Intelligent fully automatic grain sampling system
Closed laboratory automatic cutting prototype (WY-8S)
Performance Introduction and Implementation Plan
Intelligent fully automatic grain sampling system function: automatically recognize vehicles, set sampling routes at 36000 points, automatically complete without worker operation, high efficiency, low error rate, it is the preferred product for grain processing enterprises. It is highly praised and trusted by grain processing enterprises in every country in China, such as grain reserves, feed processing plants, starch factories, alcohol factories, flour factories, rice factories, etc.
1, Equipment introduction:
The closed laboratory grain cutting prototype is a patented product independently developed by Hebei Weiyu Transport Machinery Co., Ltd. This product has improved many shortcomings of domestic automated sampling.
Hebei Weiyu Conveyor Machinery Co., Ltd. was established in 2010, specializing in the research and development, production of various types of automatic grain cutting prototypes, with a production time of 8 years. The company has multiple patented technologies related to automatic grain cutting prototypes.
The automatic grain cutting prototype equipment is mainly used in grain storage and grain processing enterprises. It can replace manual operations in the process of grain sampling and transmission to the laboratory, achieving automatic and closed grain sampling and transmission. In the physical link, it isolates quality inspectors from contact with grain truck information, avoiding interference and influence of human factors on grain quality inspection and evaluation.
The closed laboratory grain cutting prototype is controlled by embedded software and uses computer technology to organize and calculate data, allowing the sampled cuttings to randomly select points within the cutting range for sampling. Technically, it truly realizes the comprehensiveness and randomness of sampling, ensuring the authenticity and representativeness of grain sample analysis results, and greatly meeting the needs of customers.
Through years of production experience and customer feedback, the prototype has gradually improved in terms of details and functions, achieving automatic sampling by clicking a button after the preparation work is completed. The prototype automatically identifies the vehicle model and determines the sampling range, the program automatically plans and selects the sampling area reasonably, randomly calculates the sampling position, and achieves uniform distribution, no blind spots, and irregular sampling. The automatic grain cutting prototype eliminates the need for manual selection of sampling positions, avoids setting blind spots for sampling, and supports remote monitoring of the cutting control process.
The various systems of the closed laboratory grain cutting prototype have been improved multiple times in terms of details, greatly reducing the failure rate and program error rate of several existing products in the same industry, and increasing the efficiency
A system to prevent misoperation and vehicle misoperation protection device has been added, which includes various speed control devices for various movements. It can adjust the running speed of large and small vehicles, probe tubes, etc. according to different requirements, and improve the detection method of probe tube touching the bottom. Therefore, it will not cause any damage to the vehicle floor and probe tubes. Effective improvements have been made to the problems of grain sample breakage and high impurities during sampling. Most devices use cold resistant materials and have added frost resistant structures, which can be used normally in extremely harsh winter weather conditions.
The closed laboratory grain cutting prototype technology is mature and has obvious advantages, which can meet the needs of different customers. The main advantages are as follows:
High degree of automation, simple operation, and easy training for operators to use;
Combining video surveillance equipment with equipment control to achieve remote operation and control of equipment;
Ensure that the sampling process is organized and not affected by weather conditions, allowing for all-weather operation;
To avoid the labor intensity and work hazards of staff during the sample signing process;
The fully automatic sampling and conveying process avoids human factors and improves work efficiency;
Widely applicable and highly practical, suitable for enterprises such as warehousing and grain deep processing;
The closed laboratory grain cutting prototype consists of multiple parts, which can be divided into functional equipment:
1. Sampling system:
Composed of a steel structure canopy and sampling mechanical equipment, the canopy is used for equipment and vehicles to shelter from wind and rain, protect mechanical and electrical equipment, and facilitate maintenance. The sampling mechanical equipment consists of a longitudinal cart, a transverse cart, a probe driving device, etc., and is the main equipment of the automatic grain cutting prototype.
2. Sample conveying system
Composed of high-pressure and low-noise vortex fans, conveying pipelines, control boxes, etc., it is used for the transportation and storage of grain samples.
3. Control operating system
It consists of a control cabinet, an operating console (including the built-in computer host), a display, and other parts, used for operating and controlling the prototype.
2, Equipment parameters
Our company's equipment technology highlights:
By using embedded software control and computer technology to organize and calculate data, the sampled cuttings are randomly selected and sampled within the sampling range
1. The Qinpeng column is made of 396X198 square H-steel; The longitudinal rail adopts 125X250 rectangular square tube
The C-shaped steel model is 140 # x 2.0mm, with a top plate thickness of 0.5mm and a wall panel of 0.4mm. The outer dimensions of the canopy are 18m in length, 5.8m in width, and 10.2m in height.
