CN110773454A

CN110773454A - Intelligent dry-method waste rock discharge system based on true dual-energy X-ray

Info

Publication number: CN110773454A
Application number: CN201911094295.2A
Authority: CN
Inventors: 张勇; 朱金波; 朱宏政; 冯岸岸; 尹建强; 史苘桧; 周伟; 张涛
Original assignee: Anhui University of Science and Technology
Current assignee: Anhui University of Science and Technology
Priority date: 2019-11-11
Filing date: 2019-11-11
Publication date: 2020-02-11

Abstract

The invention relates to the field of coal dressing and gangue discharge, in particular to an intelligent dry gangue discharge system based on true dual-energy X-ray. The invention comprises a feeding mechanism, a conveying mechanism, an identification mechanism and a sorting mechanism. The feeding mechanism consists of a feeding funnel and a spraying desliming device, wherein the outer part of the feeding funnel is in an inverted cone shape, and a wear-resistant porcelain plate capable of reducing the abrasion of the wall surface of the funnel is laid in the feeding funnel; the spraying desliming device consists of a spraying pipe and a high-frequency sieve; the conveying mechanism consists of an electronic belt scale for monitoring the feeding amount in real time, an electromagnetic iron remover for reducing impurity pollution, a belt cleaner for cleaning fine-grained materials and a queuing device capable of forming a plurality of regular coal flows; the identification mechanism consists of an X-ray generator which generates different intensities, a detector which receives X-rays, an imaging upper computer, a BP neural network and an isolation lead room; the sorting mechanism consists of a positioning device, a mechanical arm and a PLC control cabinet. The invention has strong adaptability to coal types, realizes intelligent identification, has high identification accuracy and reduces coal dust pollution.

Description

Intelligent dry-method waste rock discharge system based on true dual-energy X-ray

Technical Field

The invention relates to the field of dry coal preparation of coal preparation plants, in particular to an intelligent dry gangue discharge system based on true dual-energy X-ray

Background

With the annual increase of the coal mining amount, the coal resources with high quality grade are almost mined and used up, and the coal resources are developed in the direction of 'poor, fine and miscellaneous'. In order to improve the quality of coal, the coal preparation plant realizes the full-grain-level washing and separation of the coal at present. The current mainstream coal washing method comprises two methods of wet coal separation and dry coal separation, and for the wet coal separation, the dense medium coal separation becomes a leading process, the precision is higher, but the defects are obvious, the medium removal dehydration process is complex and the water consumption is large, and a subsequent coal slime water treatment process is needed; for dry coal separation, mainly air dense medium fluidized bed dry coal separation, air separation, composite dry separation, ray coal separation and the like, water is not needed, and the process is simple, so that the method becomes a research hotspot once, but compared with dense medium coal separation, the method has the advantages of low separation precision and serious air pollution, so that the use range is small, and the method is only limited to water-deficient areas in northwest China. Along with the implementation of national energy-saving emission-reduction and green mining policies and the long-term development of the ray technology, the gamma-ray and X-ray coal separation technology enters the sight of coal separation workers again, particularly, partial ray coal separation equipment is applied on site, although a certain effect is achieved, the defect is obvious, firstly, the gamma-ray is mostly selected as the ray by the equipment, although the penetrating power is strong, the source management is difficult, the residual gamma-ray can bring radiation injury to the body of a maintenance worker, secondly, the thickness effect can be brought by partial equipment due to the fact that the pseudo dual-energy X-ray is adopted for source safety and cost saving, the identification precision of the equipment on coal and gangue is greatly reduced, thirdly, the gangue is separated by adopting a high-pressure air valve for blowing, the service life of the equipment is short and the later maintenance cost is high due to frequent opening/closing of the air valve, and the blowing force of the air flow is limited, the separation effect on the extra-large raw coal is poor, and the application and popularization of the ray coal separation technology are limited due to the existence of the problems.

Disclosure of Invention

In order to solve the problems of difficult management of a gamma ray source based on a ray coal separation device, low identification precision of pseudo dual-energy X rays and quick abrasion of a separation device, the invention designs an intelligent dry-method waste rock discharge system based on true dual-energy X rays, which integrates feeding, conveying, identifying and separating mechanisms into a whole, has the advantages of easy management of the source, high identification and separation precision, high automation degree and the like, and can be used for the dry separation of the waste rock before selection and the raw coal in a coal preparation plant.

