CN109856412B - Intelligent full-automatic material collecting and preparing system - Google Patents
Intelligent full-automatic material collecting and preparing system Download PDFInfo
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- CN109856412B CN109856412B CN201811626376.8A CN201811626376A CN109856412B CN 109856412 B CN109856412 B CN 109856412B CN 201811626376 A CN201811626376 A CN 201811626376A CN 109856412 B CN109856412 B CN 109856412B
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Abstract
The invention relates to an intelligent full-automatic collecting and manufacturing system for raw materials, which comprises a collecting and manufacturing integrated unit, a pneumatic sample feeding unit, an analysis and test unit, a storage unit and a system control unit, wherein the collecting and manufacturing integrated unit is used for collecting samples, preparing analysis samples and check samples, detecting the moisture content of the samples, and uploading detected moisture content data of the samples to the system control unit; the analysis and test unit is used for testing various performance indexes of the sample; the storage unit is used for storing the stock check sample so as to carry out rechecking and checking when the quality objection condition occurs; the pneumatic sample feeding unit is arranged between the sampling integrated unit and the analysis and test unit and respectively transmits the analysis sample and the check sample prepared by the sampling integrated unit to the analysis and test unit and the storage unit. The automatic sampling device can realize unmanned full-automatic sampling, sample preparation, assay and storage and automatic transmission of samples, and simultaneously ensure that each quality data of the samples is real and accurate and the system error is within the standard allowable range.
Description
Technical Field
The invention belongs to the field of raw fuel quality acceptance, and particularly relates to an intelligent full-automatic raw material collecting and preparing system.
Background
At present, the quality management of large amounts of raw fuels in industries such as steel, coal, electric power, petroleum, chemical industry and the like is complex and tedious, raw fuel resources are increasingly scarce, price fluctuation is large, phenomena such as fake doping and the like are frequent, suppliers propose various quality difference and recheck requirements, and new challenges and refined requirements are provided for the quality management of the raw fuels. For a long time, the original fuel operation environment is bad, dust, noise, mechanical injury and the like seriously damage the body health of operators, and the raw fuel operation environment has the defects of numerous materials, huge batch, high labor intensity of operators and complex operation process. Therefore, the design of the fully-automatic collecting and processing system strictly according to the quality standard, the mechanical operation, the automatic control, the informationized sharing and the intelligent management is needed, the artificial interference is reduced or stopped to the maximum extent, the labor intensity of personnel is lightened, the operation environment is improved, and the fully-automatic collecting and processing system is an unattended trend of a future raw fuel quality acceptance mode. The three key links of sampling, sample preparation and test are taken as quality acceptance, and the automation level of a sampling and preparation system directly influences the quality acceptance level.
Sampling is the first link of sampling analysis, and if the ratio of the sampling to the total error of analysis is used for evaluation, the sampling accounts for 80%, the sample preparation accounts for 16%, the test accounts for 4%, and if the sampling is incorrect, the final test is accurate again. The goal of sampling is to preserve a representative of the sample. At present, the sampling mode is mainly mechanical, and is divided into automobile sampling, train sampling and belt sampling according to the feeding mode, and the sampling is automatically performed from an automobile carriage, a train carriage and a moving coal flow respectively. Any form of sampling must strictly follow the national standards of sampling to ensure that the sample's representativeness meets the requirements, thereby ensuring the accuracy and reliability of the quality acceptance work.
The preparation of the sample is between sampling and testing, and the main work is that the granularity of the collected sample is gradually reduced and the weight is gradually reduced on the premise of not damaging the representativeness of the sample until an analysis sample meeting the requirements of the testing on the granularity, the weight, the uniformity and the like of the sample is prepared, and the moisture change, the powder loss and the oxidative deterioration degree of the sample in the sample preparation process are ensured to be minimum. The final objective of the sample preparation process is to obtain various samples, typically including moisture samples, analytical samples, etc., that meet the assay granularity and quality accuracy requirements. The analysis and detection of the moisture are required to be performed as early as possible while the original state of the sample is maintained, so that the moisture detection is often performed while the sample is being prepared, and the moisture content result is obtained in the sample preparation stage. In addition, in consideration of the occurrence of the accident of the original fuel quality objection, the sample preparation process needs to keep a stock sample for checking or preventing sample preparation failure. Therefore, the results of the sample preparation step are generally the results of moisture analysis, analysis and inventory.
The test is a generation link of raw fuel quality data, and an analysis sample obtained in a sample preparation link is used for test analysis. The items of analysis and test, the analysis method and the test instrument are different from one material to another. Taking power coal widely applied in the industries of electric power, steel and the like as an example, according to the production process requirement, the coal is formed In combination with the commercial coal quality spot check and acceptance method, the dynamic coal generally comprises the following test projects (without special requirements of research and experiment and the like): total moisture (M) t ) Ash (A) d ) Total sulfur (S) t,d ) Heating value (Q) gr,d ) Etc., the assay instruments, equipment employed are as follows: industrial analyzers, calorimeters, sulfur determination instruments, total moisture analyzers, and the like. In view of the reasons of complex test projects, test methods, standards and the like, at present, the mode of manually operating single equipment or instruments is basically adopted in the test link in each industry.
At present, the full-process automation of the collecting and preparing process is not completely realized, and the following technical difficulties exist:
1) Sample preparation: the representative of the sample is seriously affected by the selective sample preparation process or equipment (such as residue of difficultly ground substances, insufficient mixing before division, and the like), which is the most technical difficulty to be overcome by a sample preparation system.
2) Assay procedure: the dependence of the test result on test personnel, equipment and instruments is strong, the interference factors are more, and the authenticity of the data is easily influenced by test errors.
3) Transmission system: the automation of the sampling and sample preparation single links is basically realized, but each link is independent and not linked with each other. The material transferring modes of all links such as the large sample obtained by sampling is conveyed to sample preparation, the small sample obtained by sample preparation is conveyed to assay, the check sample obtained by sample preparation is conveyed to a check sample cabinet and the like are not completely automated.
4) Adaptability to complex working conditions: the special state materials such as high-moisture powder, high-viscosity materials, ultra-large granularity materials, ultra-high hardness materials and the like rely on manual intervention, and the adaptability of the system of each link is poor.
Therefore, the realization of the integrated and intelligent full-process of the picking and manufacturing process has a plurality of technical difficulties to be overcome.
Disclosure of Invention
The invention aims to overcome the defects of the prior art, provides an intelligent full-automatic raw material collecting and preparing system, can realize unattended full-automatic sampling, sample preparation, assay and storage and automatic transmission of samples, and simultaneously ensures that each quality data of the samples is real and accurate and the system error is within the standard allowable range.
The invention is realized in the following way: the intelligent full-automatic raw material collecting and manufacturing system comprises a collecting and manufacturing integrated unit, a pneumatic sample conveying unit, an analysis and test unit, a storage unit and a system control unit, wherein the collecting and manufacturing integrated unit comprises a sampling module, a sample manufacturing module, a full-moisture analysis module and a sample collecting module, and the sampling module is used for collecting samples from a transportation carrier according to a sampling scheme sent by the system control unit; the sample preparation module is used for preparing the large samples of each batch collected by the sampling module into analysis samples meeting the test requirements, and preparing all-moisture samples and check samples at the same time; the full-moisture analysis module is used for detecting the moisture content of the sample and uploading detected data to the system control unit; the sample collection module is used for collecting the analysis sample and the inventory sample prepared by the sample preparation module to a sample bottle, packaging and marking;
The analysis and test unit is used for testing various performance indexes of the sample; the storage unit is used for storing a check sample so as to check when a quality objection condition occurs; the pneumatic sample conveying unit is arranged between the sampling integrated unit and the analysis and test unit and is used for conveying the analysis samples and the check samples prepared by the sampling integrated unit to the analysis and test unit and the storage unit respectively; the system comprises a collecting and manufacturing integrated unit, a pneumatic sample feeding unit, an analysis and test unit and a storage unit, wherein the collecting and manufacturing integrated unit, the pneumatic sample feeding unit, the analysis and test unit and the storage unit are respectively in communication connection with a system control unit, and the system control unit is used for issuing instructions to the units and commanding and managing the operation of the units, so that the whole-flow operation is completed, and daily raw fuel quality acceptance management work is carried out.
