Large angle down-running long distance curved belt conveyor with anti-bouncing function

Abstract

The application discloses a large-angle down-running long-distance curved belt conveyor capable of preventing jumping, and relates to the technical field of unmanned intelligent conveyors, comprising an unmanned yard intelligent control system, a jumping-preventing control module, an intelligent tensioning system and a composite braking system.The application adopts a distributed fiber strain sensor array with golden section interval distribution through the unmanned yard intelligent control system to accurately monitor dynamic tension distribution of the concave arc section, combines 10Hz high-frequency three-dimensional laser radar to scan material accumulation forms, constructs a real-time three-dimensional point cloud model, and integrates a variable parameter PID starting algorithm in the jumping-preventing control module to stabilize acceleration at 0.05-0.1 m / s 2 interval, cooperates with a variable-curvature bearing structure and a hydraulic adjusting roller group, and can reduce the risk of material centrifugal deviation during large-angle turning, thereby not only solving the jumping problem of long-distance curved conveying, but also improving equipment stability and transportation efficiency, and being suitable for high-strength continuous operation scenes of unmanned yards.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of unmanned intelligent conveyors, in particular to a long-distance curved belt conveyor with large angle and anti-bouncing. BACKGROUND

[0002] The curved belt conveyor is a continuous conveying equipment that realizes plane turning through special design, and can efficiently convey materials in complex paths, and is widely used in mining, port, chemical industry, power and other industries. The curved belt conveyor has become an indispensable key equipment in modern industrial production due to its flexible conveying path, efficient conveying capacity and environmental protection characteristics.

[0003] The existing curved belt conveyor has the following defects:

[0004] 1. Patent document JPS6487414A discloses a suspended type curved traveling belt conveyor, but the conveyor in the above document has the technical problem of unstable logistics transportation during transportation, especially when facing large angle curvature change, and cannot adapt to high-precision transportation of unmanned yards.

[0005] 2. Patent document JP2000355418A discloses a belt conveyor for sharp curves, but the conveyor in the above document has the technical problem of low braking efficiency and precision during use.

[0006] 3. Patent document JP2015020890A discloses a curved conveyor, but the conveyor in the above document has the technical problem of being unable to adjust the curvature of the conveying belt in real time to ensure stable transportation of goods.

[0007] 4. Patent document CN1572676A discloses a belt type curved conveyor, but 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

[0008] The present application aims to provide a long-distance curved belt conveyor with large angle and anti-bouncing to solve the technical problems raised in the background.

[0009] To achieve the above purpose, the present application provides the following technical solution: a long-distance curved belt conveyor with large angle and anti-bouncing, comprising an unmanned yard intelligent control system, an anti-bouncing control module, an intelligent tensioning system and a composite braking system, the unmanned yard intelligent control system comprising a distributed optical fiber strain sensor array and a three-dimensional laser radar, the optical fiber strain sensor array being arranged along the longitudinal direction of the conveying belt at a golden section interval, the interval being L0x(0.618 n(wherein n is a natural number, L0 is a reference pitch), real-time monitoring of dynamic tension distribution of the concave arc segment, and the three-dimensional laser radar acquires point cloud data of material accumulation morphology on the surface of the conveying belt at a sampling frequency of 10 Hz;

[0010] The bounce control module comprises a start acceleration control unit, a concave arc segment adaptive adjustment unit, a multi-stage tension cooperative adjustment unit and an emergency brake control unit.

[0011] The start acceleration control unit dynamically adjusts the start curve by using a variable parameter PID algorithm, so that the acceleration is stably maintained at 0.05-0.1 m / s 2 Interval, and the start time deviation is controlled within ±5%;

[0012] The concave arc segment adaptive adjustment unit comprises a variable-curvature bearing structure and a hydraulic adjustment roller group, the minimum curvature radius R min of the variable-curvature bearing structure satisfies the formula:

[0013]

[0014] wherein K is a safety factor of 1.2-1.5, T is the conveying belt tension (kN), W is the unit length conveying belt weight (kg / m), g is the gravitational acceleration (9.81 m / s 2 ), and the actual curvature radius is 1.3-1.8 times R min ;

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

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

[0017] Preferably, the buffer weight device is provided with upper and lower limit position detection modules, which comprise Hall effect proximity switches and visual recognition systems, have a sensing distance of 50±2 mm, are equipped with three-stage adjustable damping buffers, and have a main buffer cylinder stroke of 500 mm and a damping coefficient of 5000 N·s / m, and an auxiliary buffer cylinder stroke of 300 mm and a damping coefficient of 2000 N·s / m.