In order to achieve the purpose, the invention adopts the following technical scheme:

an intelligent dry-method waste rock discharge system based on true dual-energy X-ray comprises the following components:

the feeding mechanism consists of a feeding hopper and a spraying desliming device; the feeding funnel is externally inverted cone-shaped, a wear-resistant porcelain plate is laid in the feeding funnel, so that the abrasion of high-hardness materials such as gangue and the like on the funnel wall can be reduced, the service life of the feeding funnel is prolonged, the upper part of the funnel is provided with a feeding hole connected with a crude coal feeding belt in the well, the lower part of the funnel is provided with a discharging hole connected with a spraying desliming mechanism, the spraying desliming device consists of a spraying pipe and a high-frequency sieve, the high-frequency sieve is divided into two sections, the width of a front section sieve seam is 30mm, the front section sieve seam and the spraying pipe are combined to play a role in grading desliming, the coverage of fine mud on the surface can be reduced, the accuracy of an identification system is improved, the rear section sieve seam is 0.5mm, a dehydration effect is achieved, the scattering effect of moisture on the surface of raw coal on X rays;

the conveying mechanism consists of an electromagnetic iron remover, a conveying belt, an electronic belt scale, a belt cleaner and a queuing and distributing device; the bottom of the conveying belt is provided with an electronic belt scale which can monitor the feeding amount in real time; the electromagnetic iron remover is arranged on the head of the conveyer belt and is mainly used for reducing the pollution of large sundries, particularly ironworks, to materials and the damage of the sundries to the belt and preventing the occurrence of accidental shutdown; the belt cleaner is arranged at the tail of the belt conveyor and used for cleaning fine materials, so that the wear rate of the conveying belt is further reduced, and the service life of the conveying belt is prolonged; the queuing device is arranged above the belt, a plurality of coal gangue channels are formed by polyurethane plates, raw coal can form a plurality of regular coal flows after passing through the queuing device, a subsequent sorting mechanism is convenient to separate coal gangue, and the queued coal flows enter the identification mechanism for identification;

the identification mechanism mainly comprises an X-ray generator, an X-ray detector, an imaging upper computer, a BP neural network and an isolation lead room; the X-ray generators are divided into two groups, can generate rays with two intensities, are powered by a 220V conventional power supply, wherein the intensity of high-energy rays is 160kV, the intensity of low-energy rays is 90kV, and the X-ray generators are characterized in that the X-ray generators stop emitting rays after power failure, have no ray residues and cannot cause damage to the bodies of inspection workers; the X-ray detectors are divided into two groups, wherein the low-energy X-ray detector receives low-energy X-ray signals, the high-energy X-ray detector receives high-energy X-ray signals, the X-ray detector adopts a flat plate detector, the scintillator adopts cesium iodide materials, and the combination of the two groups of X-ray generators and the two groups of X-ray detectors can eliminate the thickness effect and improve the identification accuracy; the imaging upper computer is a microcomputer actually, the core of the imaging upper computer is imaging software, digital signals from an X-ray detector can be received and converted into gray level images through a series of operations of smoothing, filtering, noise reduction, reconstruction and the like, characteristic values are extracted, and therefore coal and gangue are identified; the BP neural network is an artificial neural network based on a BP algorithm, is divided into an input layer, an output layer and a hidden layer, has a self-learning function, can capture the nonlinear relation between the input layer and the output layer under the condition that the mutual relation between the input layer and the output layer is not determined, can be used for automatically learning the characteristics of coal and gangue, and further improves the identification accuracy of the coal and gangue; keep apart the protecting sheathing that lead house was made for the stereotype of inside lining 2mm thickness, install in the X ray generator outside, can keep apart X ray at X ray generator during operation to play the isolation guard action, avoid the radiation of X ray, raw coal divide into coal and waste rock after identification mechanism's discernment, get into sorting mechanism and accomplish the separation.

The sorting mechanism mainly comprises a positioning device, a mechanical arm and a PLC control cabinet; the positioning device is essentially a photoelectric sensor, the upper computer transmits the position information of the sorted materials to the photoelectric sensor, and when the materials reach the photoelectric module, the photoelectric sensor transmits the information to the PLC control cabinet in real time; the PLC control cabinet is mainly used for receiving instructions of an upper computer and controlling the action of a lower computer, and can be used for controlling the starting and stopping of an X-ray radiation source, controlling the starting and stopping and rotating speed of a belt motor, controlling the action of a manipulator and the like; the manipulator is hydraulically driven, is controlled by PLC instructions, is arranged on two sides of the belt and replaces manual selection; and a proximity sensor is arranged on the manipulator, and when the sorted materials are close to the manipulator, the manipulator grabs the materials to the product chute to complete the sorting of the coal and the gangue.