Further, the sample preparation module comprises a large sample mixing device, a primary crushing device, a secondary crushing device, a primary dividing device, a secondary dividing device, a pre-drying device, a grinding device, a dividing device and a viscosity detection device; the sample mixing device, the primary crushing device, the secondary crushing device, the primary dividing device, the secondary dividing device, the pre-drying device, the grinding device, the viscosity detection device, the bisection device, the full-moisture analysis module, the sample collection module, the sample discarding module and the pneumatic sample sending cabinet are distributed in a ring shape around the sample preparation industrial robot, and sample materials are transferred among the devices of the sample preparation module, the full-moisture analysis module, the sample collection module, the sample discarding module and the pneumatic sample sending cabinet through the sample preparation industrial robot; the large sample mixing device is used for fully mixing the large samples and providing representative strong sample materials for the subsequent process; the primary crushing device is used for crushing the uniformly mixed large sample granularity to a first set value; the primary division device is used for dividing the primary crushed large sample to obtain a full-moisture sample and a common sample; the full-moisture analysis module is used for detecting the moisture content of the full-moisture sample and uploading the detected data to the system control unit; the pre-drying device is used for pre-drying the common sample; the secondary crushing device is used for crushing the common sample particle size to a second set value; the secondary division device is used for dividing the secondarily crushed sample to obtain an analysis sample and a large sample stock sample; the aggregate module is used for collecting the large sample stock sample to the sample bottle, packaging and marking; the drying device is used for drying the analysis sample before grinding; the grinding device is used for fully grinding the dried analysis sample to prepare the analysis sample with granularity meeting the test requirement; the bipartition device is used for dividing an analysis sample into two parts; the sample collection module is used for collecting two analysis samples to a sample bottle respectively, packaging and marking, wherein one sample serves as an analysis sample for standby examination, which is called a small sample stock sample, and the other sample serves as an analysis sample for assay; the sample discarding module is used for collecting the discarded samples generated by the sample preparing module and temporarily storing the discarded samples to the batch of samples for preparing the samples;
The viscosity detection device is used for detecting the moisture content and viscosity of the common sample and uploading the detected moisture content and viscosity data to the system control unit; the system control unit is used for receiving the data uploaded by the viscosity detection device, comparing the data uploaded by the viscosity detection device with a set value respectively, and controlling to cancel a pre-drying link of the pre-drying device on the common sample when judging that the moisture content of the common sample is low and the viscosity is low, and controlling the sample preparation industrial robot to directly enter the common sample into the secondary crushing device; when the common sample is high in moisture and high in viscosity, the common sample is controlled to enter the pre-drying device by the sample preparation industrial robot for pre-drying, and then the common sample is controlled to enter the secondary crushing device by the sample preparation industrial robot.
The sample preparation module is responsible for preparing the large samples of each batch collected by the sampling module into analysis samples meeting the test requirements, and simultaneously preparing full moisture samples, stock check samples and discarding samples. The mixing can be divided into mixing of big samples and mixing of small samples; drying can be divided into pre-drying and drying before grinding; crushing can be classified into primary crushing (to-13 mm) and secondary crushing (to-3 mm), and crushing grades (to-25 mm, to-6 mm and to-1 mm) can be increased according to material properties and throughput; the division may be divided into multiple stages. The large sample comes out of the collecting hopper of the sampling module and enters the large sample mixing device firstly, the mixing device turns and stirs the accumulated samples layer by layer from bottom to top and rotates the samples to realize full mixing, if the sample uniformity is better, the large sample mixing device can be omitted; the mixed large sample enters a primary crushing device, the granularity is 13mm below zero, and then primary reduction is carried out to obtain a 13mm full moisture sample and a common sample (an analysis sample and a stock sample are shared), uniform feeding and anti-sticking materials and anti-blocking facilities are arranged in the reduction device, so that the samples with high humidity and high viscosity can be smoothly reduced, the precision requirement of reduction is met, the water loss of the crushing device is within the standard allowable range, the crushing device can also be crushed to 6mm below zero, and the 6mm full moisture sample and the common sample are reduced and separated; the condensed and separated full-moisture sample is sent to a full-moisture analysis module by an industrial robot; the shared samples after shrinkage and separation are transmitted to a pre-drying device through an industrial robot, the pre-drying device meets national standard requirements, the temperature is about 40-50 ℃, the chemical properties of the samples are not changed, the dried samples enter a secondary crushing device and a secondary shrinkage device to obtain large sample storage samples and analysis samples with granularity of-3 mm and quality meeting standard requirements, the large sample storage samples are transmitted to an aggregate module for packaging through the industrial robot, the analysis samples continue to be prepared, and the large sample storage samples enter a drying device before grinding, so that the smooth proceeding of grinding and subsequent assay work is ensured; finally, the dried analysis sample is sent to a grinding device for full grinding, the analysis sample with granularity reaching the test requirement is prepared, and the feeding and discharging of the sample in the grinding stage are weighed so as to ensure that the residual quantity in the grinding device meets the requirement and avoid the influence of selective grinding on the sample preparation precision; the ground sample is uniformly mixed, the uniform mixing can be realized by using a small sample mixing device, and finally the sample is divided into two parts by a bipartite, and the two parts are respectively sent to a sample collecting module for packaging, one part is used as an analysis sample for preparation (small sample checking sample) and the other part is used as an analysis sample for assay. All the links generate redundant waste samples and are transmitted to a waste sample module through an industrial robot.
Further, the large sample mixing device comprises a stirring cylinder, a stirring shaft and a first driving device for providing power for the stirring shaft, wherein the stirring cylinder is supported on a bracket, the upper end of the stirring cylinder is provided with a feed inlet, the bottom of the stirring cylinder is provided with a discharge outlet, the discharge outlet at the bottom of the stirring cylinder is provided with a gate device, the stirring shaft is vertically and rotatably supported in the stirring cylinder, the lower end of the stirring shaft extends out from a through hole arranged at the bottom of the stirring cylinder and is connected with the first driving device through a driving device, and the stirring shaft is provided with a stirring blade;
the stirring shaft is sleeved with a conical shaft sleeve with a small upper part and a large lower part, the stirring blade is fixed on the outer wall of the conical shaft sleeve, the upper end of the stirring shaft is fixedly provided with a top cover, the lower end of the top cover is in clearance fit with the upper end of the stirring shaft and is fixed by a screw, the upper end of the top cover is provided with a conical surface, and the vertex of the conical surface faces upwards;
the lower end of the conical shaft sleeve is fixedly provided with two first stirring blades which extend transversely, the middle part of the conical shaft sleeve is fixedly provided with two second stirring blades which extend longitudinally, the first stirring blades and the second stirring blades are blocky blades, the outer wall of the conical shaft sleeve is fixedly provided with four mounting rods for mounting the blades, each mounting rod extends along the radial direction of the conical shaft sleeve, the four mounting rods are arranged in a cross structure, the first stirring blades are fixed on the outer wall of the mounting rods, and the second stirring blades are fixed at the end parts of the mounting rods; the lengths of the mounting rods for mounting the second stirring blades are different, and the cross sections of the mounting rods are triangular; the first stirring blade is fixed on the side surface of the mounting rod through a screw; the end part of the mounting rod for mounting the second stirring blade is provided with a mounting plate, and the second stirring blade is fixed on the mounting plate through a screw.
By adopting the large sample mixing device, the mixing effect is good, the uniformity of the large sample is good, the representative strong sample is provided for the subsequent process, and the efficiency is high.
