Anti-jumping large-angle downward transportation long-distance curve belt conveyor

Abstract

The invention discloses an anti-jumping large-angle downward transportation long-distance curve belt conveyor, and relates to the technical field of unmanned intelligent conveyors. The anti-jumping large-angle downward transportation long-distance curve belt conveyor comprises an unmanned storage yard intelligent control system, an anti-jumping control module, an intelligent tensioning system and a composite braking system. According to the unmanned storage yard intelligent control system, a distributed optical fiber strain sensor array distributed at golden section intervals is adopted, dynamic tension distribution of a concave arc section is accurately monitored, a 10Hz high-frequency three-dimensional laser radar is combined to scan the material stacking form, a real-time three-dimensional point cloud model is constructed, an anti-bounce control module integrates a variable parameter PID starting algorithm, and the dynamic tension distribution of the concave arc section is accurately monitored. The acceleration is stabilized within the range from 0.05 m / s < 2 > to 0.1 m / s < 2 >, the variable-curvature bearing structure and the hydraulic adjusting carrier roller set are matched, the material centrifugal deviation risk during large-angle turning can be reduced, then the jumping problem of long-distance curve conveying is solved, the equipment stability and the conveying efficiency are improved, and the device is suitable for a high-strength continuous operation scene of an unmanned storage yard.

Description

Technical Field

[0001] The present invention relates to the technical field of unmanned intelligent conveyors, and specifically to a large-angle downward long-distance curved belt conveyor with anti-jumping function. Background Art

[0002] A curved belt conveyor is a continuous conveying device that achieves planar turning through special design, can efficiently convey materials in complex paths, and is widely used in industries such as mines, ports, chemical engineering, and power. With its flexible conveying path, high conveying capacity, and environmental protection characteristics, the curved belt conveyor has become an indispensable key device in modern industrial production.

[0003] The defects of the existing curved belt conveyors are as follows:

[0004] 1. Patent document JPS6487414A discloses a suspended type curved belt conveyor. However, in the transportation process of the conveyor in the above document, especially when facing large-angle curvature changes, there are technical problems such as unstable material transportation and inability to adapt to the high-precision transportation of unmanned yards.

[0005] 2. Patent document JP2000355418A discloses a belt conveyor for sharp curves. However, in the process of using the conveyor in the above document, there are technical problems such as low braking efficiency and accuracy.

[0006] 3. Patent document JP2015020890A discloses a curved conveyor. However, the conveyor in the above document has the technical problem that it cannot adjust the curvature of the conveyor belt in real time to ensure stable cargo transportation.

[0007] 4. Patent document CN1572676A discloses a belt-type curved conveyor. However, the conveyor in the above document has the technical problem of lacking a logistics sliding prediction model and being unable to perceive potential risks in advance. Summary of the Invention

[0008] The purpose of the present invention is to provide a large-angle downward long-distance curved belt conveyor with anti-jumping function to solve the technical problems raised in the above background art.

[0009] To achieve the above purpose, the present invention provides the following technical solution: A large-angle downward long-distance curved belt conveyor with anti-jumping function, including an unmanned yard intelligent control system, an anti-jumping control module, an intelligent tensioning system, and a composite braking system. The unmanned yard intelligent control system includes a distributed optical fiber strain sensor array and a three-dimensional lidar. The optical fiber strain sensor array is arranged along the longitudinal direction of the conveyor belt at the golden section spacing, and the spacing is L0×(0.618 n)(where n is a natural number and L0 is the reference spacing), the dynamic tension distribution of the concave arc section is monitored in real time, and the 3D lidar obtains the point cloud data of the material accumulation form on the conveyor belt surface at a sampling frequency of 10 Hz;

[0010] The anti-jump control module includes a starting acceleration control unit, a concave arc section adaptive adjustment unit, a multi-stage tension coordinated adjustment unit, and an emergency braking control unit;

[0011] The starting acceleration control unit uses a variable parameter PID algorithm to dynamically adjust the starting curve, so that the acceleration is stabilized in the range of 0.05 - 0.1 m / s 2 interval, and the starting time deviation is controlled within ±5%;

[0012] The concave arc section adaptive adjustment unit includes a variable curvature load-bearing structure and a hydraulic adjustment idler group. The minimum curvature radius R of the variable curvature load-bearing structure min satisfies the formula:

[0013]

[0014] where K is a safety factor of 1.2 - 1.5, T is the conveyor belt tension (kN), W is the weight of the conveyor belt per unit length (kg / m), and g is the acceleration due to gravity (9.81 m / s 2 ), and the actual curvature radius is taken as 1.3 - 1.8 times R min ;

[0015] The hydraulic adjustment idler group is arranged at a spacing of 20 m, integrated with a MEMS gyroscope and a pressure sensor, the dynamic adjustment range of the adjustment angle is ±3°, and at the same time, the surface of the hydraulic adjustment idler group is coated with a 0.5 mm silicon nitride ceramic layer. The hydraulic drive working pressure of the hydraulic adjustment idler group is 10 - 15 MPa, and the response time ≤ 200 ms;

[0016] The intelligent tensioning system includes a buffer weight device and a hydraulic servo actuator, and the composite braking system includes a variable frequency drive braking unit and a disc emergency braking unit.

