CN113291867A - Railway open wagon rapid constant-volume loading system and method - Google Patents
Railway open wagon rapid constant-volume loading system and method Download PDFInfo
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- CN113291867A CN113291867A CN202110729140.2A CN202110729140A CN113291867A CN 113291867 A CN113291867 A CN 113291867A CN 202110729140 A CN202110729140 A CN 202110729140A CN 113291867 A CN113291867 A CN 113291867A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G67/00—Loading or unloading vehicles
- B65G67/02—Loading or unloading land vehicles
- B65G67/04—Loading land vehicles
- B65G67/06—Feeding articles or materials from bunkers or tunnels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G65/00—Loading or unloading
- B65G65/30—Methods or devices for filling or emptying bunkers, hoppers, tanks, or like containers, of interest apart from their use in particular chemical or physical processes or their application in particular machines, e.g. not covered by a single other subclass
- B65G65/32—Filling devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G69/00—Auxiliary measures taken, or devices used, in connection with loading or unloading
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Abstract
The invention relates to a railway open wagon rapid constant volume loading system and a method, comprising the following steps: the device comprises a storage bin, a feeder, a belt conveyor, a metering bin with a discharge gate, and a loading chute which is arranged on a train travelling line and can stretch or swing to lift, wherein the storage bin, the feeder, the belt conveyor, the metering bin with the discharge gate, and the loading chute are connected in sequence, a material volume monitoring sensor group is arranged at the head of the belt conveyor, and a material level height sensor group is arranged in the metering bin. The invention utilizes the material volume monitoring sensor group to calculate the volume of the materials on the conveyer belt, and utilizes the material level height sensor group in the measuring bin to accurately calculate the bulk material volume output by the measuring bin, controls the material volume output by the measuring bin to be equal to the volume of the planned loading amount of the current loading, changes the mode of measuring the loading amount of the materials by using weight in the traditional loading station, can fully utilize the volume of a carriage, avoids the scattering caused by excessive loading, greatly increases the discharging speed, improves the loading efficiency, and simultaneously reduces the conveying cost of a steel structure frame and a belt conveyor because of abandoning a quantitative bin.
Description
Technical Field
The invention relates to a system and a method for quickly fixing the volume and loading bulk materials into a railway open wagon, in particular to a transport mechanical system and a method, and particularly relates to automatic loading equipment and a method for bulk materials.
Background
The traditional automatic loading system for bulk materials is based on quantitative weighing, namely a quantitative loading system. The quantitative loading system usually needs to be provided with a special weighing container, after materials are placed into the weighing container, the materials are statically weighed and then loaded, and the loading amount of the materials is determined by measuring the weight value. The advantage of this loading method is that weighing is a simple metering method, and is widely used and widely accepted in the commercial sale of bulk materials. And the instruments used for weighing are various in types, the technology is mature, and a great choice is provided. In fact, weighing has become an absolute measure in the trade of bulk goods, and no weighing people even know how to trade bulk goods. In modern society life, people only use a metering mode such as volume and the like for a few commodities such as liquid commodities such as oil and the like, and only use a weighing mode for commodity transaction of solid bulk materials. Train loading stations that use weighing as the measurement mode have a very troublesome problem: when the train is a mixed train, namely the train is formed by various types of carriages, the loading station only measures the loading amount according to the tonnage of each carriage, and because the volumes of the carriages are different and the specific gravity of bulk materials is different, the phenomena that some carriages are not fully loaded, the capacity of the carriages cannot be fully utilized, and some carriages are over-fully loaded or even scattered occur, so that the loading amount does not meet the requirements, and economic disputes are generated.
Another problem with a quantitative loading station is: as mentioned above, weighing requires the provision of a weighing container, and therefore, conventional automated bulk material loading stations are provided with a weighing bin (alternatively referred to as a dosing bin) and a buffer bin for discharging the bulk material to the weighing bin, and the dosing bin and the buffer bin are generally vertically arranged to deliver the bulk material by gravity. The overall height of the loading station is increased by the vertical arrangement mode, and the increase of the overall height of the loading station means the increase of the height of the steel structure frame, so that the overall cost of the loading station is increased. How to fully utilize the capacity of the carriage and avoid scattering and simplify the loading system is a problem to be solved.
Disclosure of Invention
In order to overcome the problems in the prior art, the invention provides a railway open wagon rapid constant volume loading system and a railway open wagon rapid constant volume loading method. The system and the method abandon the mode of weighing and measuring the loading amount, measure the volume of the carriage as the loading, fully utilize the easiness of the carriage, simultaneously avoid scattering, simplify the structure of the loading station and reduce the steel frame of the loading station.
The purpose of the invention is realized as follows: a railway gondola car quick constant volume loading system includes: the device comprises a storage bin, a feeding machine, a belt conveyor, a metering bin with a discharge gate, and a loading chute which is arranged on a train travelling line and can stretch or swing to lift, wherein the head of the belt conveyor is provided with a material volume monitoring sensor group, and the metering bin is internally provided with a material level height sensor group.
Furthermore, the material volume monitoring sensor group is a laser radar or a video camera and a belt speed sensor, or the combination of the laser radar, the video camera and the belt speed sensor.
