control system, which is connected to the integrated control center via a communication cable. The dust control system includes a dust spray network installed around the underground mixing station.

6. The intelligent control system for direct underground concrete preparation from coal gangue according to claim 1, characterized in that, It also includes an equipment safety monitoring system, which is connected to the integrated control center via a communication cable. The equipment safety monitoring system includes an audible and visual alarm installed at the underground mixing station site.

7. The intelligent control system for direct preparation of concrete from coal refuse underground according to claim 1, wherein, It also includes a remote monitoring system, which is connected to an Ethernet communication module integrated within the integrated control center via industrial network equipment; The remote monitoring system includes a remote control console and a central control computer located in the wellhead dispatch room.

8. The intelligent control system for direct preparation of concrete from coal refuse underground according to claim 1, wherein, The integrated control center integrates a gangue production monitoring interface and a production planning and scheduling module. The gangue production monitoring interface is connected to the underground gangue identification and production monitoring instrument.

9. The intelligent control system for direct underground concrete preparation from coal gangue according to claim 1, characterized in that, The safety environment monitoring system also includes a mining intrinsically safe touch screen installed on the local operating platform for on-site human-machine interaction.

10. The intelligent control system for direct preparation of concrete from coal refuse underground according to claim 1, wherein, The integrated control center includes a data storage and optimization module for recording historical production, environmental, and equipment operation data.

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