[0017] Preferably, the buffer weight device is provided with an upper and lower limit position detection module, including a Hall effect proximity switch and a vision recognition system, the sensing distance is 50 ± 2 mm, and it is equipped with a three-stage adjustable damping buffer. The main buffer cylinder stroke is 500 mm and the damping coefficient is 5000 N·s / m, and the auxiliary buffer cylinder stroke is 300 mm and the damping coefficient is 2000 N·s / m;

[0018] The hydraulic servo actuator communicates with the intelligent control system of the unmanned yard through the OPC UA protocol, and adjusts the position of the tensioning wheel in real time to make the tension fluctuation of the concave arc section ≤ ±5%;

[0019] The variable-frequency drive braking unit adopts S-type braking curve control, and the braking deceleration gradient ≤ 0.15m / s 2 ;

[0020] The disc type emergency braking unit integrates a speed closed-loop control system, has a braking curve database based on dynamic analysis built-in, implements multi-stage point braking, the single braking time ≤ 0.5s, and the adjustable range of the braking interval is 0.2 - 1.0s.

[0021] Preferably, the conveyor belt rack includes a bottom plate, and a number of hydraulic adjustment idler groups are arranged on the top of the bottom plate. Driving rollers are installed at both ends of the top of the bottom plate, and a first servo motor is installed on one side of the driving roller, and the first servo motor is electrically connected to the starting acceleration control unit.

[0022] Preferably, a fixing plate is installed on the top of the hydraulic structure of the hydraulic adjustment idler group. A lower protective idler is installed at the bottom of the fixing plate. A first support plate is installed in the middle of the inner bottom wall of the fixing plate. A first upper adjustment idler is installed on the top of the first support plate. Connection grooves are opened at both ends of the first support plate. The inner wall of the connection groove is connected by a hinge to a second support plate. A second upper adjustment idler is installed on the top of the second support plate. A moving groove is provided at one end of the second support plate. A moving block is installed on the inner wall of the moving groove. One end of the moving block is installed with a pressure belt wheel through a bearing. Hydraulic cylinders are respectively installed at both ends of the top of the fixing plate, and the output end of the hydraulic cylinder is installed on the top of the moving block.

[0023] Preferably, a sliding groove is provided on the inner bottom wall of the fixing plate. A second servo motor is installed on one side of the fixing plate. The output end of the second servo motor is installed with a bidirectional lead screw, and the bidirectional lead screw penetrates through the inside of the sliding groove. A slider is threadedly connected to the outer wall of the bidirectional lead screw. A first rotating shaft is installed on the top of the slider. A support rod is connected to the outer wall of the first rotating shaft. The other end of the support rod is connected to a second rotating shaft, and the top of the second rotating shaft is respectively installed at the bottom of the second support plate.

[0024] Preferably, the variable curvature load-bearing structure adopts a gradually changing curvature design optimized based on ANSYS transient analysis. A high-damping rubber cushion layer with a thickness of 20mm is provided in the transition area of the concave arc section. The high-damping rubber cushion layer is made by compound modification of butyl rubber and carbon nanotubes.

[0025] Preferably, the multi-stage tension cooperative adjustment unit includes a MEMS wireless tension sensor, a data fusion processor, and an adaptive feedback controller. The MEMS wireless tension sensors are arranged along the concave arc section according to a ratio of 0.618:1, the sampling frequency ≥ 100Hz. The data fusion processor uses an improved Kalman filtering algorithm to process the tension data to generate a three-dimensional tension thermal map. The adaptive feedback controller dynamically adjusts the PID parameters of the hydraulic servo actuator according to the characteristics of the thermal map, and the control period ≤ 50ms.

[0026] Preferably, the intelligent control system for the unmanned yard also includes a material sliding prediction model and a dynamic risk warning module. The material sliding prediction model analyzes the lidar point cloud data based on a deep neural network to predict the material sliding trend. The dynamic risk warning module is used to trigger the composite braking system 50 - 100 ms in advance when the predicted sliding amount exceeds the set threshold.

[0027] Preferably, the working steps of the belt conveyor are as follows:

[0028] S1. The hydraulic servo actuator drives the buffer weight device to a preset tension to ensure that the initial tension of the conveyor belt meets the requirements of multi-stage tension coordinated regulation;

[0029] The start acceleration control unit generates a smooth start curve through a variable parameter PID algorithm, controls the motor output to stabilize the acceleration in the range of 0.05 - 0.1 m / s 2 interval, and the start time deviation is controlled within ±5% to avoid instantaneous tension mutation;

[0030] The 3D lidar scans the surface of the conveyor belt at a frequency of 10 Hz to generate point cloud data of the material accumulation form, and synchronously transmits it to the material sliding prediction model;

[0031] S2. The distributed fiber optic strain sensor array collects the dynamic tension distribution of the concave arc section at the golden section spacing, and feeds the data back to the concave arc section adaptive adjustment unit;

[0032] The variable curvature load-bearing structure calculates the minimum curvature radius R according to the real-time tension min , the safety factor K = 1.2 - 1.5, and the actual curvature radius is taken as 1.3 - 1.8 times R min ;

[0033] The hydraulic adjustment idler group feeds back the attitude through the MEMS gyroscope and pressure sensor, dynamically adjusts the angle by ±3°, the response time ≤ 200 ms, and the surface silicon nitride ceramic layer reduces friction and wear;

[0034] S3. The multi-stage tension coordinated adjustment unit integrates the data of the fiber optic sensor and the hydraulic idler group, dynamically adjusts the tension distribution of each section of the conveyor belt, and suppresses the centrifugal offset of the material;

[0035] The material sliding prediction model analyzes the lidar point cloud based on a deep neural network, identifies features such as the slope and volume of the material accumulation, and predicts the sliding trend. If the predicted sliding amount exceeds the threshold, the dynamic risk warning module triggers the composite braking system 50 - 100 ms in advance;

[0036] S4. Conventional braking: The variable frequency drive braking unit preferentially reduces the speed through motor reverse or energy consumption braking;

[0037] Emergency braking: If the risk of slipping is not eliminated, the disc type emergency braking unit will immediately apply the brake;

[0038] S5. After braking, the intelligent control system of the unmanned yard automatically detects the status of each sensor, and resumes start-up preparation after confirming no faults.