Further, the material level height sensor group is a laser radar or a video camera or a combination of the laser radar and the video camera.
Furthermore, the material level height sensor group also comprises at least one rod type material level height sensor for monitoring the highest material level and the lowest material level.
Furthermore, a train carriage position monitoring sensor group is arranged on the train advancing route.
Furthermore, a material density detection device is arranged on one side of the belt conveyor.
A railway truck rapid loading method using the system comprises the following steps:
step 1, starting: the system starts, and the linking host computer obtains current loading data, includes: the total loading weight, the material density, the number of the carriages formed by the train, the sequence and the model of the carriages and the volume of the carriages with various models;
and 4, supplementing materials: starting a belt conveyor, continuously conveying materials into a metering bin, simultaneously monitoring the quantity of the materials entering the metering bin through a material volume monitoring sensor group, monitoring the change of the height of the materials in the metering bin through a material level height sensor group, calculating the quantity of the materials in the metering bin, and monitoring the material density through a material density detection device;
Hplan for＝H1-H2+ΔH
Wherein: hPlan forFor measuring the siloThe height of the change of the material pile corresponding to the planned loading amount; h1Measuring the height of the material pile in the bin at the beginning of emptying; h2Measuring the height of the material pairs in the bin when discharging is finished; the delta H is the stacking height of the materials input into the metering bin by the belt conveyor in the discharging process;
when reaching HPlan forWhen the height of the material pile is high, the discharging gate is closed to retract the chute, and discharging of a carriage is completed;
and 7, judging: and (4) judging whether the carriage is the last carriage or not, if yes, ending the loading process, and if not, returning to the step 5 to perform the next emptying cycle.
Further, the method for obtaining the material density in the step 2 comprises: the method comprises the steps of obtaining original data of current materials from an upper computer, sampling on a belt conveyor for real-time monitoring, and correcting the original data by using monitored data.
Further, the step 3 of compiling the loading plan includes the following sub-steps:
substep 1, calculating the total weight and total volume: calculating the total train load capacity and the total train volume of all the carriages of the train together according to the parameters of all the carriages, and calculating the total material volume planned for loading according to the total material weight planned for loading;
and substep 3, setting the loading capacity of each carriage: and according to the loading capacity of each carriage, setting the material loading volume of each carriage, verifying whether the material loading volume exceeds the carriage capacity, adjusting the material loading amount among the carriages if the material loading volume exceeds the carriage capacity, and finishing the compilation of a loading plan if the material loading volume does not exceed the carriage capacity.
Further, the step 3 of compiling the loading plan includes the following sub-steps:
substep 1, calculating the total weight and total volume: calculating the total train load capacity and the total train volume of all the carriages of the train together according to the parameters of all the carriages, and calculating the total material volume planned for loading according to the total material weight planned for loading;
and substep 3, setting the loading capacity of each carriage: and (4) establishing the weight of the materials loaded in each compartment according to the volume of each compartment, verifying whether the weight of the materials loaded in each compartment exceeds the loading capacity of the compartment, adjusting the loading capacity of the materials in the compartment if yes, and finishing the planning of loading if not.
The invention has the advantages and beneficial effects that: according to the invention, the material volume monitoring sensor group is used for carrying out volume calculation on the materials on the conveying belt, the material level height sensor group in the metering bin is used for accurately calculating the bulk material volume output by the metering bin, and the material volume output by the metering bin is controlled to be equal to the volume of the planned loading amount of the current loading, so that the mode of measuring the loading amount of the materials by using weight in the traditional loading station is changed, the capacity of a carriage can be fully utilized, the scattering caused by excessive loading is avoided, the carriage overload can be prevented, and the potential safety hazard is eliminated. Because the weighing link is not provided, the discharging speed is greatly increased, the loading efficiency is improved, and meanwhile, because a quantitative bin is abandoned and only one layer of material bin is provided, the overall height of the loading station is greatly reduced, and the cost of a steel structure frame and the cost of material conveying of a belt conveyor are reduced.
Drawings
The invention is further illustrated by the following figures and examples.
FIG. 1 is a schematic structural diagram of a system according to a first embodiment and a fifth embodiment of the present invention;
FIG. 2 is a schematic cross-sectional view of materials deposited on a belt conveyor according to a second embodiment of the present invention;
FIG. 3 is a flow chart of a loading method according to a seventh embodiment of the present invention;
fig. 4 is a schematic diagram illustrating a loading metering method according to a seventh embodiment of the present invention.
Detailed Description
The first embodiment is as follows:
the embodiment is a railway open wagon rapid volume-fixing loading system, which is shown in figure 1. The embodiment comprises the following steps: storage silo 1, batcher 2, belt feeder 3, the measuring bin 4 that has ejection of compact gate 401 that connect gradually, install the loading chute 5 that can stretch out and draw back or swing lift on the train route of advance, the belt feeder head be equipped with material volume monitoring sensor group 6, the measuring bin in be equipped with material level height sensor group 7.
