ZDJ127 Mine-used Belt Conveyor Material Metal Monitoring Device

This product is composed of GJC12 mine-used intrinsically safe metal monitoring sensor, ZDJ12-Z mine-used intrinsically safe belt conveyor material metal monitoring device host, ZDJ127-F mine-used flameproof and intrinsically safe substation, KJD127 mine-used flameproof and intrinsically safe computer, etc. The whole machine has explosion-proof performance and has passed the coal safety certification.

After the equipment is linked with the iron remover, the iron remover will only work when there is metal in the coal flow. That is, the iron remover will only be started when the device detects metal in the coal flow, and it will stop working when there is no metal. This significantly shortens the working time of the iron remover. Since the iron remover is a high-power equipment while the total power of this device is only 80W, the energy-saving effect is remarkable when the device is connected to the iron remover. Taking an RCBD-12DT3 flameproof electromagnetic iron remover as an example (excitation power 18kW, iron unloading belt motor power 7.5kW), running 20 hours a day and 300 days a year, the annual power consumption reaches 153,000 kW•h. After adopting this product, the working time of the iron remover is related to the iron content in the coal flow, which is expected to be 10% to 20% of the original. The power consumption can be reduced by 122,000 to 137,000 kW•h.

01 Detect ferrous metals in the coal flow and determine their relative size and position.

02 The entire device provides CAN/RS485/Ethernet for reliable communication and interlocking with the conveyor centralized control system and iron removers.

03 When the length of ferrous metal exceeds the set value, it can control the belt conveyor to stop or send a remote alarm signal to the monitoring room, while activating audible and visual alarms for manual removal of ferrous metal, avoiding longitudinal tearing of the belt.

04 Users can set the lower limit for detecting ferrous metal according to actual needs, and abandon removal when the metal is smaller than the lower limit.

05 The device can online real-time record the number of iron removals and the operating time of iron removers, and has speed measurement, camera, and photography functions (optional).

06 Intelligently control the start and stop of the iron remover, i.e., turn on the iron remover when iron is detected and automatically turn it off when no iron is present. In case of device failure, the system can automatically disengage from controlling terminal equipment without affecting the normal use of existing on-site equipment.

07 The device can determine the position of metal by locating marker packages dropped by the marking device (optional).

08 Prevent longitudinal belt tearing: Based on targeted iron removal and high-power iron removal technology, the manipulator can pick up long iron objects (such as anchor rods) buried in the coal flow from the middle position, eliminating the safety hazard of longitudinal belt tearing caused by long iron objects.

09 Capable of intelligently distinguishing between belt buckles and steel cord core joints.

10 Targeted iron removal: First, obtain precise information about ferrous metals in the coal flow (metal size, shape, weight, horizontal position, and height in the coal flow) through a 前置 (front-mounted) metal detection device. Then, analyze and activate the metal sorting system via control programs to accurately grab ferrous metals in the coal flow.

11 The device can be networked with the control center's background through long-distance communication (optional) for convenient real-time monitoring.

▼ Host
Includes a display and control unit (DCU) and a display unit (DSU). The DCU reads and records the judgment results from the CCU via communication and displays them through the DSU. Simultaneously, it sends control commands to the terminal control unit (TCU) via communication to control terminal equipment actions and transmits metal detection data to the host computer.

▼ Substation
This unit controls on-site terminal equipment such as belt centralized control systems, iron removers, and mine-used flameproof and intrinsically safe audible and visual alarms. It controls the start/stop of iron removers, belt shutdown, or audible/visual alarms based on different scenarios. Additionally, it supplies power to sensors and single-chip microcomputers respectively.

▼ Metal Sorting System
The metal sorting system works in conjunction with the mine-used belt conveyor material metal detection device to achieve metal detection and intelligent sorting. When the metal detection device detects metallic debris in the coal flow, it sends a control signal to the metal sorting system (when an iron remover is configured on-site, the metal detection device only sends a control signal to the sorting system upon detecting large or long metals that cannot be reliably removed by the iron remover). Upon receiving the signal, the metal sorting system operates according to the control program to remove metallic debris. The system includes a pickup unit, stepping movement mechanism, iron separation mechanism, etc.

The sensor is installed above the upper conveyor belt. The steel cords in the belt cause minimal interference to the metal detection sensor, and normally, the sensor does not generate signals. When the steel cord joints or broken cords of the belt pass through the sensor, the sensor outputs signals. These signals are sent to a computer, which generates a basic database of joints and broken cords for the entire belt loop (including position information). Based on this, the computer compares the collected signals with the basic data to filter out interference signals from joints and steel cord breakages, enabling effective identification of metal signals.

The metal detection device consists of multiple metal detection sensors (the number of sensors varies according to the belt width; for example, six sensors are configured when the belt width is 1.2 meters). When metal passes through the sensors: the sensor close to the metal outputs a signal, with the signal intensity increasing as the distance decreases, while distant sensors do not output signals. When a belt buckle passes through the sensors, all sensors output signals with roughly the same intensity, and the single-chip microcomputer judges this as a belt buckle passing through the sensors based on this characteristic.

First, the front-mounted metal detection device obtains precise information on ferrous metals in the coal flow (metal size, shape, horizontal position) through metal detection sensors, and acquires the coal flow height at the position of ferrous metals via coal flow height detection sensors. After analysis and calculation, it sends control signals to the metal sorting system. When the metal sorting system receives the control signals, it first activates the traverse mechanism to move the pickup unit above the corresponding horizontal position of the metal on the belt; then starts the longitudinal movement mechanism to bring the pickup unit close to and pick up the ferrous metal (the downward travel is dynamically determined by the coal flow height where the metal is located). Next, it controls the longitudinal movement mechanism to move upward. After reaching the target position, it controls the traverse mechanism to move to the sorting area. Finally, it controls the iron separation mechanism to act and sort the metal, achieving the purpose of iron removal.