Products Description
In the operation of coal mines, weighbridge measurement is a core link in the mining and export of raw coal and the settlement of material transportation. The safety and accuracy of measurement directly affect the operational efficiency and production safety of enterprises.
At present, coal mine Truck scales generally face the pain points of being flammable and explosive, and having a high risk of personnel entry, which seriously restricts the safe and efficient operation of the measurement process.
However, The Weightworth truck scale+The unmanned weighing system equipped.With professional explosion-proof upgrade design and remote control capabilities, it has successfully solved industry problems.
This article takes a large underground coal mine project as an example to elaborate on the entire process of system implementation and application, providing practical references for industrial weighing scenarios such as unmanned weighing in similar coal mines and grain depots.
Case background:
Flammable and explosive substances pose hidden dangers, and the demand for safety measurement is urgent
The coal mine in this case is an underground mining mine with an annual output of 8 million tons. It mainly engages in raw coal mining, washing and processing, and export. Its weighing process has long been plagued by three core pain points: First, there is a high risk of flammability and explosiveness. In the coal mine operation environment, there are flammable and explosive media such as gas and coal dust. The electrical components of traditional truck scales are prone to generating electric sparks, which can cause explosion accidents. Moreover, transport vehicles frequently enter and exit, and personnel on duty at the site face safety hazards such as falling objects from heights and vehicle collisions. Second, the measurement efficiency is low. Under the manual on-duty mode, dedicated personnel are required to guide vehicles and enter data. It takes 5 to 7 minutes to weigh a single vehicle, and during peak hours, vehicle congestion is severe, which affects the progress of raw coal sales. Thirdly, data coordination is not smooth, and manual weighing data needs to be manually entered into the mine management system.
There are problems such as delayed input, errors and omissions, which cause the measurement data to be disconnected from the production and sales systems, and are not conducive to the enterprise's refined management.
Based on the above pain points, the coal mine has clearly defined its core requirements: it needs a heavy-duty weighbridge system with explosion-proof certification, which is suitable for the flammable and explosive working conditions of the coal mine. It should be equipped with an unmanned operation function to achieve remote operation, avoiding on-site personnel. At the same time, it should support the precise connection of weighing data with the mine management system to improve measurement efficiency and data collaboration capabilities, ensuring safe measurement while reducing operating costs.
Solution: Explosion-proof core design + precise functional,adaptation to build a solid safety measurement defense line
In response to the demands of the coal mine, the project team conducted multiple rounds of on-site investigations and explosion-proof scheme arguments. Eventually, they selected the Vitworth 200-ton explosion-proof Truck scale specifically for coal mines to be paired with an unmanned weighing system. The core reasons for the selection are clear and explicit: Firstly, the explosion-proof performance is compliant and compatible. All electrical components of this Truck scale have passed Ex dIMb
Special explosion-proof certification for coal mines, featuring flameproof enclosures,Intrinsically safe circuit.The design can effectively prevent the generation of electric sparks and is suitable for flammable and explosive environments such as coal mine gas and coal dust. Secondly, it has a strong heavy-load capacity. It adopts a fully steel welded U-shaped beam weighing body with a load-bearing capacity of up to 200 tons, which can be adapted to 150-ton heavy-duty coal transport vehicles in coal mines. Thirdly, brand service guarantee. Vitworth has rich experience in implementing in industrial scenarios such as coal mines and grain depots. It can provide full-process localized services including installation, commissioning and later operation and maintenance of explosion-proof equipment, solving the equipment guarantee problems under special working conditions in coal mines.
The core functions of the system precisely match the working conditions of the sand and gravel plant, as detailed below
Unattended remote operation + explosion-proof certification: The system integrates explosion-proof license plate recognition and RFID electronic tags\Infrared beam, explosion-proof video surveillance
After the vehicle enters the weighing area, the license plate recognition, vehicle information matching and weighing data collection are automatically completed without on-site personnel intervention throughout the process. Staff can remotely operate and monitor the weighing process in real time through the remote monitoring center, completely avoiding the risk of personnel entering the site. Meanwhile, the weighing data is encrypted in real time and uploaded to the mine management system, forming an unalterable measurement ledger, which is convenient for subsequent verification and data traceability.