Further, the two-part device comprises a small sample mixing device and a two-part device, wherein the upper end of the small sample mixing device is provided with a feed inlet, the lower end of the small sample mixing device is fixedly connected with the upper end of the two-part device, the discharge outlet at the bottom of the small sample mixing device corresponds to the feed inlet at the upper end of the two-part device up and down, the two-part device comprises a first guide pipe and a second guide pipe, the feed inlet at the upper end of the first guide pipe corresponds to half of the discharge outlet at the bottom of the small sample mixing device, and the feed inlet at the upper end of the second guide pipe corresponds to the other half of the discharge outlet at the bottom of the small sample mixing device;
a connecting plate is arranged between the small sample mixing device and the bipartite, the lower end of the small sample mixing device is fixedly connected with the upper end of the connecting plate, the upper end of the bipartite is fixedly connected with the lower end of the connecting plate, and openings are arranged at positions of the connecting plate corresponding to a discharge hole at the bottom of the stirring cylinder and a feed inlet at the upper end of the bipartite for a sample to pass through;
the sample mixing device comprises a stirring barrel, an end cover is fixed at the upper end of the stirring barrel, a first driving device is fixed on the end cover, a feed inlet is further formed in the end cover, a stirring shaft is arranged in the stirring barrel, the stirring shaft is vertically arranged in the stirring barrel, the upper end of the stirring shaft penetrates through a through hole formed in the end cover and is fixedly connected with an output shaft of the driving device, the lower end of the stirring shaft is suspended, and stirring blades are arranged at the lower end of the stirring shaft; the first driving device is a motor;
The stirring barrel is conical, and is large in upper part and small in lower part; the lower end of the stirring shaft is provided with a plurality of stirring blades which are uniformly distributed for 360 degrees, the stirring blades are arranged on a fixed ring, the fixed ring is sleeved on the stirring shaft, and the fixed ring is fixedly connected with the fixed ring through a pin shaft; at least one stirring blade is arranged on each fixed ring, and at least one fixed ring is arranged at the lower end of the stirring shaft; the stirring blade is formed by folding a square sheet-shaped blade, the folding edge and two long edges of the square sheet-shaped blade are respectively provided with an intersection point, and the length of the folding edge is longer than that of the short edge of the square sheet-shaped blade;
the lower end of the stirring cylinder is fixedly provided with a fixed plate, and the fixed plate at the lower end of the stirring cylinder is fixedly connected with the connecting plate through a bolt; the fixing plate is provided with screw holes, and the connecting plate is provided with screw holes corresponding to the screw holes arranged on the fixing plate;
a gate device is arranged at a discharge hole at the bottom of the small sample mixing device; the gate device comprises a gate plate for sealing a discharge hole at the bottom of the sample mixing device and a second driving device for driving the gate plate to move, an output shaft of the second driving device is fixedly connected with the gate plate, a chute for installing the gate plate is arranged on the upper end surface of the connecting plate, the gate plate is embedded into the chute of the connecting plate and is in sliding fit with the connecting plate, and the gate plate blocks an opening on the connecting plate; the gate plate is provided with a vertical turning surface for fixedly connecting with an output shaft of the second driving device; the second driving device is fixed on the lower end face of the connecting plate; the second driving device adopts an air cylinder;
The upper end of the first guide pipe is fixedly connected with the upper end of the second guide pipe to form a bipartite device with an inverted Y-shaped structure.
Further, the sampling module comprises a sampler, a sample transmission belt and a collecting hopper, wherein the sampler is used for taking samples from a transport carrier according to a sampling scheme sent by a system control unit; the sample conveying belt is connected between the sampler and the collecting hopper and is used for conveying each batch of raw fuel samples collected by the sampler to the collecting hopper for temporary storage, and a controller of the sampling module controls the bottom gate of the collecting hopper to be automatically opened after all the batches of raw fuel samples are collected, so that a large sample falls into the sample preparation module; the sampling points of the automobile and the train are provided with spiral samplers, and the sampling points of the belt are provided with straight line or rotary cutting samplers; the bottom gate of the collecting hopper of the sampling module is respectively communicated with the feed inlet of the big sample mixing device of the sample preparation module and the feed inlet of the primary crushing device through three-way pipelines, and the on-off switching of the two pipelines is realized through a control valve arranged on the pipelines.
Further, the sample collection module comprises a sealing device, a sample bottle temporary storage device, a marking device and a plurality of sample bottles, wherein the sample bottle temporary storage device is used for queuing a plurality of sample bottles after being arranged and waiting for loading; the sample preparation industrial robot is used for clamping a sample bottle, bottling the prepared analysis sample and the prepared inventory sample, and sealing and encrypting the prepared analysis sample and the prepared inventory sample by a sealing device; the identification device is used for reading the code identification of the sample bottle and inputting the code identification information of the sample bottle and the sample information corresponding to the code identification information into the control system of the sample collecting module; each sample corresponds to a unique coded identifier.
The sample discarding module of the sampling integrated unit utilizes a sample discarding barrel to buffer samples, the sample discarding barrel is provided with a blanking gate, and after positive sample preparation success is determined, the corresponding sample discarding gate is automatically opened, and the samples are automatically discarded to a waste bin to be recovered; the sample preparation industrial robot is used for collecting the same batch of discarded samples in the same barrel.
Further, the analysis and test unit comprises an industrial analyzer, a sulfur analyzer, a calorimeter and a sample distribution device, wherein the industrial analyzer, the sulfur analyzer, the calorimeter, the sample distribution device and the pneumatic sample delivery receiving cabinet are distributed annularly around the test industrial robot, and sample materials are transferred among the industrial analyzer, the sulfur analyzer, the calorimeter, the sample distribution device and the pneumatic sample delivery receiving cabinet through the test industrial robot; the sample distribution device is used for realizing automatic uncovering and pouring of an analysis sample bottle, automatic sampling, automatic weighing and automatic filling of an analysis vessel by means of an analysis industrial robot; the industrial analysis instrument, the sulfur determination instrument and the calorimeter are used for automatically testing the quality data of ash, volatile matters, total sulfur and heat value of the samples sent by the industrial analysis robot and uploading the tested data to the system control unit; the sample after analysis is poured into a waste collection bucket by the assay industrial robot to be recovered.
Further, the pneumatic sample sending unit comprises a pneumatic sample sending power station, a pneumatic sample sending cabinet and a pneumatic sample receiving cabinet, and the pneumatic sample sending cabinet is connected with the pneumatic sample receiving cabinet through a pneumatic sample sending pipeline; the pneumatic sample feeding power station is used for providing conveying power for pneumatic sample feeding; the pneumatic sample sending and sending cabinet is used for transmitting the analysis sample bottle packaged by the collecting and manufacturing integrated unit to the pneumatic sample receiving cabinet through a conveying pipeline; the sample collection module of the sampling integrated unit and the pneumatic sample delivery sending cabinet are used for transferring sample materials through a sample preparation industrial robot; the pneumatic sample sending receiving cabinet is used for receiving an analysis sample bottle and transmitting the analysis sample bottle to the analysis and test unit for quality analysis through the test industrial robot; the pneumatic sample sending cabinet is used for transmitting the stored and checked sample bottles packaged by the collecting and manufacturing integrated unit to the storage unit through the conveying pipeline.
Further, the storage unit is responsible for automatically completing the receiving, storing and extracting of the check sample and setting the storage time to expire and automatically discharge according to the quality check and acceptance of the raw fuel and the rechecking period, and the storage unit also has the functions of automatically calling out a sample bottle, storing data and managing; the storage unit is automatically abandoned to a waste bin to be recovered; the storage unit also designs a storage bin of the storage unit according to the storage sample quantity and the storage time.
Compared with the prior art, the invention has the following beneficial effects:
the sample preparation module comprises a large sample mixing device, a primary crushing device, a secondary crushing device, a primary dividing device, a secondary dividing device, a pre-drying device, a grinding device, a bisecting device and a viscosity detection device; by adopting the device and the sample preparation flow, the high sample preparation precision can be ensured. And in the sample preparation process, the sample preparation industrial robot is adopted to transfer sample materials among devices of a sample preparation module, a full-moisture analysis module, a sample collection module and a pneumatic sample delivery and sending cabinet, so that the full automation of sample preparation is realized.
The analysis and test unit comprises an industrial analyzer, a sulfur determination instrument, a calorimeter and a sample distribution device, wherein the industrial analyzer, the sulfur determination instrument, the calorimeter, the sample distribution device and the pneumatic sample delivery receiving cabinet are distributed annularly around the test industrial robot, sample materials are transferred among the industrial analyzer, the sulfur determination instrument, the calorimeter, the sample distribution device and the pneumatic sample delivery receiving cabinet through the test industrial robot, full automation of analysis and test is realized, and a test result is more accurate.
The pneumatic sample sending and sending cabinet is used for transmitting the analysis sample bottle packaged by the collecting and manufacturing integrated unit to the pneumatic sample receiving cabinet through a conveying pipeline; the sample collection module of the sampling integrated unit and the pneumatic sample delivery sending cabinet are used for transferring sample materials through a sample preparation industrial robot; the pneumatic sample sending receiving cabinet is used for receiving an analysis sample bottle and transmitting the analysis sample bottle to the analysis and test unit for quality analysis through the test industrial robot; the pneumatic sample sending cabinet is used for transmitting the stored and checked sample bottles packaged by the collecting and manufacturing integrated unit to the storage unit through the conveying pipeline. And the material transferring modes of all links such as the large sample obtained by sampling is conveyed to sample preparation, the small sample obtained by sample preparation is conveyed to assay, the check sample obtained by sample preparation is conveyed to a check sample cabinet and the like are fully automated.