The invention has the beneficial effects that:

1) the feeding mechanism, the conveying mechanism, the recognition mechanism and the sorting mechanism jointly form an intelligent dry waste rock discharging system, an advanced BP neural network is adopted for recognition and learning, the adaptability to coal types is strong, intelligent recognition is realized, the PLC is adopted for controlling the operation of the whole system, the personnel attendance is not needed, automatic sorting is realized, manual waste rock sorting can be replaced, the labor input and the wrong sorting and missing caused by human factors are greatly reduced, the sorting efficiency is improved, and the production cost is saved.

2) The X-ray radiation source is adopted, no ray remains after power failure, and the lead room protection effect is added, so that radiation to a human body is avoided, and the problem that the radiation source is difficult to treat is solved; the real dual-energy X-ray imaging system is adopted for identification, so that the thickness effect can be eliminated, the identification accuracy is improved, the content of the gangue entering a main selection system is reduced, the argillization phenomenon of the gangue and the wear rate of equipment can be reduced, and the pressure of the slime water treatment system and the equipment maintenance cost are reduced.

3) The manipulator is adopted to replace the traditional high-pressure air valve for spraying to perform material separation, the defect that the service life of the high-pressure air valve is short can be overcome, the service life of the separation equipment is prolonged, the coal dust pollution can be reduced, and the environment protection effect is achieved.

Drawings

FIG. 1 is a block diagram of the system of the present patent;

FIG. 2 is a top plan view of the queuing distribution apparatus;

FIG. 3 is a diagram of a BP neural network architecture;

the correspondence between the illustrated structures and the names of the components of the present invention is as follows:

1-feeding hopper 2-spray pipe 3-high frequency sieve 4-electromagnetic iron remover 5-conveyer belt 6-electronic belt scale 7-belt cleaner 8-queuing material distribution device 9-high energy X-ray generator 10-high energy X-ray detector 11-low energy X-ray generator 12-low energy X-ray detector 13-imaging upper computer 14-isolation lead room 15-positioning device 16-proximity sensor 17-manipulator 18-PLC control cabinet 19-spray desliming device 20-X-ray imaging device 21-BP neural network

Detailed Description

The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

The embodiment of the invention is applied to an intelligent dry coal preparation system of a coal preparation plant:

as shown in the figure, the intelligent dry-method gangue discharge system based on the true dual-energy X-ray comprises the following components:

the feeding mechanism (A) comprises a feeding hopper (1) and a spraying desliming device (19); feed hopper (1) outside is the back taper, wear-resisting porcelain plate has been laid to inside, hopper upper portion connects crude coal feed belt in the pit for the feed inlet, the hopper lower part connects for the discharge gate and sprays desliming device (19), the crude coal gets into by feed hopper (1) and sprays desliming device (19), it comprises shower (2) and high frequency sieve (3) to spray desliming device (19), high frequency sieve (3) divide two sections, the material gets into first half and sprays the desliming earlier, reduce the fine mud on crude coal surface and cover, the undersize gets into raw coal primary election system, the oversize gets into the high frequency sieve back end and dewaters, reduce the water on raw coal surface's scattering effect to X ray, latter half undersize gets into coal slime water processing system, the oversize after the dehydration gets into conveying mechanism (B).

The conveying mechanism (B) comprises an electromagnetic iron remover (4), a conveying belt (5), an electronic belt scale (6), a belt cleaner (7) and a queuing and distributing device (8); the dehydrated oversize materials enter a conveying belt (5), an electromagnetic iron remover (4) is installed at the head of the conveying belt (5), iron product impurities in a coal flow can be removed, a belt sweeper (7) is installed at the tail of the belt conveyor and used for cleaning fine materials and reducing pollution of fine coal slime to an image background, an electronic belt scale (6) is installed at the bottom of the conveying belt and can monitor the feeding amount in real time, a queuing and distributing device (8) is installed above the conveying belt (5), a plurality of coal gangue channels are substantially formed by polyurethane plates, and raw coal on the belt can form a plurality of regular coal flows after being set by the queuing and distributing device and then enters an identification mechanism (C) for identification.

