CN117755783A - Transfer station blocking early warning method and early warning system - Google Patents
Transfer station blocking early warning method and early warning system Download PDFInfo
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- CN117755783A CN117755783A CN202311741022.9A CN202311741022A CN117755783A CN 117755783 A CN117755783 A CN 117755783A CN 202311741022 A CN202311741022 A CN 202311741022A CN 117755783 A CN117755783 A CN 117755783A
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- 238000004140 cleaning Methods 0.000 claims abstract description 31
- 238000007790 scraping Methods 0.000 claims description 20
- 238000005259 measurement Methods 0.000 claims description 17
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Abstract
The invention provides a material blocking early warning method for a transfer station, which comprises the following steps: acquiring the material volume flow P at the inlet of the transfer station in the statistical time T in And the volumetric flow rate P of the material at the outlet of the transfer station out And obtain the material between the inlet and the outletThe difference in volume flow dP; according to the difference dP of the volume flow of the materials, the sectional area S allowing the materials to pass through when the materials are blocked in the transfer station is estimated k The method comprises the steps of carrying out a first treatment on the surface of the According to the volume flow P of the material measured m times in Average value of (c) and m-time estimated cross-sectional area S k Volume flow rate of material P allowed to pass Estimation of And judging whether the transfer station needs to perform putty cleaning and early warning. The invention also provides an early warning system adopting the early warning method. The invention can dynamically estimate the sectional area S k Thereby accurately predicting the degree of plugging in the terminal.
Description
Technical Field
The invention relates to the technical field of material conveying, in particular to a material blocking early warning method and an early warning system for a transfer station.
Background
In the prior art, the detection modes of the blocking material of the transfer station comprise mechanical sampling, visual identification and the like, the mechanical structure is collided by the blocking material, so that an alarm prompt is generated to clear the transfer station, and the visual identification is that the alarm prompt is generated in an image identification mode when the blocking material occurs.
The existing mode can not predict the blocking material, and the blocking material is generally generated, or the blocking material can not be warned until a certain degree of blocking material is reached, at this time, the time for cleaning is more, and the transport capacity of the transfer station is reduced when the blocking material is started, but the transport capacity of the transfer station is gradually reduced in the period from the beginning of the blocking material to the generation of the warning, so that the transport capacity of the transfer station is seriously influenced. If the plugging material can be predicted in advance, the plugging material can be cleaned timely when the plugging material affects the transportation capacity seriously, so that the cleaning time is reduced, and the state that the transportation capacity is high can be ensured for most of the time of the transportation station.
In view of the foregoing, there is a great need for a method and a system for early warning of blocking in a transfer station to solve the problems in the prior art.
Disclosure of Invention
The invention aims to provide a transfer station putty early warning method, which aims to solve the problem that the existing putty detection mode cannot predict the putty, and the specific technical scheme is as follows:
a material blocking early warning method for a transfer station comprises the following steps:
acquiring the material volume flow P at the inlet of the transfer station in the statistical time T in And the volumetric flow rate P of the material at the outlet of the transfer station out And obtaining the difference dP between the material volume flow at the inlet and the outlet;
according to the difference dP of the volume flow of the materials, the sectional area S allowing the materials to pass through when the materials are blocked in the transfer station is estimated k ；
According to the volume flow P of the material measured m times in Average value of (c) and m-time estimated cross-sectional area S k Volume flow rate of material P allowed to pass Estimation of And judging whether the transfer station needs to perform putty cleaning and early warning, wherein m is a natural number which is more than or equal to 1.
In the above technical solution, preferably, the cross-sectional area S of the material allowed to pass through when the material blockage occurs in the transfer station is estimated according to the formula (15) k ：
Wherein: s is the flow section of the transfer station, theta is the included angle between the slope surface formed by stacking materials in the transfer station and the horizontal plane, and pi is the circumference ratio.
In the above technical solutions, the value determining method of θ preferably has two methods:
the first is: the method comprises the steps of measuring for a plurality of times when blocking occurs, and then selecting an average value;
the second is: the repose angle for stacking materials is directly selected.