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

[0019] The variable frequency drive brake unit adopts S-shaped brake curve control, and the brake deceleration gradient is less than or equal to 0.15 m / s 2 ;

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

[0021] Preferably, the conveyor frame comprises a bottom plate, and a plurality of hydraulic adjusting idler groups are arranged on the top of the bottom plate, drive rollers are arranged at the two ends of the top of the bottom plate, a first servo motor is arranged on one side of the drive roller, and the first servo motor is electrically connected with the start acceleration control unit.

[0022] Preferably, the hydraulic adjusting idler group comprises a fixed plate arranged on the top of the hydraulic structure, a lower protection roller arranged on the bottom of the fixed plate, a first support plate arranged on the middle of the inner bottom wall of the fixed plate, a first upper adjusting roller arranged on the top of the first support plate, a connecting groove arranged at the two ends of the first support plate, a second support plate hingedly connected to the inner wall of the connecting groove, a second upper adjusting roller arranged on the top of the second support plate, a moving groove arranged on one end of the second support plate, a moving block arranged on the inner wall of the moving groove, a belt pressing wheel arranged on one end of the moving block through a bearing, and a hydraulic cylinder arranged at the two ends of the top of the fixed plate, and the output end of the hydraulic cylinder is arranged on the top of the moving block.

[0023] Preferably, the inner bottom wall of the fixed plate is provided with a sliding groove, a second servo motor is arranged on one side of the fixed plate, a bidirectional screw rod is arranged on the output end of the second servo motor, the bidirectional screw rod is arranged in the interior of the sliding groove in a penetrating mode, a sliding block is threadedly connected to the outer wall of the bidirectional screw rod, a first rotating shaft is arranged on the top of the sliding block, a support rod is connected to the outer wall of the first rotating shaft, a second rotating shaft is connected to the other end of the support rod, and the top of the second rotating shaft is arranged on the bottom of the second support plate.

[0024] Preferably, the variable curvature bearing structure adopts a gradually changing curvature design based on ANSYS transient analysis optimization, a high-damping rubber pad layer is arranged in the transition area of the concave arc segment, the thickness of the high-damping rubber pad layer is 20 mm, and the high-damping rubber pad layer is made of butyl rubber and carbon nanotube composite modification.

[0025] Preferably, the multi-stage tension cooperative adjustment unit comprises a MEMS wireless tension sensor, a data fusion processor and a self-adaptive feedback controller, the MEMS wireless tension sensor is arranged along the concave arc segment at a proportion of 0.618:1, the sampling frequency is greater than or equal to 100 Hz, the data fusion processor adopts an improved Kalman filtering algorithm to process tension data to generate a three-dimensional tension thermal map, the self-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 is less than or equal to 50 ms.

[0026] Preferably, the unmanned yard intelligent control system further comprises a material sliding prediction model and a dynamic risk early warning module. The material sliding prediction model is based on a deep neural network to analyze laser radar point cloud data and predict a material sliding trend. The dynamic risk early warning module is used to trigger the composite braking system 50-100 ms in advance when the predicted sliding amount exceeds a 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, ensuring that the initial tension of the conveyor belt meets the requirements of multi-stage tension cooperative regulation;

[0029] The starting acceleration control unit 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 interval, the starting time deviation is controlled within ±5%, avoiding sudden changes in instantaneous tension;

[0030] The three-dimensional laser radar scans the surface of the conveyor belt at a frequency of 10 Hz to generate point cloud data of the material accumulation form, which is transmitted synchronously to the material sliding prediction model;

[0031] S2, the distributed fiber strain sensor array collects dynamic tension distribution of the concave arc segment at the golden section interval, and the data is fed back to the concave arc segment adaptive adjustment unit;

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

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

[0034] S3, the multi-stage tension cooperative regulation unit integrates the data of the fiber sensor and the hydraulic roller group, dynamically adjusts the tension distribution of each section of the conveyor belt, and suppresses the centrifugal deviation of the material;

[0035] The material sliding prediction model analyzes the laser radar point cloud based on a deep neural network, identifies features such as material accumulation slope and volume, and predicts the sliding trend. If the predicted sliding amount exceeds the threshold, the dynamic risk early 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 rotation or energy consumption braking;

[0037] Emergency braking: if the risk of sliding is not removed, the disc type emergency braking unit immediately engages the brake;

[0038] S5, after braking, the unmanned stockyard intelligent control system automatically detects the state of each sensor, and resumes the starting preparation after confirming that there is no fault.

