基于卷积神经网络的压滤机滤布粘料智能识别方法

    Intelligent identification of filter cloth fouling in filter presses based on convolutional neural networks

    • 摘要: 针对选煤厂压滤机卸料过程中滤布粘料人工判别与清理作业效率低、劳动强度大且存在安全隐患的问题,为实现压滤工序的全自动化与智能化运行,以南梁选煤厂压滤煤泥为研究对象,从黏附机理、智能识别方法、清理装置研发及系统联动控制四个维度开展系统研究。首先通过红外光谱、X射线衍射测试表征煤样基础性质与矿物组成,采用自制脱附力测试装置开展单因素试验,探索灰分、水分、粒度、矿物组分对煤泥-滤布间黏附力的作用规律,并量化计算各因素的影响权重;其次设计与压滤机拉板小车同步运行的轨道式随动巡检硬件方案,构建融合卷积神经网络(CNN)与循环神经网络(RNN)的粘料图像分割识别模型,开发具备实时监测、分级预警、数据追溯功能的上位机监控平台;随后针对块状、糊状两类典型粘料的特性差异,研发高频激振-柔性刮刷复合式清理装置,并通过试验优化激振频率、刮刷厚度与运行速度等工况参数;最终基于PLC控制系统构建了识别-清理联动闭环系统。研究结果表明:矿物组分与水分是影响滤布黏附力的核心因素,权重占比分别为58.48%与31.30%;所提智能识别方法像素级粘料识别准确率可达99%以上,可适配压滤车间复杂光照与粉尘工况;复合清理装置在激振频率为60 Hz、刮刷厚度为10 mm、运行速度为30 mm/s的综合工况下,可实现块状与糊状粘料的高效无损清理,充分成型滤饼的清理率可达100%,且能规避滤板凸起结构、避免损伤滤布。研究构建的“随动定位—智能识别—动态监测—实时清刷”一体化系统,能够有效替代人工完成滤布粘料的判别与清理作业,降低岗位劳动强度与安全风险,为选煤厂压滤工序的无人化、智能化改造提供了技术支撑与工程参考。

       

      Abstract: To address the industrial challenges of relying on manual inspection and cleaning of filter cloth fouling during filter press cake discharge in coal preparation plants—such as low operational efficiency, high labor intensity, and potential safety hazards—a systematic study was conducted to achieve fully automated and intelligent filter press operations. Taking the filter-pressed coal slime from Nanliang Coal Preparation Plant as the research object, this study focused on four aspects: fouling adhesion mechanism, intelligent identification methods, cleaning device development, and coordinated system control. First, Fourier-transform infrared spectroscopy (FTIR) and X-ray diffraction (XRD) were employed to characterize the fundamental properties and mineral composition of the coal samples. Single-factor experiments using a self-developed detachment-force testing apparatus were conducted to investigate the effects of ash content, moisture content, particle size, and mineral composition on the adhesion force between coal slime and filter cloth, and the weighted contributions of these factors were quantitatively determined. Subsequently, a rail-mounted inspection system synchronized with the filter plate shifting trolley was designed. An image-segmentation model integrating a convolutional neural network (CNN) with a recurrent neural network (RNN) was developed for filter cloth fouling identification. A supervisory computer monitoring platform featuring real-time display, graded warning, and data traceability was also developed. Furthermore, considering the distinct characteristics of two typical fouling types—namely, blocky and pasty fouling—a composite cleaning device combining high-frequency vibration excitation with flexible scraping and brushing was developed. The operating parameters, including vibration frequency, brush thickness, and speed, were optimized experimentally. Finally, a closed-loop identification and cleaning system was established based on a programmable logic controller (PLC) to enable coordinated operation between the identification and cleaning processes. The results indicate that mineral composition and moisture content are the dominant factors affecting the adhesion force between coal slime and filter cloth, with weighted contributions of 58.48% and 31.30%, respectively. The proposed intelligent identification method achieves a pixel-level identification accuracy of over 99% for fouling and can effectively adapt to complex lighting and dusty conditions in filter press workshops. Under the recommended conditions of a vibration frequency of 60 Hz, brush thickness of 10 mm, and speed of 30 mm/s, the composite cleaning device can efficiently and nondestructively remove both blocky and pasty fouling. The cleaning rate for fully formed filter cakes reaches 100%. Additionally, the device can avoid the raised structures of filter plates and prevent damage to the filter cloth. The integrated system, consisting of synchronized positioning, intelligent identification, dynamic monitoring, and real-time cleaning, can effectively replace manual inspection and cleaning of filter cloth fouling, thereby reducing labor intensity and mitigating safety risks. The findings provide technical support and a practical engineering reference for the unmanned and intelligent upgrading of filter press processes in coal preparation plants.

       

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