In the above technical scheme, the sectional area S is preferably obtained according to the formula (16) k Volume flow rate of material P allowed to pass Estimation of ：
P Estimation of ＝S k ×v Cutting off (16)，
Wherein: v Cutting off Is the material passing cross section S k Is a function of the speed of the machine.
In the above technical scheme, preferably, v Cutting off Obtained directly by measurement or according to formula (17):
wherein: h 1 G is the gravity acceleration, which is the height from the blanking position to the outlet of the transfer station.
The preferable technical scheme is as follows:
when the volume flow rate P of the material is measured m times in Is greater than m times the estimated cross-sectional area S k Volume flow rate of material P allowed to pass Estimation of When the average value of (a), cleaning and early warning of the transfer station are carried out:
wherein,indicating the volume flow of material at the entrance of the transfer station at the jth measurement, +.>Representing the estimated cross-sectional area of the transfer station allowing the material to pass through at the jth measurement, +.>Represents the material passing sectional area +.>Is a function of the speed of the machine.
The invention also provides a material blocking early warning system of the transfer station, which adopts the material blocking early warning method of the transfer station to judge whether to perform early warning or not; when the early warning is generated, staff is prompted by the alarm and/or the cleaning device is controlled to perform material blocking cleaning on the transfer station.
In the above technical scheme, the cleaning device comprises a driving device, a transmission shaft and a scraping rake, the scraping rake is symmetrically arranged at the lower end of the transmission shaft, the upper end of the transmission shaft is connected with the driving device, and the driving device drives the transmission shaft and the scraping rake to rotate together after receiving the cleaning signal.
In the above technical scheme, preferably, the scraping rake is arranged on the transmission shaft through the scraping rake bracket.
In the above technical scheme, the scraper and the scraper support are both made of steel bars with diamond sections, wherein the long axis of the diamond is arranged along the vertical direction.
The technical scheme of the invention has the following beneficial effects:
the invention can be based on the material volume flow P at the entrance of the transfer station in And the volumetric flow rate P of the material at the outlet of the transfer station out Is used for estimating the sectional area S of the material allowed to pass through when the material is blocked in the transfer station k By judging the influence of the material blocked in the transfer station on the operation capacity of the transfer station, the sectional area S can be dynamically estimated k Thereby accurately predicting the degree of plugging in the terminal. Selecting the volume flow rate P of m times of materials in Average value of (2) and m times material volume flow P Estimation of The average value of (1) is subjected to early warning judgment, so that false early warning caused by single prediction errors can be prevented, and the accuracy of early warning is ensured; the invention detects the difference value dP and estimates the sectional area S in real time k The early warning can be carried out when the transfer capacity of the transfer station begins to decline, so that the transfer station can be in a state of high transfer capacity most of the time.
In addition to the objects, features and advantages described above, the present invention has other objects, features and advantages. The present invention will be described in further detail with reference to the drawings.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention. In the drawings:
FIG. 1 is a schematic layout of an infeed belt conveyor, a transfer station, and an outfeed belt conveyor;
FIG. 2 is a schematic cross-sectional view of a belt conveyor belt;
FIG. 3 is an auxiliary schematic of the flow cross section of the material allowed when calculating a transfer station plug;
FIG. 4 is a schematic view of the construction of the cleaning apparatus;
the device comprises a feeding belt conveyor 1, a transfer station 2, a discharging belt conveyor 3, a driving device 4, a driving device 5, a transmission shaft 6, a scraping rake 7 and a scraping rake bracket; 01. 2D laser scanning device, 02, installing support, 03, material, 04, belt, 05, bearing roller, 06, belt support.
Detailed Description
The present invention will be described more fully hereinafter in order to facilitate an understanding of the present invention, and preferred embodiments of the present invention are set forth. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.