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

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

[0041] Compared with the prior art, the present application has the following beneficial effects:

[0042] 1. The present application adopts a distributed optical fiber strain sensor array with a golden section interval distribution through the unmanned stockyard intelligent control system, accurately monitors the dynamic tension distribution of the concave arc segment, constructs a real-time three-dimensional point cloud model in combination with a 10Hz high-frequency three-dimensional laser radar scanning material accumulation form, and integrates a variable parameter PID starting algorithm in a jumping control module, so that the acceleration is stably kept in the interval of 0.05-0.1m / s 2 , the deviation is controlled within ±5%, and the variable curvature bearing structure and the hydraulic adjusting roller group are matched, so as to reduce the risk of material centrifugal deviation during large-angle turning, thereby not only solving the jumping problem of long-distance curved conveying, but also improving the equipment stability and transportation efficiency through full-state perception and multi-parameter collaborative control, and being suitable for high-strength continuous operation scenes of unmanned stockyards;

[0043] 2. The present application realizes precise tension control and safe braking through a multi-level buffer and intelligent braking system, the buffer weight device adopts Hall effect proximity switch and visual recognition system double redundancy detection, and is matched with the gradient damping design of the main / auxiliary buffer cylinder, so as to play the effect of absorbing impact kinetic energy, and the hydraulic servo actuator realizes tension fluctuation control based on the OPC UA protocol, forms a dynamic tension closed loop, and the braking system adopts an S-shaped curve variable frequency braking and multi-stage point emergency braking composite scheme, the disc type emergency braking unit calls the dynamic braking curve database through speed closed loop control, so as to realize accurate braking, and thereby ensure that the device can still maintain the stability of the material under a large angle.

[0044] 3. The present application adopts a modular hydraulic adjusting roller group design for the conveying belt rack bottom plate, each roller group is driven by an independent hydraulic structure, the height of the adjusting device is adjusted, and the hinged support plate structure adjusted by the bidirectional screw rod is matched, so as to adjust the included angle of the first upper adjusting roller and the second upper adjusting roller in real time, and the hydraulic servo control of the belt pressing wheel is matched to form a three-dimensional adjustable conveying belt restraint system, thereby not only being able to adapt to the complex curvature change of the concave arc segment, but also being able to adjust the curvature of the conveying belt to ensure the stability of the goods transportation.

[0045] 4. The present application can significantly improve the structural bearing efficiency and reduce the dynamic impact by adopting the gradually changing curvature design optimized by ANSYS transient analysis of the variable curvature bearing structure, combining with the butyl rubber-carbon nanotube composite modified cushion layer, the multi-stage tension synergistic adjustment unit innovatively arranges the MEMS wireless tension sensor according to the golden section ratio 0.618:1 distribution, cooperates with 100Hz high frequency sampling and improved Kalman filtering algorithm, real-time generates three-dimensional tension thermal map, through the adaptive feedback controller to dynamically adjust the hydraulic servo PID parameter with ≤50ms period, realizes the high-precision tension control, the unmanned stockyard intelligent control system integrates the material sliding prediction model driven by deep neural network, directly analyzes the three-dimensional laser radar point cloud data, cooperates with the dynamic risk early warning module and can trigger the composite brake 50-100ms in advance, so that the system has the fault pre-disposal ability. BRIEF DESCRIPTION OF DRAWINGS

[0046] Figure 1 It is the system structure schematic diagram of the present application;

[0047] Figure 2 It is the overall structure perspective schematic diagram of the present application;

[0048] Figure 3 It is the overall structure cross-sectional schematic diagram of the present application;

[0049] Figure 4 It is the structure schematic diagram of the present application in A; Figure 3

[0050] Figure 5 It is the hydraulic adjusting roller group structure schematic diagram of the present application;

[0051] Figure 6 It is the structure schematic diagram of the present application in B; Figure 5

[0052] Figure 7 It is the working process schematic diagram of the present application.