[0039] Preferably, the following steps are further included in the S4:

[0040] S41. During the braking process, the hydraulic servo actuator compensates for the tension fluctuation of the conveyor belt in real time to prevent slack or belt breakage.

[0041] Compared with the prior art, the beneficial effects of the present invention are:

[0042] 1. The present invention adopts a distributed optical fiber strain sensor array with a golden section spacing distribution through the intelligent control system of the unmanned yard to accurately monitor the dynamic tension distribution of the concave arc section. Combining with a 10Hz high-frequency three-dimensional lidar to scan the material accumulation form, a real-time three-dimensional point cloud model is constructed. The anti-jump control module integrates a variable parameter PID start-up algorithm to stabilize the acceleration in the range of 0.05 - 0.1m / s 2 interval, with the deviation controlled within ±5%. Cooperating with the variable curvature load-bearing structure and the hydraulic adjustment idler group, it can reduce the risk of material centrifugal offset during large-angle turning. Furthermore, it not only solves the jumping problem of long-distance curve conveying, but also improves the equipment stability and transportation efficiency through full-state perception and multi-parameter collaborative control, and is suitable for high-intensity continuous operation scenarios of unmanned yards;

[0043] 2. The present invention realizes accurate tension control and safe braking through a multi-level buffer and intelligent braking system. The buffer weight device adopts dual-redundancy detection of a Hall effect proximity switch and a visual recognition system, and cooperates with the gradient damping design of the main / auxiliary buffer cylinders, which can absorb the impact kinetic energy. Cooperating with the hydraulic servo actuator to realize tension fluctuation control based on the OPC UA protocol to form a dynamic tension closed loop. The braking system adopts a composite scheme of S-shaped curve frequency conversion braking and multi-stage point braking emergency braking. The disc type emergency braking unit calls the dynamic braking curve database through speed closed-loop control, which can achieve accurate braking, and thus ensure the material stability rate of the device at large angles;

[0044] 3. The present invention adopts a modular hydraulic adjustment idler group design for the conveyor belt frame bottom plate. Each idler group is driven by an independent hydraulic structure to adjust the height of the device. Then, cooperating with the articulated support plate structure adjusted by a bidirectional lead screw, the included angle between the first upper adjustment roller and the second upper adjustment roller can be adjusted in real time. Cooperating with the hydraulic servo control of the belt pressing wheel, a three-dimensional adjustable conveyor belt restraint system is formed. Furthermore, it can not only adapt to the complex curvature changes of the concave arc section, but also adjust the curvature of the conveyor belt to ensure the stability of cargo transportation;

[0045] 4. The present invention adopts a gradually changing curvature design optimized by ANSYS transient analysis for the variable curvature load-bearing structure, combined with a butyl rubber-carbon nanotube composite modified cushion layer, which can significantly improve the structural load-bearing efficiency and reduce dynamic impact. The multi-stage tension collaborative adjustment unit innovatively arranges MEMS wireless tension sensors, distributed according to the golden ratio of 0.618:1, and cooperates with 100Hz high-frequency sampling and an improved Kalman filtering algorithm to generate a three-dimensional tension thermal map in real time. Through an adaptive feedback controller, the hydraulic servo PID parameters are dynamically adjusted with a period of ≤50ms to achieve high-precision tension control. The intelligent control system for unmanned yards integrates a material sliding prediction model driven by a deep neural network, directly analyzes three-dimensional lidar point cloud data, and can trigger composite braking 50 - 100ms in advance in cooperation with a dynamic risk warning module, enabling the system to have the ability of fault pre-disposal. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 is a schematic diagram of the system structure of the present invention;

[0047] Figure 2 is a three-dimensional schematic diagram of the overall structure of the present invention;

[0048] Figure 3 is a schematic cross-sectional view of the overall structure of the present invention;

[0049] Figure 4 is of the present invention Figure 3 schematic diagram of the structure at position A in;

[0050] Figure 5 is a schematic diagram of the hydraulic adjustment idler group structure of the present invention;

[0051] Figure 6 is of the present invention Figure 5 schematic diagram of the structure at position B in;

[0052] Figure 7 is a schematic diagram of the working process of the present invention.

[0053] In the figure: 1. Intelligent control system for unmanned storage yard; 2. Anti-vibration control module; 3. Intelligent tensioning system; 4. Composite braking system; 5. Conveyor belt rack; 6. Fiber optic strain sensor array; 7. 3D lidar; 8. Starting acceleration control unit; 9. Adaptive adjustment unit for concave arc section; 10. Multi-level tension coordinated adjustment unit; 11. Emergency braking control unit; 12. Variable curvature load-bearing structure; 13. Hydraulic adjustment idler set; 14. MEMS gyroscope; 15. Pressure sensor; 16. Buffer weight device; 17. Hydraulic servo actuator; 18. Variable frequency drive braking unit; 19. Disc type emergency braking unit; 20. Limit position detection module; 21. Hall effect proximity switch; 22. Visual recognition system; 23. Three-stage adjustable damping buffer; 24. Speed closed-loop control system; 25. Braking curve database; 26. Base plate; 27. Driving roller; 28. First servo motor; 29. Fixed plate; 30. Lower protection idler; 31. First support plate; 32. First upper adjustment roller; 33. Connection groove; 34. Second support plate; 35. Second upper adjustment roller; 36. Slide groove; 37. Second servo motor; 38. Bidirectional lead screw; 39. Slide block; 40. First rotating shaft; 41. Support rod; 42. Second rotating shaft; 43. High damping rubber cushion layer; 44. MEMS wireless tension sensor; 45. Data fusion processor; 46. Adaptive feedback controller; 47. Material sliding prediction model; 48. Dynamic risk warning module; 49. Moving groove; 50. Moving block; 51. Pressing belt wheel; 52. Hydraulic cylinder. Specific embodiments

[0054] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0055] In the description of the present invention, it should be noted that the orientation or positional relationship indicated by the terms "upper", "lower", "inner", "outer", "front end", "rear end", "both ends", "one end", "the other end", etc. is based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance.