The loading station described in this embodiment is an automatic loading station for a train 01 formed by marshalling train wagons of wagons (carriages) with different types, and is certainly also suitable for automatic loading of trains with uniform wagons. The biggest difference from the traditional quantitative loading station is that the loading station has only one layer of storage bins (metering bins), and one weighing bin (or buffer bin) and a corresponding weighing link (or buffer link) are reduced. The height of a steel structure frame of the loading station is greatly reduced by reducing one chamber, and the conveying height of a belt conveyor for conveying materials to the top of a metering chamber is also greatly reduced (the length of the belt conveyor with the same gradient can be reduced, and the conveying power of the belt conveyor is reduced), so that the construction cost and the use cost of the loading station are obviously reduced. More importantly, a weighing link is omitted, the speed of the loading process is increased, and the loading efficiency is obviously improved.
The principle of this embodiment is that the volume change of the materials in the measuring bin is monitored by various accurate sensors, and the loading amount is determined according to the volume change of the materials in the measuring bin. Because the weight and the volume are in a linear relation and can be directly obtained through density calculation, the method for accurately monitoring the volume change of the material by using a modern advanced sensor is mature, and therefore, the material can be completely metered by taking the volume as a metering basis instead of a weighing mode.
The storage bin, the feeder, the belt conveyor and the loading chute are all in traditional forms. The metering bin is required to be a funnel with a conical body at the upper half part and a conical body at the lower half part, and the upper half part is cylindrical with the same upper part and lower part, namely the horizontal cross section is completely consistent in shape, so that the calculation of the volume is simplified. The dosing bin may be cylindrical or rectangular, as well as other polygonal shapes. For example, the hopper of the lower half of the metering bin may be one or more than one, that is, there may be one or more than one discharge hole correspondingly, and the upper half may also be designed to be combined into several cylinders correspondingly, such as: the lower half part is four funnel discharge ports, and the upper half part is connected with a square charging barrel with four corners being round corners.
The key of this embodiment lies in material volume monitoring sensor group and material level height sensor group.
The material volume monitoring sensor group is arranged at the head of the belt conveyor, namely one end of the belt conveyor for outputting materials, and monitors the quantity (volume) of the materials entering the metering bin. The material volume monitoring sensor group can be a laser radar, the material stacking shape stacked on the conveying belt is scanned by laser, the cross section shape of the material stack is calculated according to the material stacking shape, the cross section shape of the material stack is the cross section shape of the material stack stacked on the belt conveyor, which is perpendicular to the moving direction of the belt, and meanwhile, the material volume entering the metering bin is calculated in real time according to the running speed of the belt conveyor by detecting the running speed of the belt conveyor by laser. The method can also be used for performing video image analysis on the materials stacked on the belt conveyor by using a video monitoring mode, namely a 3D camera, so that the cross section shape of the material stack is obtained in real time, and the quantity (volume quantity) of the materials entering the metering bin is calculated in real time. In order to reduce the calculated amount, a speed sensor for monitoring the movement of the belt conveyor can be installed in cooperation with the camera. And a laser radar, a 3D camera and a speed sensor can be simultaneously installed to mutually verify calculation parameters and obtain a more accurate material volume value.
The fill level sensor group is likewise a plurality of sensors, which can generally be a plurality of lidar or 3D cameras, and rod fill level sensors. The height change of the materials in the measuring bin is scanned by the plurality of laser radars or the 3D cameras from different angles, the volume change of the material pile is accurately calculated, and accurate data are provided for the loading quantity. For the accurate height of the material in the effective monitoring measurement storehouse to and minimum and the furthest of material heap, can set up one or more rod-type material level height sensor, from the height of different positions monitoring material levels in the measurement storehouse, avoid appearing the material and cross the problem of low or too high.
In order to ensure that the loading is more accurate, a carriage position monitoring sensor group can be arranged on a train running line (preferably in front of the chute), the position of the carriage is monitored in real time, and the lifting of the chute is closely controlled.
The important factor of the change of the weight and the volume of the material is the density of the material. In general, the density of the material is constant, and the seller usually gives the material density when the commodity material is sold, but in the actual sale process, because the given material density is measured under certain conditions, such as certain compactness (the degree of vibration compaction of the material in the detected volume) and humidity, the material is basically not subjected to vibration compaction but only naturally stacked when the vehicle is actually loaded. For the material with larger particles, the influence of compactness is larger, the given density has larger difference with the compactness in actual loading, and therefore, the material needs to be detected in real time so as to improve the accuracy of volumetric metering. Therefore, sampling facilities can be arranged at the material output part of the belt conveyor, and the sampling facilities are adopted in real time to carry out density detection in real time.
Example two:
the embodiment is an improvement of the first embodiment, and is a refinement of the first embodiment on a material volume monitoring sensor group, where the material volume monitoring sensor group is a laser radar or a video camera and a belt speed sensor, or a combination of a laser radar and a video camera and a belt speed sensor.
The laser radar can be used for accurately scanning the surface of the material, determining the curved surface shape of the material pile and calculating the cross section shape of the material pile according to the curved surface shape. The lower part of the stacking section shape of the stacked material 02 on the belt 301 is determined by a belt tug of the belt conveyor, the belt conveyor is provided with a horizontal supporting belt wheel 302 and two inclined supporting belt wheels 303 and 304 at two sides, as shown in fig. 2, the top curve of the material stacking is obtained from the inclined supporting belt wheel at one side to the inclined supporting belt wheel at the other side through laser radar scanning, and then the section area A can be obtained through calculation.