In a word, the invention can realize unattended full-automatic sampling, sample preparation, assay and storage and automatic transmission of samples, simultaneously ensure that each quality data of the samples is real and accurate, and the system error is within the standard allowable range, thereby greatly reducing the labor intensity of operators and furthest reducing or avoiding artificial interference by adopting a full-automatic sample preparation system.
Drawings
FIG. 1 is a process flow diagram of a full-automatic power coal mining and preparing system provided by an embodiment of the invention;
FIG. 2 is a flow chart of a process of the power coal mining and manufacturing integrated unit of the invention;
FIG. 3 is a schematic diagram of a full-automatic power coal mining and preparing system according to an embodiment of the present invention;
fig. 4 is a schematic structural view of the mixing device of the present invention;
FIG. 5 is a right side view of FIG. 4;
FIG. 6 is a schematic diagram of a bipartite device according to the present invention;
fig. 7 is a left side view of fig. 6.
In the drawing, 1 is a sampling integrated unit, 11 is a sampling module, 12 is a sample preparation module, 13 is a full-moisture analysis module, 14 is a sample discarding module, 15 is a sample collecting module, 16 is a sample preparation industrial robot, 121 is a large sample mixing device, 122a is a primary dividing device, 122b is a secondary dividing device, 123a is a pre-drying device, 123b is a drying device, 124a is a primary crushing device, 124b is a secondary crushing device, 125 is a grinding device, and 126 is a bisecting device;
2 is a pneumatic sample feeding unit, 21 is a pneumatic sample feeding and transmitting cabinet, 22 is a pneumatic sample feeding pipeline, 23 is a pneumatic sample feeding and receiving cabinet, and 24 is a pneumatic sample feeding power station;
the system comprises an analysis and test unit 3, an industrial analyzer 31, a sulfur analyzer 32, a calorimeter 33, a sample distribution device 34, an industrial robot 35, a storage unit 4 and a system control unit 5.
Detailed Description
The invention will be described in further detail with reference to specific embodiments and drawings.
Referring to fig. 1 to 5, the invention provides a full-automatic sampling and processing system, which comprises a sampling and processing integrated unit 1, a pneumatic sample feeding unit 2, an analysis and test unit 3 and a storage unit 4, wherein the system control unit 5 of the control system commands and manages the operation of each unit. The collecting and manufacturing integrated unit is positioned in a collecting and manufacturing area and is responsible for collecting samples, preparing analysis samples and inventory samples and detecting the moisture content of the samples; the analysis and test unit is positioned in a standard laboratory and is responsible for testing various performance indexes of the sample; the storage unit is positioned in a standard laboratory and is responsible for storing a check sample so as to check when a quality objection condition occurs; the pneumatic sample feeding unit is arranged between the sampling integrated unit and the analysis and test unit and respectively transmits the analysis sample and the check sample prepared by the sampling integrated unit to the analysis and test unit and the storage unit in a standard laboratory; the system control unit is arranged in a standard laboratory and commands complete flow operation to carry out daily raw fuel quality acceptance management work. The whole process is mainly distributed in two large areas, namely a mining area and a standard laboratory.
The invention is applicable to the transportation modes of automobiles, trains, belts and the like, takes the power coal of an automobile transportation factory as a specific embodiment, and is specifically described below for five units in sequence.
The power coal of the automobile transportation input factory is sampled and sampled in the integrated sampling unit 1. The sampling module 11 uses a spiral sampling head to automatically collect each sample (primary subsamples) according to the sampling scheme and the instruction sent by the system control unit 5, each sample is collected and then is collected to the collection hopper, and after all samples of the batch are collected, the gate at the bottom of the collection hopper is automatically opened, so that the large samples fall into the sample preparation module 12.
After the large sample enters the sample preparation module 12, the large sample firstly enters a mixing device 121, and the mixing device turns and stirs the accumulated samples layer by layer from bottom to top, rotates the samples to realize full mixing, and provides representative sample materials for the subsequent process; the mixed large sample enters a primary crushing device 124a, and the granularity is crushed to-13 mm; the crushed large sample with the diameter of-13 mm enters a primary shrinkage dividing device 122a, a mechanism for uniformly feeding, preventing sticking and blocking is arranged in the device, and a belt feeder, a material flow shaping baffle, a uniform stirring device and other mechanisms are adopted to meet the functional requirements, so that the samples with high humidity and high viscosity can be smoothly subjected to shrinkage division, and the precision requirement of the shrinkage division is met; primary division to obtain a full-moisture sample and a shared sample (shared by a stock sample and an analysis sample), wherein the full-moisture sample is sent to a full-moisture analysis module 13 by a sample preparation industrial robot 16, and the shared sample is subjected to sample preparation flow; the shared sample after shrinkage is transmitted to a pre-drying device 123a by a sample preparation industrial robot 16, the device meets the national standard requirement, the working temperature is about 40-50 ℃, the chemical property of the sample is not changed in the pre-drying process, and the pre-dried sample enters a secondary crushing device 124b and is crushed to the granularity of-3 mm; then the sample enters a secondary dividing device 122b, the dividing quality meets the standard requirements of-3 mm analysis sample and large sample stock sample, the large sample stock sample is sent to an aggregate module 15 by a sample preparation industrial robot 16 to be packaged, the analysis sample enters a drying device 123b to be dried before grinding, so that the grinding and subsequent test work are ensured to be carried out smoothly, and the drying temperature meets the national standard requirements; the redundant waste is transmitted to the waste module 14 through the sample preparation industrial robot 16; finally, the dried analysis sample is sent to a grinding device 125 for full grinding, so that the analysis sample with the granularity reaching-0.2 mm and meeting the test requirement is prepared, and the sample is weighed during the feeding and discharging in the grinding stage, so that the residual quantity in the grinding device 125 meets the requirement, and the influence of selective grinding on the sample preparation precision is avoided; the discharged sample is sent to the bipartite device 126, enters the small sample mixing device, realizes the full mixing of the sample, is finally divided into two parts by the bipartite device, is respectively sent to the sample collecting module 15 for packaging, and one part is used as an analysis sample for standby examination, which is called a small sample stock examination sample, and the other part is used as an analysis sample for assay.
Referring to fig. 4, the invention provides a bulk sample mixing device 121, which comprises a mixing drum, a mixing shaft and a first driving device for providing power for the mixing shaft, wherein the mixing drum 62 is supported on a bracket 61, a feed inlet is arranged at the upper end of the mixing drum, a discharge outlet is arranged at the bottom of the mixing drum, a gate device is arranged at the discharge outlet at the bottom of the mixing drum, the mixing shaft 63 is vertically and rotatably supported in the mixing drum, the lower end of the mixing shaft extends out from a through hole arranged at the bottom of the mixing drum, the mixing shaft is connected with the first driving device through a driving device, and a mixing blade is arranged on the mixing shaft. The first drive means is a motor 610.
Further, the stirring shaft is sleeved with a conical shaft sleeve 64 with a small upper part and a large lower part, the stirring blade is fixed on the outer wall of the conical shaft sleeve, the upper end of the stirring shaft is fixedly provided with a top cover, the lower end of the top cover is in clearance fit with the upper end of the stirring shaft and is fixed by a screw, the upper end of the top cover 65 is provided with a conical surface, and the vertex of the conical surface faces upwards.
Further, two first stirring blades 66 are fixed at the lower end of the conical shaft sleeve and extend transversely, two second stirring blades 67 are fixed at the middle of the conical shaft sleeve and extend longitudinally, the first stirring blades and the second stirring blades are block blades, four mounting rods 68 for mounting the blades are fixed on the outer wall of the conical shaft sleeve, each mounting rod extends along the radial direction of the conical shaft sleeve, the four mounting rods are arranged in a cross-shaped structure, the first stirring blades are fixed on the outer wall of the mounting rods, and the second stirring blades are fixed at the end parts of the mounting rods; the lengths of the mounting rods for mounting the second stirring blades are different, and the cross sections of the mounting rods are triangular; the first stirring blade is fixed on the side surface of the mounting rod through a screw; the end of the mounting rod for mounting the second stirring blade is provided with a mounting plate, and the second stirring blade is fixed on the mounting plate 69 by a screw. The stirring blade is arranged in the clockwise direction.
Further, the gate device comprises a second driving device and a gate plate, wherein the gate plate is hinged to a discharge hole at the bottom of the stirring barrel, the second driving device is arranged at the bottom of the bracket, and an output shaft of the second driving device is used for pushing the gate plate to move so as to open or close the discharge hole; the second driving means employs a cylinder 613.
Further, a guiding device 611 is fixed at the bottom of the bracket, and corresponds to the discharge hole at the bottom of the stirring cylinder.