[0056] In the description of the present invention, it should be noted that unless otherwise clearly specified and defined, terms such as "installation", "equipped with", "connection", etc. should be understood in a broad sense. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0057] Embodiment 1: Please refer to Figure 1 , an embodiment provided by the present invention: an anti-jump large-angle downward long-distance curved belt conveyor, including an unmanned yard intelligent control system 1, an anti-jump control module 2, an intelligent tensioning system 3, a composite braking system 4, and a conveyor belt rack 5. The unmanned yard intelligent control system 1 includes a distributed optical fiber strain sensor array 6 and a 3D lidar 7. The optical fiber strain sensor array 6 is arranged at the golden section spacing along the longitudinal direction of the conveyor belt to monitor the dynamic tension distribution of the concave arc section in real time. The 3D lidar 7 acquires the point cloud data of the material accumulation form on the conveyor belt surface at a sampling frequency of 10 Hz;

[0058] The anti-jump control module 2 includes a starting acceleration control unit 8, a concave arc section adaptive adjustment unit 9, a multi-stage tension coordinated adjustment unit 10, and an emergency braking control unit 11;

[0059] The starting acceleration control unit 8 dynamically adjusts the starting curve by using a variable parameter PID algorithm to stabilize the acceleration in the range of 0.05 - 0.1 m / s 2 interval, and the starting time deviation is controlled within ±5%;

[0060] The concave arc section adaptive adjustment unit 9 includes a variable curvature bearing structure 12 and a hydraulic adjustment idler group 13. The minimum curvature radius R of the variable curvature bearing structure 12 min satisfies the formula:

[0061]

[0062] where K is a safety factor of 1.2 - 1.5, T is the conveyor belt tension (kN), W is the weight of the conveyor belt per unit length (kg / m), and g is the acceleration due to gravity (9.81 m / s 2 ), and the actual curvature radius is taken as 1.3 - 1.8 times R min ;

[0063] The hydraulic adjustment idler sets 13 are arranged at an interval of 20 m, integrated with MEMS gyroscopes 14 and pressure sensors 15, with a dynamic adjustment range of the adjustment angle of ±3°. At the same time, the surface of the hydraulic adjustment idler sets 13 is coated with a 0.5-mm silicon nitride ceramic layer. The hydraulic drive working pressure of the hydraulic adjustment idler sets 13 is 10 - 15 MPa, and the response time ≤ 200 ms;

[0064] The intelligent tensioning system 3 includes a buffer weight device 16 and a hydraulic servo actuator 17, and the composite braking system 4 includes a variable-frequency drive braking unit 18 and a disc emergency braking unit 19;

[0065] Furthermore, through the unmanned yard intelligent control system 1, a distributed optical fiber strain sensor array 6 with a golden-section spacing distribution is adopted to accurately monitor the dynamic tension distribution of the concave arc section. Combining with the 10-Hz high-frequency three-dimensional lidar 7 to scan the material stacking shape, a real-time three-dimensional point cloud model is constructed. The anti-jumping control module 2 integrates a variable-parameter PID starting algorithm to stabilize the acceleration in the range of 0.05 - 0.1 m / s 2 interval, with the deviation controlled within ±5%. Cooperating with the variable-curvature load-bearing structure 12 and the hydraulic adjustment idler sets 13, it can reduce the risk of material centrifugal offset during large-angle turning. Furthermore, it not only solves the jumping problem of long-distance curve conveying, but also improves the equipment stability and transportation efficiency through full-state perception and multi-parameter collaborative control, and is applicable to the high-intensity continuous operation scenario of unmanned yards.

[0066] Example 2: Please refer to Figure 1 and Figure 2 In an embodiment provided by the present invention, the buffer weight device 16 is provided with upper and lower limit position detection modules 20, including a Hall effect proximity switch 21 and a visual recognition system 22, with an induction distance of 50 ± 2 mm, equipped with a three-stage adjustable damping buffer 23, the main buffer cylinder stroke is 500 mm, the damping coefficient is 5000 N·s / m, the auxiliary buffer cylinder stroke is 300 mm, and the damping coefficient is 2000 N·s / m;

[0067] The hydraulic servo actuator 17 communicates with the unmanned yard intelligent control system 1 through the OPC UA protocol to adjust the weight position in real time to make the tension fluctuation of the concave arc section ≤ ±5%;

[0068] The variable-frequency drive braking unit 18 adopts an S-type braking curve control, and the braking deceleration gradient ≤ 0.15 m / s 2 ;

[0069] The disc emergency braking unit 19 integrates a speed closed-loop control system 24, with a built-in braking curve database 25 based on dynamic analysis, implementing multi-stage point braking, the single braking time ≤ 0.5 s, and the adjustable range of the braking interval is 0.2 - 1.0 s;

[0070] Furthermore, precise tension control and safe braking are achieved through a multi-level buffer and intelligent braking system. The buffer weight device 16 adopts dual redundant detection of the Hall effect proximity switch 21 and the visual recognition system 22, and cooperates with the gradient damping design of the main / auxiliary buffer cylinder to absorb the impact kinetic energy. It cooperates with the hydraulic servo actuator 17 to realize tension fluctuation control based on the OPC UA protocol to form a dynamic tension closed loop. The braking system adopts a composite solution of S-shaped curve variable frequency braking and multi-level point brake emergency braking. The disc emergency brake unit 19 calls the dynamic braking curve database 25 through speed closed-loop control, which can achieve precise braking, thereby ensuring that the device can still maintain the material stability rate at a large angle.