Using a video camera, a 3D camera can also be used to determine effects similar to lidar.
Laser radar or 3D camera integration may also be used. In practice, multiple radars or cameras may be used to obtain more accurate data by scanning the stack from multiple angles and using the data to verify with each other.
Example three:
the present embodiment is an improvement of the above-mentioned embodiment, and is a refinement of the above-mentioned embodiment regarding to the level height sensor group, and the level height sensor group described in the present embodiment is a laser radar or a video camera or a combination of a laser radar and a video camera.
The material level height sensor group can adopt a laser radar and a 3D video camera to approximately and accurately monitor the change of the height of the material pile in the measuring bin. The material level height sensor group can also adopt a mode of combining a laser radar or a video camera, and can also adopt a rod type material level height sensor which is mainly used for monitoring the lowest material level and the highest material level.
Example four:
the present embodiment is an improvement of the above-mentioned embodiment, and is a refinement of the above-mentioned embodiment with respect to the level height sensor group, and the level height sensor group described in the present embodiment further includes at least one lever level height sensor for monitoring a highest level and a lowest level.
The rod type material level height sensor is also required to be provided with two or more than three rod type material level height sensors, the rod type material level height sensors are arranged at different positions of the metering bin, and the material level heights of the different positions are monitored so as to obtain accurate material level values.
Example five:
the present embodiment is an improvement of the above-mentioned embodiment, and is a refinement of the above-mentioned embodiment regarding the train traveling route, and the train traveling route described in the present embodiment is provided with a train car position monitoring sensor group 8, as shown in fig. 1.
The carriage position monitoring sensor group can adopt a grating group, namely a plurality of gratings are arranged on two sides of a train at intervals to monitor the neutral position between carriages, and the position of the carriage can be calculated to be too accurate through the position of the neutral position.
Example six:
the embodiment is an improvement of the above embodiment, and is a refinement of the above embodiment about a belt conveyor, wherein a material density detection device is arranged on one side of the belt conveyor.
The material density measuring device may be provided with a container of a certain (known) capacity, for example 10cm3The cylindrical barrel body samples the materials which flow out of the belt conveyor head randomly, and the materials are weighed after the cylindrical barrel body is filled, so that the accurate density of the current materials is calculated. It is also possible to use a plate as a container for the contents, with a fixed number (for example 10 cm)3) The materials are naturally dropped on the flat plate to form a conical material pile, and the material pile is scanned through a laser radar or a 3D video camera to obtain the accurate material volume, so that the density of the current materials is accurately obtained.
Example seven:
the embodiment is a railway open wagon rapid loading method using the system of the previous embodiment. The method can be simply expressed as calculating the total loading capacity and the total capacity of the train, comparing whether the current train can safely and efficiently load and transport the cargos or not by calculating the total weight and the total volume of the materials, and distributing the loading capacity and the capacity of each carriage, so that the whole train can balance and properly load all cargos. The loading process uses the capacity of the materials as a metering criterion instead of using the conventional weight as the metering criterion, so that the loading efficiency is better, and the loading is safer.
The method comprises the following specific steps, and the flow is shown in FIG. 3:
step 1, starting: the system starts, and the linking host computer obtains current loading data, includes: the total loading weight, the material density, the number of the carriages formed by the train, the sequence and the model of the carriages and the volume of the carriages with various models.
The general detection when the system is started comprises the steps of detecting each sensor group and carrying out system self-detection, and the step mainly comprises the step of detecting the condition of materials in the system, namely whether the materials exist on the belt conveyor and the quantity of the materials in the metering bin. Another important action after starting is to get link with the upper computer to get each item of data. These data include: various data of materials and various data of trains. The material data includes the particle size, moisture, and, of course, the most important density of the material. The conventional loading station takes weight as a measurement standard, but takes capacity as a measurement standard in the embodiment, and takes weight as a measurement standard before and after loading, that is, two times of conversion between weight and capacity are required, and therefore, accurate density data is required to achieve the purpose of accurate loading.
The initialization is to monitor whether the remaining materials are left in the loading station, calculate the number of the remaining materials, and detect whether each sensor works normally.
The total amount of the materials is the weight which is customary when the train is loadedCalculated, the cars due to the train consist may be various models of cars, such as: the carrying capacity of the open wagon wagons of various models such as C62, C70, C80 and the like is respectively 60 tons, 70 tons and 80 tons, and the capacity of the open wagon wagons is respectively 71m3、77m3、87m3. Once the train is marshalled, the volume and carrying capacity of each carriage is determined, and the carrying capacity and volume of the whole train are determined. The bearing capacity and the carriage volume of carriages of various types are stored in a database, and the total bearing capacity and the total volume of the train can be easily calculated.