2. Horizontal and vertical main force motor: CH32-0.75KW-S-B vertical horizontal brake reducer:
3. Shengqiang Air Pump: Model SQ160B Air Storage Tank Capacity: 160L, Speed: 1400r/min
Exhaust pressure: 0.8m, input power 1680wX34, grain suction fan: 2HB-820-H37-11KW-2900r/min, air volume 600m/h, pressure 68Kpa
5. The supplier shall provide the basic drawing of the cutting prototype and the external drawing of the equipment.
6. Cable: Model: YCW3X4+1X2.5YCW 3X2.5+1X1.5. Cable length: The supplier is only responsible for the wiring from the control cabinet to the entire set of equipment.
7. Cutting probe rod: 32mm, material: stainless steel 201, quantity: 8 pieces, length: 4.2m8. The supplier is responsible for installation, debugging, and technical guidance.
3, Design of storage tanks
2, Equipment parametersOur company's equipment technology highlights:
By using embedded software control and computer technology to organize and calculate data, the sampled cuttings are randomly selected and sampled within the sampling range
1. The Qinpeng column is made of 396X198 square H-steel; The longitudinal rail adopts 125X250 rectangular square tube
The C-shaped steel model is 140 # x 2.0mm, with a top plate thickness of 0.5mm and a wall panel of 0.4mm. The outer dimensions of the canopy are 18m in length, 5.8m in width, and 10.2m in height.
2. Horizontal and vertical main force motor: CH32-0.75KW-S-B vertical horizontal brake reducer:
3. Shengqiang Air Pump: Model SQ160B Air Storage Tank Capacity: 160L, Speed: 1400r/min
Exhaust pressure: 0.8m, input power 1680wX34, grain suction fan: 2HB-820-H37-11KW-2900r/min, air volume 600m/h, pressure 68Kpa
5. The supplier shall provide the basic drawing of the cutting prototype and the external drawing of the equipment.
6. Cable: Model: YCW3X4+1X2.5YCW 3X2.5+1X1.5. Cable length: The supplier is only responsible for the wiring from the control cabinet to the entire set of equipment.
7. Cutting probe rod: 32mm, material: stainless steel 201, quantity: 8 pieces, length: 4.2m8. The supplier is responsible for installation, debugging, and technical guidance.
3, Design of storage tanks
2, Equipment parameters
Our company's equipment technology highlights:
By using embedded software control and computer technology to organize and calculate data, the sampled cuttings are randomly selected and sampled within the sampling range
1. The Qinpeng column is made of 396X198 square H-steel; The longitudinal rail adopts 125X250 rectangular square tube
The C-shaped steel model is 140 # x 2.0mm, with a top plate thickness of 0.5mm and a wall panel of 0.4mm. The outer dimensions of the canopy are 18m in length, 5.8m in width, and 10.2m in height.
2. Horizontal and vertical main force motor: CH32-0.75KW-S-B vertical horizontal brake reducer:
3. Shengqiang Air Pump: Model SQ160B Air Storage Tank Capacity: 160L, Speed: 1400r/min
Exhaust pressure: 0.8m, input power 1680wX34, grain suction fan: 2HB-820-H37-11KW-2900r/min, air volume 600m/h, pressure 68Kpa
5. The supplier shall provide the basic drawing of the cutting prototype and the external drawing of the equipment.
6. Cable: Model: YCW3X4+1X2.5YCW 3X2.5+1X1.5. Cable length: The supplier is only responsible for the wiring from the control cabinet to the entire set of equipment.
7. Cutting probe rod: 32mm, material: stainless steel 201, quantity: 8 pieces, length: 4.2m8. The supplier is responsible for installation, debugging, and technical guidance.
3, Design of storage tanks
1. The storage device is designed as a four in one system, allowing each probe to collect grain in a centralized manner.
2. The storage device is equipped with bag filtration and pulse automatic cleaning, which ensures that the filtration area and air permeability never decrease, and reduces the workload of operators and cleaning of filter materials.
3. Voice reminder design, using voice software to design multiple voice prompts, with corresponding voice prompts for each step from before the vehicle enters the equipment to the completion of sampling. Combined with the lifting and lowering of the barrier gate, it ensures the safety of vehicle passage, making the equipment operate reliably and safely.