Examples:
referring to fig. 1-3, the embodiment provides a method for early warning of blocking materials of a transfer station, which includes the following steps:
firstly, acquiring the material volume flow P at the inlet of a transfer station in the statistical time T in And the volumetric flow rate P of the material at the outlet of the transfer station out And obtaining the difference dP between the material volume flow at the inlet and the outlet;
as shown in FIG. 1, the material 03 is fed into the entrance of the transfer station 2 by the feeding belt conveyor 1, and the material 03 discharged from the transfer station is transported away from the exit of the transfer station by the discharging belt conveyor 3, so that the material volumetric flow P can be obtained by detecting the material on the feeding belt conveyor 1 and the discharging belt conveyor 3 respectively in And the material volume flow P out 。
The belt conveyor is a short name of a belt conveyor, has a fixed type and a movable type, has a simple structure and high efficiency, and is a continuous conveying machine for carrying and pulling a crop by using a flexible conveying belt. An endless conveyor belt surrounds the drive roller and the direction-changing roller, and upper and lower branches between the two rollers are supported by a plurality of carrier rollers. The materials are placed on the upper branch, and the friction force between the driving roller and the belt is utilized to drag the conveying belt and the materials to run. The belt conveyor is suitable for conveying bulk materials and finished articles in horizontal and inclined directions, and can also be used for a production line for carrying out certain technological operations. Simple structure, stable and reliable operation, strong adaptability to materials, larger conveying capacity, small power consumption and wide application.
In this embodiment, in order to obtain the volume flow of the material, flow detection devices are respectively arranged on the feeding belt conveyor 1 and the discharging belt conveyor 3. As shown in fig. 2, the flow detection device includes a 2D laser scanning device 01 (line structure light scanning can be replaced), the 2D laser scanning device 01 is installed right above the belt through a mounting bracket 02, the mounting bracket 02 is arranged on the belt bracket 06, the installation height can be adjusted according to the field environment, the range is between 1 meter and 4 meters, and the 2D laser scanning device scans the material 03 on the belt 04 along with the movement of the belt.
A two-dimensional coordinate system is established by a 2D laser scanning device, the direction and the position of X, Y of the coordinate system are shown in fig. 2, and the center of the coordinate system is at the optical center position of the 2D laser scanning device. The 2D laser scanning device collects data of a section at a time to obtain data of n points, wherein the data comprise distances from n measured points to the 2D laser scanning device and measurement angles of each point, the data can be converted into two-dimensional points under a X, Y coordinate system according to the angle and distance information of each measurement point, and the two-dimensional points form surface contour lines of materials on a belt; in fig. 2, H is the maximum distance from the scanner (i.e., the 2D laser scanning device) to the upper surface of the belt, and L is the width of the belt.
The distance from n measuring points to the scanner and corresponding angle data are generated when the 2D laser scanning device performs single data measurement, wherein the kth data are points P k The measured angle is theta k A measured distance value d k Its corresponding X, Y coordinate value P k-x 、P k-y The method comprises the following steps of:
P k-x ＝d k *cos(θ k ) (1)，
P k-y ＝d k *sin(θ k ) (2) fitting a B spline interpolation curve according to the measured n discrete data points, wherein the curve equation is as follows:
wherein: n (N) k,p (t) is a B-spline basis function at degree p, typically p is taken to be 2, t= [0,1]；x k As discrete data points P k X-axis coordinate value, y k As discrete data points P k Is defined by the Y-axis coordinate values of (c).
Each input variable x can be described as a corresponding t by the formula (3), and then a corresponding y value is calculated by t: y=b (x) =g (f -1 (x))。
Because of the presence of the idler roller 05 on the belt support 06, the belt at the measuring position is not deformed, and the function of the belt is as follows: h (x) is a higher order curve, possibly the lower half of an ellipse, or a parabola or piecewise parabola, so assuming the equation for the belt is a cubic curve, then:
h(x)＝a*x 3 +b*x 2 +c*x+d (4)，
in actual measurement, the belt profile coordinates without materials can be measured through a laser scanner, and the position coordinate points of the belt are brought into an equation (4) to calculate the coefficients of the equation.