The conventional automatic loading method calculates the loading amount according to the bearing capacity (weight of bearing materials) of each carriage. The method for calculating the loading amount in a weighing mode is not reasonable, when the whole train loads the same material, the density of the material is the same (only the density of the material is slightly changed under the influence of the humidity of the material), when the train is loaded, a carriage with large volume can contain more material, if the carriage is filled, the weight of the material borne by the carriage even exceeds the weight borne by the carriage, and the side plates of some carriages are lower and can only contain less material, so that the bearing weight of the carriage cannot be achieved. If the weight is used as the measuring standard for automatic loading conventionally, the carriage with small volume may have the phenomenon of material scattering, and if the weight is used as the measuring standard for automatic loading, the carriage with large volume may have the phenomenon of overload. For example: c62 open wagon, load 60 tons, capacity 71m3If the loading density is 0.85 ton/m3The full coal amount reaches 60.35 tons, and basically meets the load requirement. However, the C70 load capacity was 70 tons and the volume was 77m3If the loading density is 0.85 ton/m3The coal is full, and can only reach 65.45 tons, if the coal is weighed by 70 tons, the coal exceeds the accommodating degree of the carriage, and the material scattering phenomenon can occur.
In order to solve the problem, the loading amount is calculated based on the capacity of the carriage, namely, based on how much material the carriage can accommodate, so that the carriage can be filled as much as possible, and such a loading metering mode is very beneficial to the material with the density less than 1, such as coal, and each carriage can be filled as much as possible, so as to improve the transportation efficiency.
Due to the density rho (unit: ton/m) of the passing material3) The weight of material M (unit: ton) and the volume of material V (in units: m is3) Can be conveniently converted:
as long as the material density value is accurate, the difference generated during the interconversion of the weight and volume of the material is within the allowable range.
Calculating the loading capacity by the train capacity can cause a problem of how to make the volume of the loaded material meet the requirement of the train capacity and meet the loading capacity of the train at the same time. In order to make the weight and volume of the loaded material meet the loading capacity and volume of the train, the carriage capacity (total capacity) and the total loading capacity (total loading capacity) of the whole train can be calculated, and then compared with the total weight and volume of the material planned to be loaded. If the total loading capacity and the total volume which can be carried by the whole train are more than or equal to the total weight and the total volume of the materials of the planned loading capacity, the loading planning process is continued, and then whether the volume and the loading capacity of each compartment accord with the weight and the volume of the materials which can be carried is judged one by one. If the total loading capacity and the total volume which can be borne by the whole train are smaller than the total weight and the total volume of the materials of the planned loading capacity, the total amount of the loading plan needs to be adjusted, for example, the total weight of the loading materials is reduced. That is to say, the weight and the volume of the loading materials are required to meet the requirements, and the loading can be correctly carried out without scattering and overweight loading phenomena.
In the actual loading process, the total loading weight is usually determined by a sales department and a client through a purchase contract, the train formation of the train is determined by a railway department according to the total loading weight, that is, the train is formed according to the total weight specified by the purchase contract, the total weight of the planned loading or the total weight of the train formation is determined by comparison, the volume of the train after formation is also determined, only the volume of the planned loading is related to the density of the materials, the densities of the materials are different (for example, the densities of ore and sand are higher, and the densities of coal are lower), in the same volume, the weights of the materials are different, and only the bulk materials loaded by the same loading station are basically unchanged, so the densities of the materials can be considered to be the same.
According to the analysis, before the train enters the loading station, the total load capacity and the total volume of the marshalled train are determined, the total planned loading capacity can be determined after the product of the total planned load weight and the material density, the total load capacity and the total volume of the train are compared with the total planned load weight and the total planned loading volume, the requirements that the total planned load weight and the total planned loading volume are smaller than the total load capacity and the total volume of the train are met, the judgment of the carriages one by one is carried out to determine whether each carriage meets the requirements that the planned load weight and the planned loading volume are smaller than the load weight and the carriage volume of the carriage, and the load capacity of each carriage is adjusted according to the requirements, so that each carriage meets the requirements of both the load weight and the carriage volume.
The specific method for evaluating the load and volume of the individual cars can be determined from the weight (weight-first) or from the volume (volume-first).
And 4, supplementing materials: the belt conveyor is started, materials are conveyed into the metering bin continuously, the quantity of the materials entering the metering bin is monitored through the material volume monitoring sensor group, the change of the height of the materials in the metering bin is monitored through the material level height sensor group, the quantity of the materials in the metering bin is calculated, and the material density detection device monitors the density of the materials.
The supplement of the materials is continuously carried out in the whole train loading process, and the conveying of the belt conveyor is suspended only when the materials in the metering bin reach the highest material level. Generally, at least one section of wagon is stored in the measuring bin to meet the loading requirement.
The carriage is scanned primarily to determine the exact position of the carriage to determine the exact time the chute is lowered and retracted, which helps to evenly fill the entire carriage with material. When the position of the carriage is confirmed, the type of the carriage which comes to the loading position at present is confirmed to confirm whether the type of the carriage is known as the type of the planned carriage or not, so that the material loss caused by errors is avoided.