The identification mechanism (C) comprises an X-ray imaging device (20), an imaging upper computer (13), a BP neural network (21) and an isolation lead room (14); the X-ray imaging device (20) comprises an X-ray generator and an X-ray detector, wherein the X-ray generator is divided into two groups, namely a high-energy X-ray generator (9) and a low-energy X-ray generator (11) which can generate rays with the intensities of 160k and 90kV respectively, the X-ray detector is also divided into two groups, namely a high-energy X-ray detector (10) and a low-energy X-ray detector (12) which respectively receive high-energy X-ray signals and low-energy X-ray signals, the high-energy X-ray generator (9) and the high-energy X-ray detector (10) form a high-energy imaging section, the low-energy X-ray generator (11) and the low-energy X-ray detector (12) form a low-energy imaging section, an isolation lead room (14) is arranged outside each group of X-ray imaging mechanism and can isolate X-rays when the X-ray generator works and avoid ionizing radiation, and, the X-ray intensity is attenuated to different degrees, the corresponding high-energy and low-energy X-ray detectors receive the attenuated X-ray signals and transmit the attenuated X-ray signals to the imaging upper computer (13), the imaging upper computer (13) carries out smoothing, filtering, noise reduction, reconstruction and other operations on the received X-ray signals to convert the X-ray signals into gray level images, characteristic values such as gray level values, texture characteristics and material attribute values are extracted and identified through a BP (back propagation) neural network (21), the three characteristic values enter an input layer of the neural network, an identification result can be derived from an output layer through calculation of a BP algorithm of a hidden layer, namely, the materials are distinguished into coal and gangue, and the identified coal and gangue enter a sorting mechanism to complete separation (D).

The sorting mechanism (D) comprises a positioning device (15), a manipulator (17) and a PLC control cabinet (18); supposing that the gangue is the sorted material in the patent, after the material is identified as the gangue by a neural network of an imaging mechanism, the position information of the gangue is transmitted to a positioning device (15) in real time, and when the gangue reaches the vicinity of the positioning device, the real-time position information of the gangue is transmitted to a PLC control cabinet (18); at the moment, the PLC control cabinet (18) receives an instruction of an upper computer and controls the mechanical arms (17) on two sides of the belt to act, when a proximity sensor (16) on each mechanical arm judges that the gangue approaches, the manipulator (17) grabs the gangue to a gangue chute, when materials are identified as clean coal by a neural network of an imaging mechanism, position information of the materials is not shared in real time, the manipulator (17) does not act, the clean coal is freely horizontally thrown at the tail of the belt and enters the clean coal chute, so that separation of the coal and the gangue is completed, in order to prolong the service life of the manipulator, the manipulator can be controlled to act according to the content of the medium coal and the gangue in the materials, when the gangue content is low, the manipulator clamps the gangue, when the gangue content is high, the manipulator clamps the coal, and the PLC control instruction can be written according to actual conditions.

In conclusion, the invention provides an intelligent dry-method waste rock discharge system based on true dual-energy X-ray, which integrates feeding, conveying, identifying and sorting into a whole, adopts a BP neural network and a PLC to carry out self-learning identification and sorting respectively, has the advantages of accurate identification, efficient sorting, high intelligent degree and the like, and provides a good sorting environment for the subsequent raw coal main washing process.

Claims

1. The utility model provides an intelligence dry process waste rock system of arranging based on true dual energy X ray which characterized in that: the outer part of the feeding funnel (1) is in an inverted cone shape, and the inner side wall is laid with a wear-resistant porcelain plate, so that the abrasion of high-hardness materials such as waste rocks and the like to the funnel wall can be reduced; the upper part of the feeding funnel (1) is provided with a feeding hole and is connected with an underground raw coal feeding belt; the lower part of the feeding funnel (1) is provided with a discharge hole and is connected with a spraying desliming device (19), the spraying desliming device (19) consists of a spraying pipe (2) and a high-frequency sieve (3), the high-frequency sieve (3) is divided into two sections, the width of a sieve seam at the front section is 30mm, and the high-frequency sieve and the spraying pipe (2) are combined to play a role in grading desliming; the screen seam at the rear section of the high-frequency screen (3) is 0.5mm, the dewatering effect is achieved, the scattering effect of moisture on the surface of raw coal on X rays is reduced, the transmission effect of the X rays is enhanced, undersize materials of the high-frequency screen (3) are fed into a raw coal main washing system, and oversize materials are fed into the conveying mechanism.