[0071] Example 3: Please refer to Figure 2 , Figure 3 , Figure 4 , Figure 5 and Figure 6 , an embodiment provided by the present invention: the conveyor belt frame 5 includes a bottom plate 26, and a plurality of hydraulic adjustment roller groups 13 are arranged on the top of the bottom plate 26, transmission rollers 27 are installed at both ends of the top of the bottom plate 26, and a first servo motor 28 is installed on one side of the transmission roller 27, and the first servo motor 28 is electrically connected to the start acceleration control unit 8;

[0072] A fixed plate 29 is installed on the top of the hydraulic structure of the hydraulic adjustment roller group 13, a lower protective roller 30 is installed on the bottom of the fixed plate 29, a first support plate 31 is installed in the middle of the inner bottom wall of the fixed plate 29, a first upper adjustment roller 32 is installed on the top of the first support plate 31, connecting grooves 33 are provided at both ends of the first support plate 31, a second support plate 34 is connected to the inner wall of the connecting groove 33 by a hinge, a second upper adjustment roller 35 is installed on the top of the second support plate 34, a moving groove 49 is provided at one end of the second support plate 34, a moving block 50 is installed on the inner wall of the moving groove 49, a belt pressure roller 51 is installed on one end of the moving block 50 through a bearing, hydraulic cylinders 52 are installed at both ends of the top of the fixed plate 29, and the output end of the hydraulic cylinder 52 is installed on the top of the moving block 50;

[0073] The inner bottom wall of the fixed plate 29 is provided with a slide groove 36, a second servo motor 37 is installed on one side of the fixed plate 29, a bidirectional lead screw 38 is installed at the output end of the second servo motor 37, and the bidirectional lead screw 38 is penetrated and arranged inside the slide groove 36, a slider 39 is threadedly connected to the outer wall of the bidirectional lead screw 38, a first rotating shaft 40 is installed on the top of the slider 39, a support rod 41 is connected to the outer wall of the first rotating shaft 40, the other end of the support rod 41 is connected to the second rotating shaft 42, and the top of the second rotating shaft 42 is respectively installed on the bottom of the second support plate 34;

[0074] Furthermore, by adopting a modular hydraulic adjustable idler group 13 design for the bottom plate 26 of the conveyor belt rack 5, each idler group is driven by an independent hydraulic structure to adjust the height of the adjusting device. Then, in combination with the articulated support plate structure adjusted by the bidirectional lead screw 38, the included angle between the first upper adjusting roller 32 and the second upper adjusting roller 35 can be adjusted in real time. Coupled with the hydraulic servo control of the belt pressing wheel 51, a three-dimensional adjustable conveyor belt restraint system is formed. Furthermore, it can not only adapt to the complex curvature changes of the concave arc section, but also adjust the curvature of the conveyor belt to ensure the stability of cargo transportation.

[0075] Example 4: Please refer to Figure 1 and Figure 3 , an embodiment provided by the present invention: The variable curvature load-bearing structure 12 adopts a gradually changing curvature design optimized based on ANSYS transient analysis. A high-damping rubber cushion layer 43 with a thickness of 20 mm is arranged in the transition area of the concave arc section. The high-damping rubber cushion layer 43 is made by compound modification of butyl rubber and carbon nanotubes;

[0076] The multi-stage tension collaborative adjustment unit 10 includes a MEMS wireless tension sensor 44, a data fusion processor 45, and an adaptive feedback controller 46. The MEMS wireless tension sensor 44 is arranged along the concave arc section according to a ratio of 0.618:1, and the sampling frequency is ≥100 Hz. The data fusion processor 45 uses an improved Kalman filtering algorithm to process the tension data to generate a three-dimensional tension thermal map. The adaptive feedback controller 46 dynamically adjusts the PID parameters of the hydraulic servo actuator 17 according to the characteristics of the thermal map, and the control period is ≤50 ms;

[0077] The unmanned yard intelligent control system 1 further includes a material sliding prediction model 47, which analyzes the lidar point cloud data based on a deep neural network to predict the material sliding trend, and a dynamic risk warning module 48. When the predicted sliding amount exceeds the set threshold, the composite braking system 4 is triggered 50 - 100 ms in advance;

[0078] Furthermore, by adopting a gradually changing curvature design optimized by ANSYS transient analysis for the variable curvature load-bearing structure 12 and combining it with a butyl rubber - carbon nanotube composite modified cushion layer, the structural load-bearing efficiency can be significantly improved and the dynamic impact can be reduced. The multi-stage tension collaborative adjustment unit 10 innovatively arranges the MEMS wireless tension sensor 44, which is distributed according to the golden ratio of 0.618:1. Combined with 100 Hz high-frequency sampling and an improved Kalman filtering algorithm, a three-dimensional tension thermal map is generated in real time. The adaptive feedback controller 46 dynamically adjusts the hydraulic servo PID parameters with a period of ≤50 ms to achieve high-precision tension control. The unmanned yard intelligent control system 1 integrates a material sliding prediction model 47 driven by a deep neural network, directly analyzes the three-dimensional lidar 7 point cloud data, and can trigger composite braking 50 - 100 ms in advance in cooperation with the dynamic risk warning module 48, enabling the system to have the ability of fault pre-disposal.