WY8S type cutting prototype (8 probe rods), with a canopy selection of 18.5 meters * 6.2 meters. The specific parameters are shown in the table below:
Number of large vehicles: 4. The speed of the large vehicle is 0.2-0.4 meters/second. The large vehicle moves longitudinally, with 2 small vehicles per vehicle
Number of cars: 8 cars. The speed of the car is 0.2-0.4 meters/second. The car moves horizontally, and each car is equipped with one cutting rod
The number of cuttings is 8. The distance between the cuttings and the ground is 5-1.1 meters. The cuttings move vertically and take 36 seconds to travel back and forth throughout the journey
The minimum spacing between cuttings on each large vehicle is 0.39 meters, and the maximum spacing is 2.4 meters.
Covering an area of 18.5 meters * 6.25 meters, with an effective area of 18.2 meters * 2.6 meters. The standard can be sampled 30-40 times per hour
The maximum model carriage length is 17.5 meters, and the minimum model carriage length is 2.4 x 1.5 meters. The standard trailer carriage length is less than 17.5 meters
The control mode automatically randomly samples the number of sampling points, which can achieve random sampling, no blind spots, and no dead corners according to the defined effect of the vehicle model
4, Installation plan
According to the specific situation of Party A, the design plan is as follows:
The cutting prototype and canopy are installed outside or at the entrance of the grain depot, with a width of 6.25 meters, a length of 18 meters, and a height of 10 meters.
The prototype shed, control room, and laboratory are connected to each other through truss cables and grain pipes. The principle of convenient access to the main control cabinet is based on the proximity of the main power supply.
The side of the truss near the wall should be supported by columns, with an unlimited height of no less than 5 meters.
High pressure and low noise vortex fan: installed outside the control room or on the side of the prototype shed, dust collector, fine filter, muffler, control box, etc;
Control room: control cabinet, operation touch screen, monitor, amplifier, etc;
Laboratory: Storage tanks, prompt buttons, status indicator lights, discharge and dust removal boxes, dust removal axial fans, etc. are installed indoors;
Specific cutting process:
(The process flow network hardware adopts the original network equipment of Party A, and our company is responsible for laying network cables to connect; the software is the responsibility of the original network technology company). After the driver and other accompanying personnel get off the vehicle and leave below the prototype, the operator clicks the start sampling button, and the prototype automatically starts random sampling based on the vehicle model.
The grain samples taken during the operation of the cutting prototype are directly transported to the storage device in the laboratory through a pipeline (flexible polyurethane steel wire pipeline),
1) The laboratory technician confirms the quantity of grain samples and notifies the operator through voice hardware (bidirectional solidification voice device, voice bar can be edited as needed, and voice playback can be made by clicking on the corresponding text bar without generating additional information communication). The operator determines whether to continue sampling or to let the vehicle leave after the sampling is completed based on the feedback from the laboratory technician.
After the cutting sample is completed, the grain delivery truck will leave the shed and wait in the waiting area for the test results of the cutting sample.
Vehicles that meet the grain collection standards according to the grain sample analysis results should be registered at the entrance guard before entering the warehouse. They should go straight to the weighbridge to weigh the gross weight of the vehicle, and then proceed with other processes such as unloading grain; Vehicles with unsatisfactory test results should drive directly into the road from the waiting area and leave. If vehicles need to be re sampled, they need to queue up again to perform the above sampling steps.
The low-noise high-pressure vortex fan or Roots fan, dust removal tank, fine filter, and other equipment of the vacuum sampling system in the prototype are installed in the mobile board room, and the electrical cabinet and operating platform are placed in the operating room.
The laboratory is located near the sample shed and separated from the operating room. Storage hoppers, sample racks, and other necessary equipment are installed next to the laboratory table.
The total power cable of the prototype is directly connected to the control room. The total power of the WY-8S cutting prototype is 53kW.
5, Equipment List
The main equipment of the entire set, except for on-site production, steel structural components, and pipeline fittings, is as follows:
Number Name Unit Quantity Remarks
1. Vertical movement of large vehicles 8. Installation in the canopy of the prototype
2 horizontally moving small vehicles 16 installed in the canopy of the prototype
3. The sampling rod driver part 16 is installed in the greenhouse of the cutting machine
4 cameras, 6 installed in the greenhouse of the prototype
5 lighting fixtures and 4 installed in the greenhouse of the prototype
6 external speakers, 2 installed in the greenhouse of the prototype
7 PLC control cabinets, 2 installed in the operating room with PLC
8 fan control cabinets, 2 installed in the operating room
Install 9 control boxes and 8 on the sample truck
10 industrial control displays, 2 installed in the operating room
11. Operator work platform 2 is installed on the operation platform
12 voice prompts, 2 installed in the laboratory, connected to the operating room
13 button operation boxes, 4 installed in the laboratory, controlled by the operation room
14 dust storage tanks, 2 automatic mixing hoppers installed in the laboratory
15 Low noise high-pressure vortex fans or Roots fans, 10 installed in the laboratory
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