Further, a bearing seat 614 is fixed at the bottom of the bracket, the lower end of the stirring shaft penetrates through the bearing seat and is connected with the transmission device, and the stirring shaft is rotatably supported in a bearing in the bearing seat. The bearing may be a thrust roller bearing.
Further, the transmission 612 employs a gear drive or a sprocket drive or a belt drive.
Further, a speed reducing device is arranged between the first driving device and the transmission device, an output shaft of the first driving device is fixedly connected with an input shaft of the speed changing device, and an output shaft of the speed changing device is fixedly connected with the transmission device; the axial lead of the input shaft of the speed changing device extends along the horizontal direction, and the axial lead of the output shaft of the speed changing device extends along the vertical direction; the first belt pulley of the output shaft of the speed change device is fixedly connected, the second belt pulley is fixedly connected with the stirring shaft, and the first belt pulley is connected with the second belt pulley through a belt.
Further, the upper end of the stirring cylinder is open or an end cover is arranged at the upper end of the stirring cylinder, and a feed inlet is arranged on the end cover.
Further, the stirring barrel is cylindrical.
The large sample mixing device has good mixing effect, ensures that the large sample has good uniformity, provides a representative sample for the subsequent process, and has high efficiency.
Referring to fig. 5, this embodiment provides a bipartite device, including blending device 71 and bipartite 72, the upper end of blending device is equipped with the feed inlet, the lower extreme of blending device and the upper end fixed connection of bipartite, the discharge gate 719 of blending device bottom corresponds from top to bottom with the feed inlet of bipartite upper end, the bipartite includes first honeycomb duct 721 and second honeycomb duct 722, the feed inlet of first honeycomb duct upper end corresponds with half of the discharge gate of blending device bottom, the feed inlet of second honeycomb duct upper end corresponds with half of the discharge gate of blending device bottom.
Further, a connecting plate 73 is arranged between the mixing device and the bipartite device, the lower end of the mixing device is fixedly connected with the upper end of the connecting plate, the upper end of the bipartite device is fixedly connected with the lower end of the connecting plate, and openings 731 are arranged at positions of the connecting plate corresponding to the discharge port at the bottom of the stirring cylinder and the feed inlet at the upper end of the bipartite device, so that samples can pass through the connecting plate.
Further, the mixing device comprises a stirring cylinder 711, an end cover 712 is fixed at the upper end of the stirring cylinder, a first driving device 713 is fixed on the end cover, a feed inlet is further arranged on the end cover, a stirring shaft 714 is arranged in the stirring cylinder, the stirring shaft is vertically arranged in the stirring cylinder, the upper end of the stirring shaft penetrates through a through hole formed in the end cover and is fixedly connected with an output shaft of the driving device, the lower end of the stirring shaft is suspended, and stirring blades 715 are arranged at the lower end of the stirring shaft. The first driving device is a motor.
Further, the stirring barrel is conical, and is large in upper part and small in lower part.
Further, a plurality of stirring blades are arranged at the lower end of the stirring shaft 714, the stirring blades are equally divided into 360 degrees, the stirring blades are arranged on a fixed ring, the fixed ring is sleeved on the stirring shaft, and the fixed ring is fixedly connected with the fixed ring through a pin shaft; at least one stirring blade is arranged on each fixed ring, and at least one fixed ring is arranged at the lower end of the stirring shaft; the stirring blade is formed by folding a square sheet-shaped blade, two long sides of the folding side and the square sheet-shaped blade are respectively provided with an intersection point, and the length of the folding side is greater than the length of the short side of the square sheet-shaped blade. The turning directions of the plurality of stirring blades are the same, such as all in the clockwise direction.
Further, two stirring blades are arranged on each fixing ring, and three fixing rings are arranged at the lower end of the stirring shaft.
Further, a fixed plate 716 is fixed at the lower end of the stirring cylinder, and the fixed plate at the lower end of the stirring cylinder is fixedly connected with the connecting plate through a bolt; the fixing plate is provided with screw holes, and the connecting plate is provided with screw holes corresponding to the screw holes arranged on the fixing plate.
Further, a gate device is arranged at a discharge hole at the bottom of the mixing device; the gate device comprises a gate plate 717 for sealing a discharge hole at the bottom of the mixing device and a second driving device for driving the gate plate to move, an output shaft of the second driving device 718 is fixedly connected with the gate plate, a chute for installing the gate plate is arranged on the upper end surface of the connecting plate, the gate plate is embedded into the chute of the connecting plate and is in sliding fit with the connecting plate, and the gate plate blocks an opening on the connecting plate; the gate plate is provided with a vertical turning surface for fixedly connecting with an output shaft of the second driving device; the second driving device is fixed on the lower end face of the connecting plate. The second driving device adopts an air cylinder, a hydraulic cylinder and the like.
Further, the upper end of the first guide pipe is fixedly connected with the upper end of the second guide pipe to form a bipartite device with an inverted Y-shaped structure.
Further, the bipartite device further comprises an inlet pipe section, a partition plate is arranged in the inlet pipe section, the inlet pipe section is divided into two halves, the two halves respectively correspond to the first flow guide pipe and the second flow guide pipe, the upper ends of the first flow guide pipe and the second flow guide pipe are fixedly connected with the partition plate and fixedly connected with the lower end of the inlet pipe section, and the bipartite device with an inverted Y-shaped structure is formed.
Further, the two-part device for raw fuel sample preparation of the embodiment further comprises a bottom plate 74, a connecting frame 75 is arranged between the first flow guide pipe and the second flow guide pipe, a third driving device is arranged on the connecting frame, and an output shaft of the third driving device is connected with the bottom plate; the third driving device adopts an air cylinder or a hydraulic cylinder and the like. Of course, the connecting frame can also be directly and fixedly connected with the bottom plate. The above-described structure of this patent is set as required.
Further, the lower end of the first flow guiding pipe is fixedly connected with a first outlet pipe section 76, the upper end of the first outlet pipe section is fixedly connected with the lower end of the first flow guiding pipe, the lower end of the first outlet pipe section is communicated with a through hole formed in the bottom plate, the lower end of the second flow guiding pipe is fixedly connected with a second outlet pipe section 77, the upper end of the second outlet pipe section is fixedly connected with the lower end of the second flow guiding pipe, the lower end of the second outlet pipe section is communicated with the through hole formed in the bottom plate, and the axial leads of the first outlet pipe section and the second outlet pipe section extend along the vertical direction; the upper end of the first outlet pipe section is fixedly connected with the lower end of the first flow guide pipe through a bolt; the upper end of the second outlet pipe section is fixedly connected with the lower end of the second flow guide pipe through a bolt; the first flow guide pipe and the second flow guide pipe are square pipes, and the first outlet pipe section and the second outlet pipe section are round pipes.
By adopting the bipartite device, samples are input from the upper feed inlet, the motor is controlled to drive the stirring shaft to rotate, the samples are uniformly mixed, the samples are fully mixed, the uniformly mixed samples are uniformly fed into the first guide pipe and the second guide pipe of the bipartite device, and the samples are cut by the bipartite device, so that bipartite is realized. The sample can be uniformly supplied into the bipartite through the mixing device at the upper end, and then the sample quantity entering the bipartite is basically equal, so that the problem of larger mass deviation between the samples after shrinkage separation is solved. And the lower end of the mixing device is fixedly connected with the upper end of the bipartite device, so that the occupied space is small.
Preferably, if the sample uniformity is good, the mixing link (mixing device 121) of the large sample can be omitted, and the primary crushing (primary crushing device 124 a) of the original large sample is directly performed.
Preferably, if the moisture content of the sample is unstable, there is a large difference between batches, and a viscosity detection mechanism can be added before secondary crushing: if the moisture content of the common sample is low and the viscosity is low, a large sample drying link (a pre-drying device 123 a) can be omitted, and the common sample with the diameter of-13 mm which is primarily separated directly enters a secondary crushing device 124b; if the common sample has high moisture and high viscosity, the sample enters the pre-drying device 123a.
Preferably, when the dividing devices 122, 124 perform the procedures of cyclic crushing, grinding and dividing, the requirements of national standards on minimum quality after dividing different granularity can be met, and according to the configuration of the primary dividing device 122a, the secondary dividing device 122b, the primary crushing device 124a, the secondary crushing device 124b and the grinding device 125 in this embodiment, the following more refined classification modes can be selected by comprehensively considering the granularity of the materials, the processing capacity of the equipment and other factors: primary crushing: less than or equal to 13mm and more than or equal to 15kg; secondary crushing: less than 13mm, less than or equal to 6mm, more than or equal to 3.75kg; three-stage crushing: less than or equal to 3mm and more than or equal to 700g; primary grinding: less than or equal to 1mm and more than or equal to 100g; secondary grinding: less than or equal to 0.2mm and more than or equal to 60g.