HPlan for＝H1-H2+ΔH
Wherein: hPlan forThe height of the change of the material pile in the material metering bin when the loading amount is planned; h1Measuring the height of the material pile in the bin at the beginning of emptying; h2Measuring the height of the material pairs in the bin when discharging is finished; the delta H is the stacking height of the materials input into the metering bin by the belt conveyor in the discharging process;
when reaching HPlan forWhen the height of the material pile is high, the discharging gate is closed to retract the chute, and discharging of a carriage is completed;
the material discharging process is the key of constant volume loading, and the principle of the formula is shown in figure 3. Volume in volume V (m)3) In this embodiment, since the metering bin is a cylinder body with the same height and the horizontal sectional area S of the metering bin is the same height, then:
V＝S×H
therefore, the change of the volume is reflected on the change of the height H of the material pile, and the output of partial volume of the material is reflected on the reduction of the height of the material pile in the measuring bin. The change of the height of the material pile is monitored through the material level height sensor group, so that the volume of material output can be accurately calculated, and the traditional quantitative loading is changed into constant-volume loading.
In the process of constant volume loading,the material level height sensor group can detect the height H of a material pile in the measuring bin when the emptying is started1Measuring the height H of the material pile in the bin when the emptying is finished2And the stacking height delta H of the materials input into the measuring bin by the belt conveyor in the discharging process, as shown in figure 3, the height H of the change of the material stack in the material measuring bin when the loading amount is planned is obtainedPlan for：
HPlan for＝H1-H3
Wherein: the height of a material pile in the metering bin is measured when the discharge gate is closed under the condition that the belt conveyor does not convey materials into the metering bin in the loading process. The formula expresses that in the discharging process, the belt conveyor is in a stopped state, namely materials are not conveyed into the metering bin, and the volume of the materials discharged in the opening process of the discharging gate is the height of a material pile when the gate is opened minus the height of the material pile when the discharging gate is closed.
However, in practice, in the opening process of the discharge gate, the belt conveyor continues to convey materials into the metering bin, namely when the discharge gate is closed, the height of the material pile in the metering bin is not only H3The method also comprises a part of material delta H input into the metering bin by the belt conveyor in the opening process of the gate, namely, when the discharge gate is closed, the height of a material pile monitored by the material level height sensor group is not H3But the actual height H of the stack when the discharge gate is closed2And H is2The method comprises the following steps:
H2＝H3+ΔH
that is to say:
H3＝H2-ΔH
this makes it possible to obtain:
Hplan for＝H1-H3
＝H1-(H2-ΔH)
＝H1-H2+ΔH
Wherein: Δ H is the height of the material pile of the belt conveyor to the material input into the measuring bin during the gate opening:
wherein: the quantity of the delta V is determined by the conveying speed of the belt conveyor:
wherein: a is the sectional area of a material stack on the belt (see figure 2); l is the moving distance of the material on the belt conveyor (see figure 1).
The step is different from the traditional discharging process of the loading station, and a weighing link is not provided. Because the traditional loading process needs weighing, the weighing link utilizes the vehicle running time between two carriages, in order to ensure that sufficient time is provided for discharging and weighing the materials in the quantitative bin, in the actual loading, the running speed of the train can only be reduced, which means that the total loading speed of the train is reduced (the train can not rapidly advance during discharging, but slowly advance between the two carriages), and the loading efficiency is also reduced. In the embodiment, the bottleneck of limiting the speed of the train by weighing is eliminated due to the absence of a weighing link, the ascending and descending speed of the chute is used for limiting the advancing speed of the train, the train can be prevented from colliding with front and rear side plates of a carriage as long as the ascending and descending speed of the chute is proper, the train speed can be improved a lot, the integral loading efficiency of the train is greatly improved, the actual measurement calculation of the train can reach the level of 5000 tons/hour, and the loading efficiency is unimaginable for the traditional quantitative loading station.
And 7, judging: and (4) judging whether the carriage is the last carriage or not, if yes, ending the loading process, and if not, returning to the step 5 to perform the next emptying cycle.
The train is discharged in a cyclic reciprocating process, after one train wagon is discharged, whether the train wagon is the last carriage needs to be judged, and the cyclic reciprocating discharge is carried out until the last carriage is completely loaded.
Example eight:
the present embodiment is an improvement of the above embodiment, and is a refinement of the above embodiment with respect to step 2, and the method for obtaining the material density in step 2 described in the present embodiment includes: the method comprises the steps of obtaining original data of current materials from an upper computer, sampling on a belt conveyor for real-time monitoring, and correcting the original data by using monitored data.
The density parameter of the material in the constant volume loading is very critical, and the accuracy of the material loading is influenced by the accuracy degree of the density parameter, so that a more accurate numerical value is required. The conventional density of a given material is usually measured under ideal conditions, including: the material is relatively closely knit (the sample to be measured is compressed tightly to a certain extent), and humidity is certain (the sample to be measured is made according to certain humidity standard), and these conditions have certain disparity with the material state when the actual loading, for example the material heap is that the free fall nature forms, does not vibrate the compaction, and the humidity state of material also influences the density of material simultaneously. Therefore, the density is monitored in real time in the loading process, and the given conventional density is corrected by using the density data monitored in real time so as to achieve the numerical conversion of the theoretical density and the weight as far as possible and avoid the occurrence of commercial disputes.
Example nine:
this embodiment is an improvement of the above embodiment, and is a refinement of the above embodiment with respect to step 3, and the creating of the loading plan in step 3 described in this embodiment includes the following sub-steps:
substep 1, calculating the total weight and total volume: and calculating the total train load capacity and the total train volume of all the carriages of the train together according to the parameters of all the carriages, and calculating the total material volume of the planned loading according to the total material weight of the planned loading.
