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The head-mounted belt sampler is installed at the head of the belt conveyor. As materials flow along the designated trajectory, the sampler traverses the full cross-section of the discharge profile to collect representative samples. The captured material is transferred to a primary feeder, which evenly delivers it to a primary crusher for initial size reduction. Subsequently, the processed material undergoes precision splitting and proceeds to a secondary crusher for further refinement. The final sample is directed to a sealed collection unit, while residual coal is reintroduced into the main system via a closed-loop return mechanism.
The sampling device performs full cross-sectional scraping on the conveyor belt at preset intervals. The rotary motion of the sampling head is driven by a PLC-controlled deceleration mechanism, while the rotating sampling bucket is powered by a gear-driven reduction system. At the conveyor head, the roller discharges materials at a controlled speed, ensuring the sampling cutter traverses the entire width and thickness of the material flow to capture complete sub-samples.
The collected sub-samples are channeled through a chute to a primary feed conveyor, which uniformly delivers the material to a crusher for size reduction. The crushed material is then transferred via a secondary conveyor to a precision splitter, dividing it into retained samples and discarded residues. Retained samples are automatically stored in sealed collection tanks, while discarded residues are returned to the main conveyor via a bucket elevator.
When the sampler rotates to a predetermined angle, the original samples collected by the drum assembly, hopper, and chute are automatically directed to the sample collector or downstream equipment. At the end of each rotation cycle, the PLC system halts the motor via relay control, initiating the next sampling cycle only when predefined conditions are met. This ensures precise batch-specific sampling frequency and volume control, with all timing and intervals dynamically adjusted by the PLC.
1.Non-Contact Sampling Bucket Design
The sampling bucket is positioned beneath the belt roller without direct contact with the conveyor belt, ensuring complete cross-sectional material capture while preventing belt wear. Its robust stainless steel construction guarantees stable and safe operation
2.Full Cross-Sectional Sampling Under All Conditions
The sampler uniformly intercepts the entire material flow cross-section regardless of flow rate variations or operational conditions, delivering highly representative samples with exceptional reliability
3.Fully Automated Control System
From initiation to completion, the entire workflow is managed by host computer + PLC automation, enabling parameter configuration, real-time status monitoring, and automated data acquisition. The system operates autonomously, requiring zero on-site human intervention.
4.Flexible Control Modes
Operators can select from automatic, manual, host computer, or remote control modes, adapting to diverse operational scenarios for maximum flexibility.
5.Moisture-Resistant Crushing Technology
Equipped with wet coal-specific crushers, the system controls output particle size to 3–12 mm. An automatic cleaning mechanism prevents material adhesion, ensuring smooth sampling even for high-moisture or sticky materials, with no blockages or spillage.
6.Compact and Maintenance-Friendly Design
The sampler features a simplified structure with minimal space requirements, enabling easy installation, debugging, and maintenance while maintaining high operational reliability.
7.Closed-Loop Residual Recycling System
A bucket elevator returns residual materials to the inbound or furnace coal conveyor belt. The fully enclosed system ensures dust-free and residue-free operation from sampling to recycling.