The full moisture sample obtained by the primary shrinkage of the sample preparation module 12 is sent to the full moisture analysis module 13 by the sample preparation industrial robot 16 for moisture content detection. The total moisture analysis module 13 mainly includes an air blast drying box (a box-type container with a heating function for drying moisture in a material), a tray lifting mechanism, a sample flattening mechanism, a weighing mechanism, and the like. The rotating disc with the multi-station sample containers is adopted to carry out rotary switching stations, the sample containers are supported to enter and exit the oven through the tray lifting mechanism to realize automatic sample entering and exiting functions, and the flattening mechanism realizes uniform flattening of samples. The blast drying box continuously supplies heat to a drying chamber (the drying chamber is a working area of the blast drying box, namely, a space for storing samples except an electric control element), the temperature of the drying chamber is automatically detected, an automatic constant temperature function is kept, and the drying temperature is adjustable. The whole moisture analysis of the power coal meets the GB/T211 requirement. According to the system efficiency requirement, the number of the drying stations is generally more than 12 (the drying stations refer to the working area of the blast drying box, namely, the positions of each sample in the drying box are respectively stored, one sample is placed in one position, namely, one station, the rotating disc rotationally switches each station, the dried stations are rotated to the outlet of the drying box, the stations just entering the blast drying box are rotated to the drying box, and the rotating disc plays a role in transferring the samples). According to the thickness and weight requirements of the moisture sample and the clamping size of the industrial robot, a tray is designed, and according to the production efficiency requirement, a drying station is designed. The drying temperature, time, weighing precision and the like are set according to national standard requirements. The detected data result is automatically uploaded to the system control unit 5.
The reject generated by the sample preparation module 12 is transferred to the reject module 14 by the sample preparation industrial robot 16. The sample discarding module 14 uses a sample discarding barrel to buffer samples, the sample discarding barrel is provided with a blanking gate, and after the positive sample preparation of the batch of samples is determined to be successful (packaging is completed), the gate corresponding to the samples is automatically opened, and the samples are automatically discarded to a waste bin to be recovered. The same batch of discarded samples are collected in the same barrel, the number of the barrels can be determined according to the batch number of samples per shift and the production efficiency of the sample preparation device, and 8-12 barrels are generally set.
The analysis sample and the stock sample (including the large sample stock sample and the small sample stock sample) completed by the sample preparation module 12 are sent to the sample collection module 15 by the sample preparation industrial robot 16. The sample collection module is responsible for collecting analysis samples and inventory samples prepared by the sample preparation module to a sample bottle, and packaging and marking (coding, inputting, reading codes, writing codes and the like). The sample collection module 15 comprises a capping device, a sample bottle temporary storage device, a marking device and the like. The sample preparation industrial robot 16 clamps the sample bottles, fills the prepared analysis samples and the prepared inventory samples into bottles, encrypts the bottles by sealing with a sealing device to form the sample bottles, and inputs sample information corresponding to the sample bottle information into a controller of the module. The sample bottle can be reused, and the sample is subjected to unique coding identification by adopting a chip, a two-dimensional code or a bar code, so that the sample can be correctly read in a flow link (the coding rule is given by an intelligent management and control system). The sample bottle temporary storage device arranges empty bottles in a queue, the samples are received after being grabbed by the sample preparation industrial robot 16, and the sample bottle arranging station is calculated according to the production efficiency of the system and is generally not less than 3 times of the number of large samples. After the sample bottle is filled, the sealing cover is sealed, so that the subsequent pneumatic sample feeding unit 2 is convenient to convey, and the sealing cover can be a screw cap type or a gland type. The sample bottle temporary storage device is designed according to the production efficiency of the sample preparation module 12, and the sample bottle specification is designed according to the weight and the volume of the bottled sample materials and the size of the conveying pipeline of the pneumatic sample conveying unit 2.
The pneumatic sample feeding unit 2 plays a role in transferring sample bottles, and the sample bottles generated by the sampling integrated unit 1 are transferred to the analysis and test unit 3 and the storage unit 4. The pneumatic sample feeding unit 2 comprises a sample bottle sending cabinet 21, a conveying pipeline and a pipeline accessory 22, a sample bottle receiving cabinet 23, a power station 24 and the like: the sample bottle sending cabinet is positioned in a sampling area (sampling integrated unit 1) and is responsible for conveying the analysis sample bottles and the inventory sample bottles which are completed by the sampling integrated unit 1 into a pipeline; the sample bottle receiving cabinet is positioned in a standard laboratory (comprising an analysis and test unit 3, a storage unit 4 and a system control unit 5), is responsible for receiving analysis sample bottles and inventory sample bottles, and respectively sends the analysis and test unit 3 and the storage unit 4 according to instructions of the system control unit 5; the conveying pipeline is connected with the sending cabinet and the receiving cabinet, and the route and the length of the pipeline are determined by the distance from the mining area to the standard laboratory.
The analysis and assay unit 3 includes an industrial analyzer 31, a sulfur analyzer 32, a calorimeter 33, a sample distribution device 34, and an assay industrial robot 35, and the industrial analyzer 31, the sulfur analyzer 32, the calorimeter 33, and the sample distribution device 34 are arranged in a ring shape around the assay industrial robot 35. The pneumatic sample feeding unit 2 feeds the analysis sample for assay generated by the sampling and processing integrated unit 1 to the analysis and assay unit 3 for quality analysis according to the instruction of the system control unit 5. After the analysis sample bottle reaches the analysis and test unit 3, the analysis sample bottle is clamped to the sample bottle split charging device 34 by the test industrial robot 35, and the automatic uncovering, material pouring, automatic sampling, automatic weighing, automatic test vessel filling and other works of the analysis sample bottle are completed; the filled industrial analysis sample, the full sulfur sample and the heat value sample are respectively sent to an industrial analyzer 31, a sulfur determination instrument 32 and a calorimeter 33 by an analysis industrial robot 35, the quality data of ash, volatile matters, full sulfur, heat value and the like are automatically tested by the analysis instruments, and the results are uploaded to a system control unit 5. The sample after analysis is poured into a waste collection hopper by an assay industrial robot 35 to be recovered.
The pneumatic sample feeding unit 2 feeds the sample storage bottles (including the large sample storage bottles and the small sample storage bottles) generated by the sampling integrated unit 1 to the storage unit 4 according to the instruction of the system control unit 5. The storage unit 4 is responsible for automatically completing the functions of receiving, storing, extracting, discharging out-of-date samples, automatically transferring out-of-sample bottles, storing data and managing. According to the requirements of rechecking and checking of each production unit, the stock check samples can be divided into a large sample stock check sample and a small sample stock check sample, wherein the large sample stock check sample is used for rechecking sample preparation and sampling errors, and the small sample stock check sample is the same as an analysis sample and is used for rechecking test errors. The storage unit 4 sets storage time according to the quality acceptance and rechecking period of the raw fuel, automatically goes out of the warehouse due to the expiration, and automatically discards the raw fuel to a waste bin to be recovered. According to the number of stored sample bottles and the storage time, the storage bins of the storage unit 4 are designed, and the bins of the storage sample cabinet are generally not less than 1000.
The control system comprises a system control unit and a plurality of controllers, wherein the controllers can adopt PLC controllers, and the controllers respectively correspond to different units or modules. The system control unit adopts a computer, is a central nervous system of the whole full-automatic sampling and preparing system, is the central nervous system of the whole full-automatic sampling and preparing system, and comprises the steps of sending sampling, sample preparing, testing and storing schemes to controllers of the sampling and preparing integrated unit 1, the pneumatic sample delivering unit 2, the analysis and testing unit 3 and the storing unit 4, sending various working instructions to each unit, receiving all-moisture data obtained by the sampling and preparing integrated unit, analyzing and processing quality data of sulfur content, ash content, volatile matters, heat value and the like obtained by the analysis and testing unit, managing the storing state of each sample bottle of the storing unit 4, sending a regulating and fetching and checking instruction and the like, and grasping the whole flow control and management functions of real-time working conditions and the like of each unit, module, device, instrument, equipment and the like. The system control unit 5 realizes the full-process automation and intelligent management of the mining and manufacturing of the power coal.