The total load capacity and total volume of the train are determined at the time of train formation, and the tandem arrangement of each car is also determined. The planned loading amount (including weight and volume) is also determined in the contract between the sales department and the client, so that the railway department performs train formation according to the requirements of the sales department, and the mode of planning the loading plan is implemented when the railway department performs train formation. However, in practice, the train loading station often cannot control the train formation of the railway department, so that the load capacity and the volume of the train provided by the railway part where the train formation is installed can only be verified before the train loading, and the train loading plan specific to each carriage can be compiled in the verification process.
When the material density is more than 1, the weight of the material is larger, the capacity of the compartment of the open wagon is always larger, the cargo can be loaded as much as possible on the premise of no overload, and the loading capacity is mainly checked at the moment, wherein the loading capacity comprises the total loading capacity of the train and the respective loading capacity of each compartment. When the material density is less than 1, the material weight is small, the capacity of the carriage of the open wagon is not large, and the load capacity has large allowance, so that the capacity of the carriage is mainly checked, the carriage can be filled or even rolled to the top as much as possible, and the load capacity of the carriage is fully utilized.
And substep 3, setting the loading capacity of each carriage: and according to the loading capacity of each carriage, setting the material loading volume of each carriage, verifying whether the material loading volume exceeds the carriage capacity, adjusting the material loading amount among the carriages if the material loading volume exceeds the carriage capacity, and finishing the compilation of a loading plan if the material loading volume does not exceed the carriage capacity.
The loading plan of this embodiment is based on the volume of the car (volume priority), and it is determined that the volume of the car is greater than or equal to the volume of the loaded materials, and it is verified whether the weight of the materials is greater than the loading weight of the car. The verification mode mainly aims at materials with the density less than 1, such as coal and other materials. The density of the materials is small, whether the carriage can accommodate the materials is a main problem, and therefore the materials need to be verified in advance, and scattering caused by excessive loading materials is avoided.
The adjustment of the loading amount of the materials among the carriages means that the loading capacity of some types of carriages is smaller, but the volume is larger, and conversely, the loading capacity of some types of carriages is larger but the volume is smaller, when overload or excess capacity occurs, the adjustment is performed among the carriages, optimization is realized, the loading capacity and the load capacity of each carriage are balanced, the requirements of the loading capacity and the load capacity are met, materials can be loaded as much as possible, the balance of the integral loading of the whole train is achieved, and the carriages are prevented from being too much or too little loaded.
Example ten:
this embodiment is an improvement of the above embodiment, and is a refinement of the above embodiment with respect to step 3, and the creating of the loading plan in step 3 described in this embodiment includes the following sub-steps:
substep 1, calculating the total weight and total volume: and calculating the total train load capacity and the total train volume of all the carriages of the train together according to the parameters of all the carriages, and calculating the total material volume of the planned loading according to the total material weight of the planned loading.
And substep 3, setting the loading capacity of each carriage: and (4) establishing the weight of the materials loaded in each compartment according to the volume of each compartment, verifying whether the weight of the materials loaded in each compartment exceeds the loading capacity of the compartment, adjusting the loading capacity of the materials in the compartment if yes, and finishing the planning of loading if not.
The first two substeps of the loading plan making process described in this embodiment are the same as those of the ninth embodiment except that in substep 3, it is determined that the weight of the car is greater than or equal to the weight of the loaded materials, and it is verified whether the volume of the materials is greater than the capacity of the car, on the basis of the weight as a prerequisite. The verification mode mainly aims at materials with the density larger than 1, such as sand, broken stone and the like. The density of the materials is high, whether the carriage can bear the weight of the materials is a main problem, and therefore the materials need to be confirmed and verified in advance, and overload is avoided.
Finally, it should be noted that the above is only for illustrating the technical solution of the present invention and not for limiting, although the present invention has been described in detail with reference to the preferred arrangement, it should be understood by those skilled in the art that the technical solution of the present invention (such as the form of loading station, the conveying manner of materials, the sequence of steps, etc.) can be modified or substituted equivalently without departing from the spirit and scope of the technical solution of the present invention.
Claims (10)
1. A railway gondola car quick constant volume loading system includes: the device comprises a storage bin, a feeder, a belt conveyor, a metering bin with a discharge gate, and a loading chute which is arranged on a train travelling line and can stretch or swing to lift, wherein the storage bin, the feeder, the belt conveyor, the metering bin with the discharge gate are sequentially connected.
2. The constant volume loading system of claim 2, wherein the material volume monitoring sensor group is a laser radar or a video camera and a belt speed sensor, or a combination of a laser radar and a video camera and a belt speed sensor.
3. The constant volume loading system of claim 2, wherein the level height sensor group is a laser radar or a video camera or a combination of a laser radar and a video camera.
4. The constant volume truck loading system according to claim 3, wherein the material level height sensor group further comprises at least one rod type material level height sensor for monitoring the highest material level and the lowest material level.
5. The constant volume loading system according to claim 4, wherein a train carriage position monitoring sensor group is arranged on the train travelling route.