According to the calculated data contour line equation, the sectional area of the material can be calculated, and then the sectional area of the material on the belt is calculated as follows:
wherein:for the step in the X direction, i.e. +.>
The volume flow of the material on the belt can be calculated by combining the speed of the belt according to the sectional area calculated by the formula (5). According to the running speed v of the belt, the frequency of data measurement is f, and the distance of the belt running in unit time dt is l:
l=v x dt/f (6), the volumetric flow rate of the material on the endothelial tape per unit time can be calculated in an additive manner:
wherein: s is S i Is the cross-sectional area of the material detected for the ith time.
So far, the material volume flow P at the inlet in the statistical time T can be obtained in ：
The material volume flow P at the outlet is obtained by the same calculation out ；
The difference dP between the volumetric flows of the material at the outlet and inlet is:
dP＝P in -P out (9)。
then, according to the difference dP of the volume flow of the materials, the sectional area S allowing the materials to pass through when the materials are blocked in the transfer station is estimated k The method comprises the steps of carrying out a first treatment on the surface of the Then according to the volume flow P of the material measured m times in Average value of (c) and m-time estimated cross-sectional area S k Volume flow rate of material P allowed to pass Estimation of Judging whether the transfer station needs to perform putty cleaning and early warning, wherein m is a natural number which is more than or equal to 1;
specifically, as the blocking starts from the bottom of the transfer station, for a cylindrical transfer station, the blocking can lead the transfer station to form an inverted cone in the transfer station firstly and then until an inverted cone is formed, the transfer station is blocked completely but not blocked completely when the inverted cone is formed, and the transfer station is blocked completely when the inverted cone is formed, so that the transfer station needs to be cleaned in the process of changing the inverted cone into the inverted cone; when turning toWhen forming a rounding table in the station, the flow cross-sectional area S of the lower part of the rounding table can be estimated according to the difference dP of the volume flow of the materials k Referring to FIG. 3, the estimated sectional area S in the present embodiment is shown k An explanation is given.
As shown in fig. 3, an auxiliary line is established for the inverted cone which has been formed so as to form an inverted cone, wherein h 1 Is the height of an inverted cone, h 2 Height of cylinder formed by auxiliary line r 1 For the inner diameter of the transfer station r 2 Radius of flow cross section formed for accumulated material (i.e. plug), S k The flow cross section of the transfer station is the area of the flow cross section which allows the material to pass through when the blocking occurs, S is the flow cross section of the transfer station, and theta is the included angle between the slope formed by stacking the material in the transfer station and the horizontal plane; θ may be selected empirically, for example, multiple measurements may be made when a jam occurs, and then an average value is selected; meanwhile, the theta can also directly select the repose angle of material accumulation.
From the trigonometric relationship, it is possible to obtain:
the bulk volume V of the material in the transfer station can be obtained according to the formula (12) -formula (14) l The expression is as follows:
due to the bulk V of the material in the transfer station l Namely the difference dP between the volume flows of the materials, thus the following can be obtained:
wherein: pi is the circumference ratio.
After the difference dP between the volume flows of the materials is obtained, the cross-sectional area S allowing the materials to pass through when the materials are blocked in the transfer station can be obtained according to the formula (15) k The method comprises the steps of carrying out a first treatment on the surface of the Cross-sectional area S of combined material k Velocity v of (2) Cutting off The material volume flow P passing through the section in single measurement can be obtained Estimation of As shown in equation (16):
P estimation of ＝S k ×v Cutting off (16)，
Wherein v is Cutting off The sensor can be obtained through direct measurement by a sensor, or can be obtained through estimation according to a formula (17):
wherein: h 1 G is gravity acceleration, which is the height from the discharging position of the feeding belt conveyor to the outlet of the transfer station (the material vertically enters the inlet of the transfer station from the discharging position and leaves the transfer station from the outlet of the transfer station, and the material moves in a free falling manner in the process); because the material blocking of the transfer station is blocked from the bottom, and the material is free falling, the actual requirement can be met by adopting the formula (17) for estimation.