The full-automatic production method of the invention comprises the following steps: the sampling and sample preparation links are highly integrated, sample transmission from sampling to sample preparation is completed through belt transmission, the sample preparation links directly prepare an analysis sample and a check sample from the collected large sample, packaging and marking are completed, meanwhile, the moisture content is detected, and the abandoned sample generated in the sample preparation process is temporarily stored in a fixed container until the sample preparation is completed, so that the sample is prevented from being traceed back due to sample preparation failure or equipment failure. The analysis sample and the check sample bottle are quickly and automatically conveyed to an analysis and test unit and a storage unit through the pneumatic sample conveying unit. The analysis and test unit automatically completes the test of each performance index of the sample and uploads the data to the control unit. And the sample transmission of the collecting and manufacturing integrated unit and the analysis and test unit is completed by an industrial robot. The manipulator can be stopped at any instrument, equipment or device for pouring, receiving and transferring in the working radius range. The whole quality inspection and acceptance process, namely the steps of picking, manufacturing, melting and storing are unattended, the automation and the intellectualization are high, and the production efficiency is high.
The above embodiments are provided for illustrating the present invention and not for limiting the present invention, and various changes and modifications may be made by one skilled in the relevant art without departing from the spirit and scope of the present invention, and thus all equivalent technical solutions fall within the scope of the present invention.
Claims (10)
1. A full-automatic system of making is adopted to raw materials intelligence, its characterized in that: the system comprises a sampling integrated unit, a pneumatic sample feeding unit, an analysis and assay unit, a storage unit and a system control unit, wherein the sampling integrated unit is positioned in a sampling area and is responsible for collecting samples, preparing analysis samples and storage samples and detecting the moisture content of the samples; the analysis and test unit is positioned in the standard laboratory, the storage unit is positioned in the standard laboratory, the pneumatic sample feeding unit is arranged between the sampling and manufacturing integrated unit and the analysis and test unit, and the analysis sample and the stored sample manufactured by the sampling and manufacturing integrated unit are respectively conveyed to the analysis and test unit and the storage unit in the standard laboratory;
the sampling and manufacturing integrated unit comprises a sampling module, a sample preparation module, a full-moisture analysis module and a sample collection module, wherein the sampling module is used for taking samples from a transport carrier according to a sampling scheme sent by the system control unit; the sample preparation module is used for preparing the large samples of each batch collected by the sampling module into analysis samples meeting the test requirements, and preparing all-moisture samples and check samples at the same time; the full-moisture analysis module is used for detecting the moisture content of the sample and uploading detected data to the system control unit; the sample collection module is used for collecting the analysis sample and the inventory sample prepared by the sample preparation module to a sample bottle, packaging and marking;
The analysis and test unit is used for testing various performance indexes of the sample; the storage unit is used for storing a check sample so as to check when a quality objection condition occurs; the pneumatic sample conveying unit is arranged between the sampling integrated unit and the analysis and test unit and is used for conveying the analysis samples and the check samples prepared by the sampling integrated unit to the analysis and test unit and the storage unit respectively; the system comprises a collecting and manufacturing integrated unit, a pneumatic sample feeding unit, an analysis and test unit and a storage unit, wherein the collecting and manufacturing integrated unit, the pneumatic sample feeding unit, the analysis and test unit and the storage unit are respectively connected with a system control unit, and the system control unit is used for issuing instructions to the units and commanding and managing the operation of the units to complete the whole-flow operation and perform daily raw fuel quality acceptance management work;
the sample preparation module comprises a large sample mixing device, a primary crushing device, a secondary crushing device, a primary dividing device, a secondary dividing device, a pre-drying device, a grinding device, a bisecting device and a viscosity detection device; the sample mixing device, the primary crushing device, the secondary crushing device, the primary dividing device, the secondary dividing device, the pre-drying device, the grinding device, the dividing device, the viscosity detection device, the full-moisture analysis module, the sample collection module, the pneumatic sample sending cabinet and the sample discarding module are annularly distributed around the sample preparation industrial robot, and sample materials are transferred among the devices of the sample preparation module, the full-moisture analysis module, the sample collection module, the sample discarding module and the pneumatic sample sending cabinet through the sample preparation industrial robot; the large sample mixing device is used for fully mixing the large samples and providing representative strong sample materials for the subsequent process; the primary crushing device is used for crushing the uniformly mixed large sample granularity to a first set value; the primary division device is used for dividing the primary crushed large sample to obtain a full-moisture sample and a common sample; the full-moisture analysis module is used for detecting the moisture content of the full-moisture sample and uploading the detected data to the system control unit; the pre-drying device is used for pre-drying the common sample; the secondary crushing device is used for crushing the common sample particle size to a second set value; the secondary division device is used for dividing the secondarily crushed sample to obtain an analysis sample and a large sample stock sample; the sample collection module is used for collecting the large sample stock sample to a sample bottle, packaging and marking; the drying device is used for drying the analysis sample before grinding; the grinding device is used for fully grinding the dried analysis sample to prepare the analysis sample with granularity meeting the test requirement; the bipartition device is used for dividing an analysis sample into two parts; the sample collection module is used for collecting two analysis samples to a sample bottle respectively, packaging and marking, wherein one sample serves as an analysis sample for standby examination, which is called a small sample stock sample, and the other sample serves as an analysis sample for assay; the sample discarding module is used for collecting the discarded samples generated by the sample preparing module and temporarily storing the discarded samples to the batch of samples for preparing the samples;
The large sample mixing device comprises a stirring cylinder, a stirring shaft and a first driving device for providing power for the stirring shaft, wherein the stirring cylinder is supported on a bracket, the upper end of the stirring cylinder is provided with a feed inlet, the bottom of the stirring cylinder is provided with a discharge outlet, the discharge outlet at the bottom of the stirring cylinder is provided with a gate device, the stirring shaft is vertically and rotatably supported in the stirring cylinder, the lower end of the stirring shaft extends out from a through hole arranged at the bottom of the stirring cylinder and is connected with the first driving device through a driving device, and the stirring shaft is provided with a stirring blade;
the stirring shaft is sleeved with a conical shaft sleeve with a small upper part and a large lower part, the stirring blade is fixed on the outer wall of the conical shaft sleeve, the upper end of the stirring shaft is fixedly provided with a top cover, the lower end of the top cover is in clearance fit with the upper end of the stirring shaft and is fixed by a screw, the upper end of the top cover is provided with a conical surface, and the vertex of the conical surface faces upwards;
the lower end of the conical shaft sleeve is fixedly provided with two first stirring blades which extend transversely, the middle part of the conical shaft sleeve is fixedly provided with two second stirring blades which extend longitudinally, the first stirring blades and the second stirring blades are blocky blades, the outer wall of the conical shaft sleeve is fixedly provided with four mounting rods for mounting the blades, each mounting rod extends along the radial direction of the conical shaft sleeve, the four mounting rods are arranged in a cross structure, the first stirring blades are fixed on the outer wall of the mounting rods, and the second stirring blades are fixed at the end parts of the mounting rods; the length of the mounting bars for mounting the second stirring blades is different.
2. The system according to claim 1, wherein: the viscosity detection device is used for detecting the moisture content and viscosity of the common sample and uploading the detected moisture content and viscosity data to the system control unit; the system control unit is used for receiving the data uploaded by the viscosity detection device, comparing the data uploaded by the viscosity detection device with a set value respectively, and controlling to cancel a pre-drying link of the pre-drying device on the common sample when judging that the moisture content of the common sample is low and the viscosity is low, and controlling the sample preparation industrial robot to directly enter the common sample into the secondary crushing device; when the common sample is high in moisture and high in viscosity, the common sample is controlled to enter the pre-drying device by the sample preparation industrial robot for pre-drying, and then the common sample is controlled to enter the secondary crushing device by the sample preparation industrial robot.
3. The system according to claim 1, wherein: the cross section of the mounting rod is triangular; the first stirring blade is fixed on the side surface of the mounting rod through a screw; the end part of the mounting rod for mounting the second stirring blade is provided with a mounting plate, and the second stirring blade is fixed on the mounting plate through a screw.