6. The constant-volume loading system according to claim 5, wherein a material density detection device is arranged on one side of the belt conveyor.
7. A method of quickly loading a railway truck using the system of claim 6, the method comprising the steps of:
step 1, starting: the system starts, and the linking host computer obtains current loading data, includes: the total loading weight, the material density, the number of the carriages formed by the train, the sequence and the model of the carriages and the volume of the carriages with various models;
step 2, initialization: the material volume monitoring sensor group monitors whether the head of the belt conveyor has materials, if so, the material volume of the head of the belt conveyor is calculated, the material level height sensor group monitors the height of the materials in the measuring bin, if the height of the materials in the measuring bin is lower than the lowest height of the materials, the belt conveyor is started to convey the materials into the measuring bin, the material volume monitoring sensor group monitors the volume of the materials entering the measuring bin, the material level height sensor group monitors the height of the materials in the measuring bin, until the height of the materials in the measuring bin reaches or exceeds the lowest height of the materials, the belt conveyor is closed, the conveying of the materials into the measuring bin is stopped, and the volume and the weight of initial materials in the measuring bin are calculated according to the material density;
step 3, compiling a loading plan: calculating the loading capacity of each carriage according to the total loading amount, the material density, the number of carriages formed by train marshalling, the sequence and the model of the carriages and the volume of each model of carriage;
and 4, supplementing materials: starting a belt conveyor, continuously conveying materials into a metering bin, simultaneously monitoring the quantity of the materials entering the metering bin through a material volume monitoring sensor group, monitoring the change of the height of the materials in the metering bin through a material level height sensor group, calculating the quantity of the materials in the metering bin, and monitoring the material density through a material density detection device;
step 5, carriage scanning: before the carriage reaches a loading position of a loading station and in the loading process, scanning the carriage by a carriage position monitoring sensor group to obtain an accurate carriage position so as to determine accurate chute putting-down and lifting time and chute putting-down height;
step 6, discharging: the carriage reaches the loading position, and the chute puts down, opens discharge gate, and the material flows into the carriage through the chute, and the change of the height of monitoring material in the measurement storehouse simultaneously whether reaches the material heap height of plan loading volume:
Hplan for= H1- H2+ ΔH
Wherein: hPlan forThe height of the material stack change corresponding to the planned loading amount in the metering bin; h1Measuring the height of the material pile in the bin at the beginning of emptying; h2Measuring the height of the material pairs in the bin when discharging is finished;Δh is the stacking height of the materials input into the metering bin by the belt conveyor in the discharging process;
when reaching HPlan forWhen the height of the material pile is high, the discharging gate is closed to retract the chute, and discharging of a carriage is completed;
and 7, judging: and (4) judging whether the carriage is the last carriage or not, if yes, ending the loading process, and if not, returning to the step 5 to perform the next emptying cycle.
8. The method as claimed in claim 7, wherein the method for obtaining the density of the material in the step 2 comprises: the method comprises the steps of obtaining original data of current materials from an upper computer, sampling on a belt conveyor for real-time monitoring, and correcting the original data by using monitored data.
9. The method of claim 8, wherein said step 3 of compiling a loading plan comprises the substeps of:
substep 1, calculating the total weight and total volume: calculating the total train load capacity and the total train volume of all the carriages of the train together according to the parameters of all the carriages, and calculating the total material volume planned for loading according to the total material weight planned for loading;
substep 2, total weight and total volume comparison: comparing the total load capacity of the train with the total weight of the materials planned to be loaded, comparing the total volume of the train with the total volume of the materials planned to be loaded, determining whether the total load capacity of the train is greater than the total weight of the materials planned to be loaded and whether the total volume of the train is greater than the total volume of the materials planned to be loaded, if so, continuing the loading process, and if not, adjusting the loading plan;
and substep 3, setting the loading capacity of each carriage: and according to the loading capacity of each carriage, setting the material loading volume of each carriage, verifying whether the material loading volume exceeds the carriage capacity, adjusting the material loading amount among the carriages if the material loading volume exceeds the carriage capacity, and finishing the compilation of a loading plan if the material loading volume does not exceed the carriage capacity.
10. The method of claim 8, wherein said step 3 of compiling a loading plan comprises the substeps of:
substep 1, calculating the total weight and total volume: calculating the total train load capacity and the total train volume of all the carriages of the train together according to the parameters of all the carriages, and calculating the total material volume planned for loading according to the total material weight planned for loading;
substep 2, total weight and total volume comparison: comparing the total load capacity of the train with the total weight of the materials planned to be loaded, and comparing the total volume of the train with the total volume of the materials planned to be loaded, determining whether the total load capacity of the train is greater than the total weight of the materials planned to be loaded, and whether the total volume of the train is greater than the total volume of the materials planned to be loaded, if so, continuing the loading process, and if not, adjusting the loading plan;
and substep 3, setting the loading capacity of each carriage: and (4) establishing the weight of the materials loaded in each compartment according to the volume of each compartment, verifying whether the weight of the materials loaded in each compartment exceeds the loading capacity of the compartment, adjusting the loading capacity of the materials in the compartment if yes, and finishing the planning of loading if not.
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