Further, in this embodiment, the material volume flow P is measured m times in Is greater than m times the estimated cross-sectional area S k Volume flow rate of material P allowed to pass Estimation of When the average value of (a), cleaning and early warning of the transfer station are carried out:
wherein,indicating the volume flow of material at the entrance of the transfer station at the jth measurement, +.>Representing the estimated cross-sectional area of the transfer station allowing the material to pass through at the jth measurement, +.>Represents the material passing sectional area +.>Speed of (1), wherein>The measurement can be obtained by carrying out prediction according to a formula (17) or can be obtained by measuring a sensor.
The material blocking early warning method of the transfer station is arranged in the early warning system, when the early warning system judges that the transfer station needs to be cleaned according to the early warning method, operators can be reminded in an alarm (such as sound and light alarm) mode, and meanwhile, the cleaning device can be controlled by the early warning system to clean the transfer station; the components of the early warning system are referred to in the prior art, and will not be described in detail in this embodiment.
Referring to fig. 4, the embodiment further provides a cleaning device for a transfer station, the cleaning device comprises a driving device 4, a transmission shaft 5 and a scraping rake 6, the scraping rake 6 is symmetrically arranged at the lower end of the transmission shaft 5, the upper end of the transmission shaft 5 is connected with the driving device 4, and the transmission shaft 5 and the scraping rake 6 are driven to rotate together by the driving device 4; preferably, the scraping rake 6 is arranged on the transmission shaft 5 through a scraping rake bracket 7, and the driving device is one of a motor or a hydraulic motor.
Further preferably, the scraping rake 6 and the scraping rake support 7 are both made of steel bars with diamond sections, wherein long shafts of the diamond shapes are arranged in the vertical direction, so that impact of blanking on the scraping rake support and the scraping rake and material accumulation can be reduced.
The rake structure is adopted, so that the contact with materials is small when the piled materials are scraped, and the power required by rotation is reduced; meanwhile, the symmetrically arranged scraping rakes are arranged in the transfer station, and a circle of sticky materials can be cleaned by rotating for half a circle.
The early warning system and the cleaning device can be communicated, and when the early warning system judges that the transfer station needs to be subjected to material blockage cleaning by adopting the judging method in the embodiment, the cleaning signal is given to the early warning system so as to control the cleaning device to perform cleaning action. Of course, the cleaning device shown in fig. 4 is only one way provided by the present embodiment, and when it is determined that the transfer station needs to be cleaned, it is possible for a person skilled in the art to use other means to clean the transfer station.
The method of the embodiment can be based on the volume flow rate P of the material at the inlet of the transfer station in And the volumetric flow rate P of the material at the outlet of the transfer station out Is used for estimating the sectional area S of the material allowed to pass through when the material is blocked in the transfer station k Thereby judging the influence of the material blocked in the transfer station on the operation capacity of the transfer station, and dynamically estimating the sectional area S k Thereby accurately predicting the degree of plugging in the terminal. Selecting the volume flow rate P of m times of materials in Average value of (2) and m times material volume flow P Estimation of The average value of (1) is subjected to early warning judgment, so that false early warning caused by single prediction errors can be prevented, and the accuracy of early warning is ensured; the method of the embodiment detects the difference dP and estimates the sectional area S in real time k The early warning can be carried out when the transfer capacity of the transfer station begins to decline, so that the transfer station can be in a state of high transfer capacity most of the time.
The cleaning device is controlled by the early warning system to perform cleaning action, so that the automatic material blocking cleaning can be realized, the material blocking fault probability of the transfer station is reduced, and meanwhile, the cleaning device is simple in equipment structure, low in maintenance cost, stable and reliable.