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2.Unattended sealed control cabinet + automatic cleaning linkage: Equipped with a special explosion-proof sealed control cabinet for coal mines, it adopts a flameproof sealed structure, which can effectively isolate coal dust and gas, ensuring the stable operation of electrical components. The linked explosion-proof high-pressure automatic cleaning system automatically cleans the surface of the scale body in all directions after the vehicle weighing is completed, removing residual coal slag and dust to prevent debris from affecting the measurement accuracy. At the same time, it reduces the safety hazards caused by the accumulation of coal dust and lowers the workload of manual cleaning.
3.Classification weighing of sanitation vehicles + data integration with mine management system: The system supports the classification weighing of engineering vehicles transporting raw coal and sanitation vehicles cleaning coal gangue and garbage. It presets weighing rules and data statistics dimensions for different vehicle models to achieve separate accounting for raw coal and waste. The core highlight lies in the seamless integration with the mine management system. Weighing data can be automatically synchronized to subsystems such as production scheduling, sales settlement, and financial statistics, achieving a full-process data loop of "weighing - production - sales" and enhancing the enterprise's refined management level.
Implementation process: Scientific construction + standardized commissioning to ensure the efficient implementation of the system
The implementation of this project strictly adheres to the principle of "prioritizing explosion-proof compliance and step-by-step debugging and adaptation" to ensure a perfect match between the system and the working conditions of the coal mine. The first step is on-site investigation and optimization of the explosion-proof plan. The technical team conducts on-site investigation of the weighing area of the coal mine, combines the distribution of gas concentration and vehicle passage routes, and designs the installation position and data transmission plan of the explosion-proof floor scale to ensure compliance with the safety regulations of the coal mine.
The second step is the installation and integration of explosion-proof equipment. Complete the installation of the main body of the explosion-proof floor scale, sensors, sealed control cabinets automatic cleaning devices, and explosion-proof monitoring equipment. Build a dedicated encrypted data transmission network to achieve connection with the mine management system. The third step is explosion-proof testing and trial operation, focusing on testing the explosion-proof performance of the equipment, the function of unattended remote operation and the effect of data synchronization. Multiple rounds of calibration are conducted on the measurement accuracy, and peak weighing and gas warning scenarios are simulated to optimize the system response speed.
Implementation Effect: Data verifies the effectiveness, achieving stable and efficient operation
After the unmanned explosion-proof floor scale system was put into use, the weighing process in coal mines has achieved a dual upgrade in safety and efficiency. The core effects are quantified by data: First, the safety risk has been significantly reduced. The entire weighing process is fully unmanned on-site, and the risk of personnel entering the site has been reduced to zero. Since the equipment started operation, no explosion-proof safety hazards have occurred, meeting the requirements of coal mine safety regulations. Second, the weighing efficiency has been significantly enhanced.
The time taken to weigh a single vehicle has been reduced from 5 to 7 minutes to less than 40 seconds, with an efficiency increase of 65%. The problem of vehicle congestion during peak hours has been completely resolved, and the average daily number of weighing vehicles has increased from 280 to 500. Third, labor and management costs have been reduced. The 24-hour manual on-duty system has been abolished, and only two operation and maintenance personnel are needed for remote monitoring and equipment inspection. Labor costs have been reduced by 62%, saving 800,000 yuan in labor expenses annually.
The data is automatically connected to the mine management system, reducing the error and omission rate of data to zero and increasing the efficiency of financial settlement by 50%. Fourth, the stability of the equipment has been enhanced. The explosion-proof sealing design effectively resists coal dust and gas erosion, reducing the equipment failure rate by 78% and cutting operation and maintenance costs by 50%.
Summary: Precise scene adaptation empowers the intelligent upgrade of coal mine safety
The successful implementation of this explosion-proof upgrade project for coal mine weighbridges has fully verified the precise adaptability of Vitworth's unmanned explosion-proof weighbridge system to the flammable, explosive and high-risk working conditions in coal mines. This system, with its explosion-proof core design, has addressed the safety pain points in the industry. Through functions such as unmanned remote operation and data integration with the mine management system, it has achieved safe measurement, efficient operation, and intelligent management, providing core support for cost reduction, efficiency improvement, and safe production in coal mines. For industrial equipment operation and maintenance personnel, the explosion-proof compliance and convenient operation and maintenance features of the system have reduced the difficulty of equipment management under the special working conditions of coal mines. For enterprise procurement, its explosion-proof certification guarantee, all-scenario adaptability, and significant safety and economic benefits have made it the preferred solution for upgrading coal mine truck scales. In the future, as the intelligent transformation of coal mines accelerates, explosion-proof and unmanned weighbridge systems will become the standard for safety measurement in the industry, promoting the high-quality and safe development of the coal mining industry.