4. The system according to claim 1, wherein: the device comprises a small sample mixing device and a divider, wherein the upper end of the small sample mixing device is provided with a feed inlet, the lower end of the small sample mixing device is fixedly connected with the upper end of the divider, the feed outlet at the bottom of the small sample mixing device corresponds to the feed inlet at the upper end of the divider up and down, the divider comprises a first guide pipe and a second guide pipe, the feed inlet at the upper end of the first guide pipe corresponds to half of the feed outlet at the bottom of the small sample mixing device, and the feed inlet at the upper end of the second guide pipe corresponds to the other half of the feed outlet at the bottom of the small sample mixing device;
a connecting plate is arranged between the small sample mixing device and the bipartite, the lower end of the small sample mixing device is fixedly connected with the upper end of the connecting plate, the upper end of the bipartite is fixedly connected with the lower end of the connecting plate, and openings are arranged at positions of the connecting plate corresponding to a discharge hole at the bottom of the stirring cylinder and a feed inlet at the upper end of the bipartite for a sample to pass through;
the sample mixing device comprises a stirring barrel, an end cover is fixed at the upper end of the stirring barrel, a first driving device is fixed on the end cover, a feed inlet is further formed in the end cover, a stirring shaft is arranged in the stirring barrel, the stirring shaft is vertically arranged in the stirring barrel, the upper end of the stirring shaft penetrates through a through hole formed in the end cover and is fixedly connected with an output shaft of the driving device, the lower end of the stirring shaft is suspended, and stirring blades are arranged at the lower end of the stirring shaft; the first driving device is a motor;
The stirring barrel is conical, and is large in upper part and small in lower part; the lower end of the stirring shaft is provided with a plurality of stirring blades which are uniformly distributed for 360 degrees, the stirring blades are arranged on a fixed ring, the fixed ring is sleeved on the stirring shaft, and the fixed ring is fixedly connected with the fixed ring through a pin shaft; at least one stirring blade is arranged on each fixed ring, and at least one fixed ring is arranged at the lower end of the stirring shaft; the stirring blade is formed by folding a square sheet-shaped blade, the folding edge and two long edges of the square sheet-shaped blade are respectively provided with an intersection point, and the length of the folding edge is longer than that of the short edge of the square sheet-shaped blade;
the lower end of the stirring cylinder is fixedly provided with a fixed plate, and the fixed plate at the lower end of the stirring cylinder is fixedly connected with the connecting plate through a bolt; the fixing plate is provided with screw holes, and the connecting plate is provided with screw holes corresponding to the screw holes arranged on the fixing plate;
a gate device is arranged at a discharge hole at the bottom of the small sample mixing device; the gate device comprises a gate plate for sealing a discharge hole at the bottom of the sample mixing device and a second driving device for driving the gate plate to move, an output shaft of the second driving device is fixedly connected with the gate plate, a chute for installing the gate plate is arranged on the upper end surface of the connecting plate, the gate plate is embedded into the chute of the connecting plate and is in sliding fit with the connecting plate, and the gate plate blocks an opening on the connecting plate; the gate plate is provided with a vertical turning surface for fixedly connecting with an output shaft of the second driving device; the second driving device is fixed on the lower end face of the connecting plate; the upper end of the first guide pipe is fixedly connected with the upper end of the second guide pipe to form a bipartite device with an inverted Y-shaped structure.
5. The system according to claim 1, wherein: the sampling module comprises a sampler, a sample transmission belt and a collecting hopper, wherein the sampler is used for taking samples from a transport carrier according to a sampling scheme sent by a system control unit; the sample conveying belt is connected between the sampler and the collecting hopper and is used for conveying each batch of raw fuel samples collected by the sampler to the collecting hopper for temporary storage, and a controller of the sampling module controls the bottom gate of the collecting hopper to be automatically opened after all the batches of raw fuel samples are collected, so that a large sample falls into the sample preparation module; the sampling points of the automobile and the train are provided with spiral samplers, and the sampling points of the belt are provided with straight line or rotary cutting samplers; the bottom gate of the collecting hopper of the sampling module is respectively communicated with the feed inlet of the big sample mixing device of the sample preparation module and the feed inlet of the primary crushing device through three-way pipelines, and the on-off switching of the two pipelines is realized through a control valve arranged on the pipelines.
6. The system according to claim 1, wherein: the sample collection module comprises a sealing device, a sample bottle temporary storage device, a marking device and a plurality of sample bottles, wherein the sample bottle temporary storage device is used for arranging and queuing the plurality of sample bottles to wait for loading; the sample preparation industrial robot is used for clamping a sample bottle, bottling the prepared analysis sample and the prepared inventory sample, and sealing and encrypting the prepared analysis sample and the prepared inventory sample by a sealing device; the identification device is used for reading the code identification of the sample bottle and inputting the code identification information of the sample bottle and the sample information corresponding to the code identification information into the control system of the sample collecting module; each sample corresponds to a unique coded identifier.
7. The system according to claim 1 or 2, characterized in that: the sample discarding module of the sampling integrated unit utilizes a sample discarding barrel to buffer samples, the sample discarding barrel is provided with a blanking gate, and after positive sample preparation success is determined, the corresponding sample discarding gate is automatically opened, and the samples are automatically discarded to a waste bin to be recovered; the sample preparation industrial robot is used for collecting the same batch of discarded samples in the same barrel.
8. The system according to claim 1, wherein: the analysis and test unit comprises an industrial analyzer, a sulfur determination instrument, a calorimeter and a sample distribution device, wherein the industrial analyzer, the sulfur determination instrument, the calorimeter, the sample distribution device and the pneumatic sample delivery receiving cabinet are distributed annularly around the test industrial robot, and sample materials are transferred among the industrial analyzer, the sulfur determination instrument, the calorimeter, the sample distribution device and the pneumatic sample delivery receiving cabinet through the test industrial robot; the sample distribution device is used for realizing automatic uncovering and pouring of an analysis sample bottle, automatic sampling, automatic weighing and automatic filling of an analysis vessel by means of an analysis industrial robot; the industrial analysis instrument, the sulfur determination instrument and the calorimeter are used for automatically testing the quality data of ash, volatile matters, total sulfur and heat value of the samples sent by the industrial analysis robot and uploading the tested data to the system control unit; the sample after analysis is poured into a waste collection bucket by the assay industrial robot to be recovered.
9. The system according to claim 1, wherein: the pneumatic sample sending unit comprises a pneumatic sample sending power station, a pneumatic sample sending cabinet and a pneumatic sample receiving cabinet, and the pneumatic sample sending cabinet is connected with the pneumatic sample receiving cabinet through a pneumatic sample sending pipeline; the pneumatic sample feeding power station is used for providing conveying power for pneumatic sample feeding; the pneumatic sample sending and sending cabinet is used for transmitting the analysis sample bottle packaged by the collecting and manufacturing integrated unit to the pneumatic sample receiving cabinet through a conveying pipeline; the sample collection module of the sampling integrated unit and the pneumatic sample delivery sending cabinet are used for transferring sample materials through a sample preparation industrial robot; the pneumatic sample sending receiving cabinet is used for receiving an analysis sample bottle and transmitting the analysis sample bottle to the analysis and test unit for quality analysis through the test industrial robot; the pneumatic sample sending cabinet is used for transmitting the stored and checked sample bottles packaged by the collecting and manufacturing integrated unit to the storage unit through the conveying pipeline.
10. The system according to claim 1, wherein: the storage unit is responsible for automatically completing the receiving, storing and extracting of the check sample and setting the expiration and automatic discharging of the storage time according to the quality check and the recheck period of the raw fuel, and also has the functions of automatically transferring out a sample bottle, storing data and managing; the storage unit is automatically abandoned to a waste bin to be recovered; the storage unit also designs a storage bin of the storage unit according to the storage sample quantity and the storage time.
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| CN102680720A (en) * | 2012-04-26 | 2012-09-19 | 赛摩电气股份有限公司 | Modular coal automatic sample preparation analysis system and method |
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| CN203455204U (en) * | 2013-08-23 | 2014-02-26 | 南昌光明化验设备有限公司 | Unattended laboratory ore sample preparation system |
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| CN107941578A (en) * | 2017-11-14 | 2018-04-20 | 中冶南方工程技术有限公司 | A kind of automatic intelligent sample-preparing system and method |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN102680720A (en) * | 2012-04-26 | 2012-09-19 | 赛摩电气股份有限公司 | Modular coal automatic sample preparation analysis system and method |
| CN103424297A (en) * | 2013-08-23 | 2013-12-04 | 南昌光明化验设备有限公司 | Unattended laboratory ore sample preparation system |
| CN203455204U (en) * | 2013-08-23 | 2014-02-26 | 南昌光明化验设备有限公司 | Unattended laboratory ore sample preparation system |
| CN107643202A (en) * | 2017-11-14 | 2018-01-30 | 中冶南方工程技术有限公司 | A kind of fully-automatic intelligent sample-preparing system and method |
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