The above description is only of the preferred embodiments of the present invention and is not intended to limit the present invention, but various modifications and variations can be made to the present invention by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. The utility model provides a transfer station putty early warning method which is characterized in that the method comprises the following steps:
acquiring the material volume flow P at the inlet of the transfer station in the statistical time T in And the volumetric flow rate P of the material at the outlet of the transfer station out And obtaining the difference dP between the material volume flow at the inlet and the outlet;
according to the difference dP of the volume flow of the materials, the sectional area S allowing the materials to pass through when the materials are blocked in the transfer station is estimated k ；
According to the volume flow P of the material measured m times in Average value of (c) and m-time estimated cross-sectional area S k Volume flow rate of material P allowed to pass Estimation of And judging whether the transfer station needs to perform putty cleaning and early warning, wherein m is a natural number which is more than or equal to 1.
2. The method for early warning of a material jam at a transfer station according to claim 1, wherein the sectional area S allowing the material to pass through when the material jam occurs in the transfer station is estimated according to formula (15) k ：
Wherein: s is the flow section of the transfer station, theta is the included angle between the slope surface formed by stacking materials in the transfer station and the horizontal plane, and pi is the circumference ratio.
3. The method for early warning of a terminal plugging according to claim 2, wherein the value determining method of θ has two kinds:
the first is: the method comprises the steps of measuring for a plurality of times when blocking occurs, and then selecting an average value;
the second is: the repose angle for stacking materials is directly selected.
4. The method for early warning of a terminal plugging according to claim 1, wherein the sectional area S is obtained according to formula (16) k Volume flow rate of material P allowed to pass Estimation of ：
P Estimation of ＝S k ×v Cutting off (16)，
Wherein: v Cutting off Is the material passing cross section S k Is a function of the speed of the machine.
5. The terminal block warning method of claim 4, wherein v Cutting off Obtained directly by measurement or according to formula (17):
wherein: h 1 G is the gravity acceleration, which is the height from the blanking position to the outlet of the transfer station.
6. The terminal plugging early warning method according to any one of claims 1 to 5, wherein:
when the volume flow rate P of the material is measured m times in Is greater than m times the estimated cross-sectional area S k Volume flow rate of material P allowed to pass Estimation of When the average value of (a), cleaning and early warning of the transfer station are carried out:
wherein,indicating the volume flow of material at the entrance of the transfer station at the jth measurement, +.>Representing the estimated cross-sectional area of the transfer station allowing the material to pass through at the jth measurement, +.>Represents the material passing sectional area +.>Is a function of the speed of the machine.
7. A transfer station blocking early warning system, characterized in that the early warning system adopts the transfer station blocking early warning method according to any one of claims 1-6 to judge whether to perform early warning; when the early warning is generated, staff is prompted by the alarm and/or the cleaning device is controlled to perform material blocking cleaning on the transfer station.
8. The transfer station blocking early warning system according to claim 7, wherein the cleaning device comprises a driving device (4), a transmission shaft (5) and a scraping rake (6), the scraping rake (6) is symmetrically arranged at the lower end of the transmission shaft (5), the upper end of the transmission shaft (5) is connected with the driving device (4), and the driving device (4) drives the transmission shaft (5) and the scraping rake (6) to rotate together after receiving the cleaning signal.
9. The transfer station blockage warning system according to claim 8, characterized in that the scraper (6) is arranged on the transmission shaft (5) through a scraper bracket (7).
10. The transfer station blockage warning system according to claim 9, wherein the scraper (6) and the scraper support (7) are steel bars with rhombic cross sections, and the long axis of the rhombic is arranged along the vertical direction.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311741022.9A CN117755783A (en) | 2023-12-15 | 2023-12-15 | Transfer station blocking early warning method and early warning system |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202311741022.9A CN117755783A (en) | 2023-12-15 | 2023-12-15 | Transfer station blocking early warning method and early warning system |
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| CN117755783A true CN117755783A (en) | 2024-03-26 |
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| CN202311741022.9A Pending CN117755783A (en) | 2023-12-15 | 2023-12-15 | Transfer station blocking early warning method and early warning system |
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