[0079] Example 5: Please refer to Figure 7 , an embodiment provided by the present invention: The working steps of the belt conveyor are as follows:

[0080] S1. The hydraulic servo actuator 17 drives the buffer weight device 16 to a preset tension to ensure that the initial tension of the conveyor belt meets the requirements of multi-stage tension collaborative regulation;

[0081] The start acceleration control unit 8 generates a smooth start curve through a variable parameter PID algorithm, controls the motor output to stabilize the acceleration in the range of 0.05 - 0.1 m / s 2 interval, and the start time deviation is controlled within ±5%, avoiding instantaneous tension mutation;

[0082] The 3D lidar 7 scans the surface of the conveyor belt at a frequency of 10 Hz to generate point cloud data of the material accumulation form, and synchronously transmits it to the material sliding prediction model 47;

[0083] S2. The distributed fiber optic strain sensor array 6 collects the dynamic tension distribution of the concave arc section at the golden section spacing, and feeds back the data to the concave arc section adaptive adjustment unit 9;

[0084] The variable curvature load-bearing structure 12 calculates the minimum curvature radius R according to the real-time tension min , the safety factor K = 1.2 - 1.5, and the actual curvature radius takes 1.3 - 1.8 times R min ;

[0085] The hydraulic adjustment idler group 13 feeds back the attitude through the MEMS gyroscope 14 and the pressure sensor 15, dynamically adjusts the angle by ±3°, the response time ≤ 200 ms, and the surface silicon nitride ceramic layer reduces friction and wear;

[0086] S3. The second servo motor 37 drives the bidirectional lead screw 38, and the linkage mechanism of the support rod 41 enables the second support plate 34 to generate an angle adjustment of ±3°. Based on the curvature gradual change design of ANSYS transient analysis, it automatically matches the conveyor belt form, and the high-damping rubber cushion layer 43 can absorb vibration energy;

[0087] S4. The MEMS wireless tension sensor 44 uploads data at a sampling frequency of 100 Hz. The data fusion processor 45 uses an improved Kalman filter to generate a three-dimensional tension heat map. The adaptive feedback controller 46 dynamically adjusts the PID parameters, and the buffer weight device 16 absorbs the impact load through a three-stage adjustable damping buffer 23;

[0088] S5. The multi-stage tension collaborative regulation unit 10 integrates the data of the fiber optic sensor and the hydraulic idler group, dynamically adjusts the tension distribution of each section of the conveyor belt, and suppresses the centrifugal offset of the material;

[0089] The material sliding prediction model 47 analyzes the lidar point cloud based on a deep neural network, identifies features such as the slope and volume of the material accumulation, and predicts the sliding trend. If the predicted sliding amount exceeds the threshold, the dynamic risk warning module 48 triggers the composite braking system 4 50 - 100 ms in advance;

[0090] S6. Conventional braking: The variable-frequency drive braking unit 18 preferentially reduces the speed by motor reverse rotation or energy consumption braking;

[0091] Emergency braking: If the sliding risk is not eliminated, the disc emergency braking unit 19 immediately applies the brake;

[0092] S7. After braking, the intelligent control system 1 of the unmanned yard automatically detects the status of each sensor, and resumes the start-up preparation after confirming no faults;

[0093] S6 also includes the following steps:

[0094] S61. During braking, the hydraulic servo actuator 17 compensates for the tension fluctuation of the conveyor belt in real time to prevent slack or belt breakage.

[0095] Working principle: The intelligent control system 1 of the unmanned yard uses a distributed optical fiber strain sensor array 6 with a golden section spacing distribution to accurately monitor the dynamic tension distribution of the concave arc section, combines with a 10 Hz high-frequency three-dimensional lidar 7 to scan the material accumulation form, constructs a real-time three-dimensional point cloud model, and the anti-jump control module 2 integrates a variable-parameter PID start-up algorithm to stabilize the acceleration at 0.05 - 0.1 m / s 2The interval is controlled within ±5%. In cooperation with the variable curvature load-bearing structure 12 and the hydraulic adjustable idler group 13, it can reduce the risk of material centrifugal offset during large-angle turning. Furthermore, it not only solves the problem of jitter during long-distance curve conveying, but also improves the equipment stability and transportation efficiency through full-state perception and multi-parameter collaborative control. It is applicable to the high-intensity continuous operation scenario of an unmanned yard. Through multi-level buffering and an intelligent braking system, precise tension control and safe braking are achieved. The buffer weight device 16 adopts dual-redundancy detection of the Hall effect proximity switch 21 and the visual recognition system 22. In cooperation with the gradient damping design of the main / auxiliary buffer cylinders, it can absorb the impact kinetic energy. In cooperation with the hydraulic servo actuator 17, tension fluctuation control is realized based on the OPCUA protocol to form a dynamic tension closed loop. The braking system adopts a composite solution of S-shaped curve variable-frequency braking and multi-stage point braking emergency braking. The disc emergency braking unit 19 calls the dynamic braking curve database 25 through speed closed-loop control, and can achieve precise braking. Furthermore, it can ensure that the device can still maintain the material stability rate at large angles. Through the design of the modular hydraulic adjustable idler group 13 for the bottom plate 26 of the conveyor belt rack 5, each idler group is driven by an independent hydraulic structure to adjust the height of the device. Then, in cooperation with the articulated support plate structure adjusted by the bidirectional lead screw 38, the included angle between the first upper adjusting roller 32 and the second upper adjusting roller 35 can be adjusted in real time. In cooperation with the hydraulic servo control of the belt pressing wheel 51, a three-dimensional adjustable conveyor belt constraint system is formed. Furthermore, it can not only adapt to the complex curvature changes of the concave arc section, but also adjust the curvature of the conveyor belt to ensure the stability of cargo transportation. Through the variable curvature load-bearing structure 12 adopting a gradually changing curvature design optimized by ANSYS transient analysis, combined with a butyl rubber-carbon nanotube composite modified cushion layer, it can significantly improve the structural load-bearing efficiency and reduce dynamic impact. The multi-stage tension collaborative adjustment unit 10 innovatively arranges MEMS wireless tension sensors 44, distributed according to the golden ratio of 0.618:1. In cooperation with 100Hz high-frequency sampling and an improved Kalman filtering algorithm, a three-dimensional tension heat map is generated in real time. Through the adaptive feedback controller 46, the hydraulic servo PID parameters are dynamically adjusted with a period of ≤50ms to achieve high-precision tension control. The intelligent control system 1 of the unmanned yard integrates a material sliding prediction model 47 driven by a deep neural network, directly analyzes the point cloud data of the 3D lidar 7. In cooperation with the dynamic risk warning module 48, the composite braking can be triggered 50-100ms in advance, enabling the system to have the ability of fault pre-disposal.