2. The intelligent dry waste rock discharging system based on the true dual-energy X-ray according to claim 1, characterized in that: the conveying mechanism consists of a conveying belt (5), the conveying belt (5) is connected with a screen at the rear section of the high-frequency screen (3) in the feeding mechanism, and an electronic belt scale (6) is arranged below the conveying belt (5) for monitoring the feeding amount in real time; an electromagnetic iron remover (4) is arranged at the front end of the conveying belt (5), so that the pollution of iron-containing impurities in the raw coal to ore dressing is eliminated, and the damage to a belt is reduced; the tail end of the conveying belt (5) is provided with a belt sweeper (7) for sweeping fine materials, so that the wear rate of the conveying belt (5) is further reduced, and the service life of the conveying belt (5) is prolonged; the queuing and distributing device (8) is arranged above about one third of the front end of the conveying belt (5), a plurality of coal gangue channels are formed by polyurethane plates, raw coal can form a plurality of regular coal flows after passing through the queuing and distributing device (8), a subsequent sorting mechanism can conveniently separate coal gangue, and the coal flows in the ordered arrangement enter the recognition mechanism for recognition.

3. The intelligent dry waste rock discharge system based on the true dual-energy X-ray is characterized in that: the identification mechanism mainly comprises an X-ray generator, an X-ray detector, an imaging upper computer (13), a BP neural network (21) and an isolation lead room (14); the X-ray generator is arranged in the middle of the conveying belt (5) and is about 50-70cm away from the upper surface of the conveying belt (5); the X-ray generator is divided into two groups, can generate rays with two intensities, is powered by a 220V conventional power supply, wherein the intensity of high-energy rays is 160kV, the intensity of low-energy rays is 90kV, and the X-ray generator is characterized in that the X-ray generator stops emitting rays after power failure, has no ray residue and cannot cause damage to the body of an inspection worker; the X-ray detectors are arranged below the conveying belt (5), are also divided into two groups and are respectively opposite to the two groups of X-ray generators, wherein the low-energy X-ray detector (12) receives signals of the low-energy X-ray generator (11), the high-energy X-ray detector (10) receives signals of the high-energy X-ray generator (9), the X-ray detector adopts a flat plate detector, and the scintillator adopts cesium iodide material; the imaging upper computer (13) is a microcomputer, the core of the imaging upper computer is imaging software, and the imaging upper computer can receive digital signals from an X-ray detector and convert the digital signals into gray images through a series of operations of smoothing, filtering, noise reduction, reconstruction and the like; the BP neural network (21) is an artificial neural network based on a BP algorithm, is divided into an input layer, an output layer and a hidden layer, has a self-learning function, can capture the nonlinear relation between the input layer and the output layer under the condition that the mutual relation between the input layer and the output layer is not determined, and can be used for automatically learning the characteristics of coal and gangue; keep apart lead house (14) and install in the X ray generator outside for the protective housing that lead plate that the inside lining 2mm is thick made, can keep apart the X ray at X ray generator during operation to play the isolation guard action, avoid the radiation of X ray, raw coal is divided into coal and waste rock after identification mechanism's discernment, gets into sorting mechanism and accomplishes the separation.

4. The intelligent dry waste rock discharging system based on the true dual-energy X-ray according to the claims 1, 2 and 3, is characterized in that: the sorting mechanism mainly comprises a positioning device (15), a manipulator (17) and a PLC control cabinet (18); the positioning device (15) is a photoelectric sensor in essence, the upper computer transmits the position information of the sorted materials to the photoelectric sensor, and when the materials reach the photoelectric module, the photoelectric sensor transmits the information to the PLC control cabinet (18) in real time; the PLC control cabinet (18) is externally connected with the imaging upper computer (13) and is mainly used for receiving instructions of the imaging upper computer (13), controlling the starting, stopping and rotating speed of the belt motor, controlling the actions of the manipulator (17) and the like; the manipulator (17) is hydraulically driven, is controlled by PLC instructions, is arranged on two sides of the belt and replaces hand selection; and a proximity sensor (16) is arranged on the manipulator (17), and when the sorted materials are close to, the manipulator (17) grabs the materials to the product chute to complete the sorting of the coal and the gangue.