Explanation of the Main Components of a Fully Automatic Coal Belt Sampling System

As industrial production gradually becomes more mechanized and automated, the methods of coal sampling in enterprises such as thermal power plants, coking plants, and steel mills are also changing.

The traditional manual sampling method, characterized by low efficiency, high labor intensity, and poor sampling representativeness, can no longer meet the development requirements of enterprises. Consequently, various sampling machines and systems are being adopted to replace manual sampling.

A fully automatic coal belt sampling system is designed to continuously sample coal during its transportation on a belt conveyor. The system is strictly designed and manufactured according to relevant sampling standards.

The sampling machine is installed either in the middle or at the head of the belt conveyor, performing a full-cross-section sweep of the coal flow at predetermined intervals. The collected subsamples pass through a chute into a primary feeder belt conveyor for iron removal, while the samples are evenly fed into a crusher for pulverization.

The subsamples are then divided into retained samples and discarded materials by a secondary belt divider. The retained samples are automatically collected in storage tanks, while the discarded materials are returned to the belt conveyor by a bucket elevator.

The entire sampling process is automated and completed by various components and devices, offering high sampling efficiency, strong representativeness, and reduced labor intensity. The main components of the system include the sampling machine, feeder belt conveyor, crusher, divider, automatic sample splitter, and control system.

(1) Sampling Machine: It employs a scraper-type sampling head made of stainless steel, which is wear-resistant and durable. The lower end is equipped with a soft-contact scraping plate that does not damage the coal conveyor belt while effectively sweeping the full cross-section of the coal flow. The rotating sampling bucket, driven by a reduction gear, cuts through the material flow at a certain rotational speed as it descends from the head drum of the belt conveyor, ensuring a complete subsample across the full width and thickness of the material flow.

(2) Feeder Belt Conveyor: Comprising a conveyor belt, idlers, an iron removal device, a cleaning device, and a tensioning device, the feeder belt conveyor has a smooth and flat belt surface that is easy to clean and resistant to adhesion, effectively preventing blockages and facilitating sampling. The materials are evenly transported to the next stage.

(3) Crusher: Featuring specialized technology for crushing wet coal, the crusher controls the discharge size within the range of 3-12mm. It is equipped with an automatic cleaning function to prevent material adhesion, ensuring unrestricted sampling regardless of material moisture or viscosity.

The sampling process is smooth, uniform, and reliable, with no blockages, adhesions, or spillages. The crusher is made of wear-resistant materials to ensure normal system operation and prevent equipment damage caused by large, hard-to-crush materials. It also incorporates reliable electrical and mechanical dual protection to ensure the safety of both the equipment and operators.

(4) Divider: The belt-sweeping divider is characterized by its simple structure, low failure rate, easy maintenance, high division accuracy, and a wide adjustable division ratio range. It operates reliably and stably. The machine rotates at a high speed, with a large rear plate inclination angle, generating centrifugal force that prevents material adhesion.

The parts in contact with the materials and the discharge chute are made of stainless steel, effectively preventing cross-contamination and coal blockages. The division ratio can be conveniently adjusted via PLC, with a wide adjustment range and a division accuracy of ≤0.37A without systematic errors. The adjustment can be made by regulating the rotational time interval of the cutting head or the opening size of the cutter.

(5) Control System: The entire fully automatic coal belt sampling system is controlled by PLC, enabling automatic or manual sampling modes that can be switched via a changeover switch. The control system is equipped with linkage and interlock functions to prevent misoperations that could affect the normal operation of the equipment.

The fully automatic coal belt sampling system is a mechanized and automated coal sampling device specifically designed for coal conveyor belts, capable of fully automatically completing the entire process of sampling, sample preparation, and sample collection. Its components are wear-resistant, durable, highly precise, compactly structured, and reliable in performance.