[0096] It is obvious to those skilled in the art that the present invention is not limited to the details of the above-described exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention. Therefore, in any regard, the embodiments should be regarded as exemplary and non-limiting. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be embraced within the present invention. Any reference signs in the claims should not be construed as limiting the claims concerned.

Claims

1. An anti-jumping large-angle downward long-distance curved belt conveyor, comprising an unmanned yard intelligent control system (1), an anti-jumping control module (2), an intelligent tensioning system (3), a composite braking system (4) and a conveyor belt frame (5), characterized in that: The unmanned yard intelligent control system (1) comprises a distributed optical fiber strain sensor array (6) and a three-dimensional laser radar (7), wherein the optical fiber strain sensor array (6) is arranged at a golden section interval along the longitudinal direction of the conveyor belt to monitor the dynamic tension distribution of the concave arc segment in real time, and the three-dimensional laser radar (7) acquires point cloud data of the material accumulation morphology on the surface of the conveyor belt at a sampling frequency of 10 Hz; The anti-jump control module (2) comprises a starting acceleration control unit (8), a concave arc segment adaptive adjustment unit (9), a multi-stage tension coordination adjustment unit (10) and an emergency braking control unit (11); The starting acceleration control unit (8) uses a variable parameter PID algorithm to dynamically adjust the starting curve so that the acceleration is stabilized at 0.05-0.1 m / s 2 The start time deviation is controlled within ±5%; The concave arc segment adaptive adjustment unit (9) comprises a variable curvature bearing structure (12) and a hydraulic adjustment roller group (13), wherein the minimum curvature radius R of the variable curvature bearing structure (12) is min Satisfy the formula: Where K is a safety factor of 1.2-1.5, T is the conveyor belt tension (kN), W is the weight of the conveyor belt per unit length (kg / m), and g is the acceleration due to gravity (9.81m / s 2 ), the actual radius of curvature is 1.3-1.8 times R min ; The hydraulically adjustable roller group (13) is arranged at a spacing of 20m, and is integrated with a MEMS gyroscope (14) and a pressure sensor (15), and has an angle dynamic adjustment range of ±3°. At the same time, the surface of the hydraulically adjustable roller group (13) is coated with a 0.5mm silicon nitride ceramic layer. The hydraulic driving working pressure of the hydraulically adjustable roller group (13) is 10-15MPa, and the response time is ≤200ms; The intelligent tensioning system (3) comprises a buffer weight device (16) and a hydraulic servo actuator (17), and the composite braking system (4) comprises a variable frequency drive braking unit (18) and a disc emergency braking unit (19).

2. The anti-jumping large-angle downward long-distance curved belt conveyor according to claim 1 is characterized in that: The buffer weight device (16) is provided with an upper and lower limit position detection module (20), including a Hall effect proximity switch (21) and a visual recognition system (22), with a sensing distance of 50±2 mm, and is equipped with a three-level adjustable damping buffer (23), a main buffer cylinder stroke of 500 mm, a damping coefficient of 5000 N·s / m, an auxiliary buffer cylinder stroke of 300 mm, and a damping coefficient of 2000 N·s / m; The hydraulic servo actuator (17) communicates with the unmanned yard intelligent control system (1) through the OPC UA protocol, and adjusts the position of the tension wheel in real time so that the tension fluctuation of the concave arc section is ≤±5%; The variable frequency drive brake unit (18) adopts S-type brake curve control, and the braking deceleration gradient is ≤0.15m / s 2 ; The disc emergency brake unit (19) is integrated with a speed closed-loop control system (24), has a built-in braking curve database (25) based on dynamic analysis, implements multi-stage point braking, has a single braking time of ≤0.5s, and an adjustable braking interval range of 0.2-1.0s.

3. The anti-jumping large-angle downward long-distance curved belt conveyor according to claim 1 is characterized in that: The conveyor belt frame (5) comprises a bottom plate (26), and a plurality of hydraulically adjustable roller groups (13) are arranged on the top of the bottom plate (26), transmission rollers (27) are installed at both ends of the top of the bottom plate (26), and a first servo motor (28) is installed on one side of the transmission roller (27), and the first servo motor (28) is electrically connected to the starting acceleration control unit (8).

4. The anti-jumping large-angle downward long-distance curved belt conveyor according to claim 1 is characterized in that: The hydraulic structure of the hydraulic adjustment roller group (13) is provided with a fixed plate (29) at the top, a lower protection roller (30) is provided at the bottom of the fixed plate (29), a first support plate (31) is provided at the middle of the inner bottom wall of the fixed plate (29), a first upper adjustment roller (32) is provided at the top of the first support plate (31), connecting grooves (33) are provided at both ends of the first support plate (31), the inner wall of the connecting groove (33) is connected to a second support plate (34) through a hinge, a second upper adjustment roller (35) is provided at the top of the second support plate (34), a movable groove (49) is provided at one end of the second support plate (34), a movable block (50) is provided on the inner wall of the movable groove (49), a belt pressure roller (51) is provided at one end of the movable block (50) through a bearing, hydraulic cylinders (52) are provided at both ends of the top of the fixed plate (29), and the output end of the hydraulic cylinder (52) is installed at the top of the movable block (50).

5. The anti-jumping large-angle downward long-distance curved belt conveyor according to claim 4 is characterized in that: The inner bottom wall of the fixed plate (29) is provided with a slide groove (36), a second servo motor (37) is installed on one side of the fixed plate (29), a bidirectional lead screw (38) is installed at the output end of the second servo motor (37), and the bidirectional lead screw (38) is arranged inside the slide groove (36), the outer wall of the bidirectional lead screw (38) is threadedly connected with a slider (39), the top of the slider (39) is provided with a first rotating shaft (40), the outer wall of the first rotating shaft (40) is connected with a support rod (41), the other end of the support rod (41) is connected with a second rotating shaft (42), and the top of the second rotating shaft (42) is respectively installed at the bottom of the second support plate (34).

6. The anti-jumping large-angle downward long-distance curved belt conveyor according to claim 1, characterized in that: The variable curvature bearing structure (12) adopts a gradual curvature design based on ANSYS transient analysis optimization, and a high damping rubber cushion layer (43) with a thickness of 20 mm is arranged in the concave arc transition zone. The high damping rubber cushion layer (43) is made of butyl rubber and carbon nanotubes composite modification.

7. The anti-jumping large-angle downward long-distance curved belt conveyor according to claim 1, characterized in that: The multi-stage tension coordinated adjustment unit (10) comprises a MEMS wireless tension sensor (44), a data fusion processor (45) and an adaptive feedback controller (46), wherein the MEMS wireless tension sensor (44) is arranged along the concave arc segment at a ratio of 0.618:1, and the sampling frequency is ≥100 Hz, the data fusion processor (45) uses an improved Kalman filter algorithm to process tension data to generate a three-dimensional tension heat map, and the adaptive feedback controller (46) dynamically adjusts the PID parameters of the hydraulic servo actuator (17) according to the characteristics of the heat map, and the control period is ≤50 ms.

8. The anti-jumping large-angle downward long-distance curved belt conveyor according to claim 1, characterized in that: The unmanned yard intelligent control system (1) also includes a material sliding prediction model (47) and a dynamic risk warning module (48). The material sliding prediction model (47) analyzes laser radar point cloud data based on a deep neural network to predict the material sliding trend. The dynamic risk warning module (48) is used to trigger the composite braking system (4) 50-100 ms in advance when the predicted sliding amount exceeds a set threshold.

9. The method for using the anti-jumping large-angle downward long-distance curved belt conveyor according to claim 8 is characterized in that: The working steps of the belt conveyor are as follows: S1, the hydraulic servo actuator (17) drives the buffer weight device (16) to a preset tensioning force to ensure that the initial tension of the conveyor belt meets the requirements of multi-level tension coordinated adjustment; The starting acceleration control unit (8) generates a smooth starting curve through a variable parameter PID algorithm, and controls the motor output to stabilize the acceleration at 0.05-0.1 m / s 2 The start time deviation is controlled within ±5% to avoid sudden changes in tension; The three-dimensional laser radar (7) scans the conveyor belt surface at a frequency of 10 Hz to generate point cloud data of material accumulation morphology, which is synchronously transmitted to the material sliding prediction model (47); S2, a distributed optical fiber strain sensor array (6) collects dynamic tension distribution of the concave arc segment at a golden section interval, and feeds the data back to the concave arc segment adaptive adjustment unit (9); The variable curvature bearing structure (12) calculates the minimum curvature radius R according to the real-time tension min , safety factor K = 1.2-1.5, the actual curvature radius is 1.3-1.8 times R min ; The hydraulically adjustable roller group (13) uses a MEMS gyroscope (14) and a pressure sensor (15) to feedback the posture, dynamically adjust the angle by ±3°, and the response time is ≤200ms. The silicon nitride ceramic layer on the surface reduces friction and wear. S3, a multi-level tension coordination adjustment unit (10) integrates the data of the optical fiber sensor and the hydraulic roller group to dynamically adjust the tension distribution of each section of the conveyor belt to suppress the centrifugal deviation of the material; The material sliding prediction model (47) analyzes the laser radar point cloud based on a deep neural network, identifies the material accumulation slope, volume and other characteristics, and predicts the sliding trend. If the predicted sliding amount exceeds the threshold, the dynamic risk warning module (48) triggers the composite braking system (4) 50-100ms in advance; S4, conventional braking: the variable frequency drive braking unit (18) preferentially reduces the speed by motor reversal or energy consumption braking; Emergency braking: If the risk of sliding is not eliminated, the disc emergency brake unit (19) will immediately engage the brake; S5. After the braking is completed, the unmanned yard intelligent control system (1) automatically detects the status of each sensor and resumes the start-up preparation after confirming that there is no fault.

10. The method for using the anti-jumping large-angle downward long-distance curved belt conveyor according to claim 9, characterized in that: The step S4 also includes the following steps: S41. During the braking process, the hydraulic servo actuator (17) compensates for the tension fluctuation of the conveyor belt in real time to prevent the belt from loosening or breaking.

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