[0053] ​​In the figure: 1, intelligent control system of unmanned yard; 2, anti-bounce control module; 3, intelligent tensioning system; 4, composite braking system; 5, conveyor frame; 6, optical fiber strain sensor array; 7, three-dimensional laser radar; 8, start acceleration control unit; 9, concave arc segment adaptive adjustment unit; 10, multi-stage tension collaborative adjustment unit; 11, emergency braking control unit; 12, variable curvature bearing structure; 13, hydraulic adjusting roller group; 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, bottom plate; 27, transmission roller; 28, first servo motor; 29, fixed plate; 30, lower guard roller; 31, first support plate; 32, first upper adjusting roller; 33, connecting groove; 34, second support plate; 35, second upper adjusting roller; 36, sliding groove; 37, second servo motor; 38, bidirectional lead screw; 39, sliding block; 40, first rotating shaft; 41, support rod; 42, second rotating shaft; 43, high-damping rubber pad layer; 44, MEMS wireless tension sensor; 45, data fusion processor; 46, adaptive feedback controller; 47, material sliding prediction model; 48, dynamic risk early warning module; 49, moving groove; 50, moving block; 51, belt pressing wheel; 52, hydraulic cylinder. DETAILED DESCRIPTION

[0054] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0055] In the description of the present application, it should be noted that the terms "upper", "lower", "inner", "outer", "front end", "rear end", "two ends", "one end", "the other end" and the like indicate the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application. In addition, the terms "first" and "second" are only for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0056] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "mounting", "provided with", "connection" and the like should be understood broadly, for example, "connection" can be fixed connection, can also be detachable connection, or integral connection; can be mechanical connection, can also be electrical connection; can be direct connection, can also be indirect connection through intermediate medium, can be internal communication of two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0057] Embodiment 1: please refer to Figure 1 The present application provides an embodiment: a large-angle anti-bouncing down-running long-distance curved belt conveyor, comprising an unmanned yard intelligent control system 1, an anti-bouncing 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 comprises a distributed optical fiber strain sensor array 6 and a three-dimensional laser radar 7. The optical fiber strain sensor array 6 is arranged along the longitudinal direction of the conveyor belt at a golden section interval, and monitors the dynamic tension distribution of the concave arc segment in real time. The three-dimensional laser radar 7 obtains point cloud data of the material accumulation form on the surface of the conveyor belt at a sampling frequency of 10 Hz.

[0058] The anti-bouncing control module 2 comprises a start-up acceleration control unit 8, a concave arc segment adaptive adjustment unit 9, a multi-stage tension cooperative adjustment unit 10 and an emergency braking control unit 11.

[0059] The start-up acceleration control unit 8 adopts a variable parameter PID algorithm to dynamically adjust the start-up curve, so that the acceleration is stably controlled in the range of 0.05-0.1 m / s 2 , and the start-up time deviation is controlled within ±5%;

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

[0061]

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

[0063] The hydraulic adjusting roller group 13 is arranged at a 20m interval, integrated with a MEMS gyroscope 14 and a pressure sensor 15, the dynamic adjusting range of the adjusting angle is ±3°, meanwhile, the surface of the hydraulic adjusting roller group 13 is coated with a 0.5mm silicon nitride ceramic layer, the hydraulic driving working pressure of the hydraulic adjusting roller group 13 is 10-15MPa, and the response time is less than or equal to 200ms;

[0064] 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 driving braking unit 18 and a disc type emergency braking unit 19;

[0065] Further, the unmanned yard intelligent control system 1 adopts a distributed optical fiber strain sensor array 6 distributed at a golden section interval, accurately monitors the dynamic tension distribution of the concave arc segment, constructs a real-time three-dimensional point cloud model in combination with a 10Hz high-frequency three-dimensional laser radar 7 scanning the material accumulation form, the anti-jumping control module 2 is integrated with a variable parameter PID starting algorithm, so that the acceleration is stably kept at 0.05-0.1m / s 2 interval, the deviation is controlled within ±5%, and in cooperation with the variable curvature bearing structure 12 and the hydraulic adjusting roller group 13, the risk of material centrifugal deviation during large-angle turning can be reduced, thereby not only solving the jumping problem of long-distance curve conveying, but also improving the equipment stability and transportation efficiency through full-state perception and multi-parameter collaborative control, and being suitable for high-strength continuous operation scenes of unmanned yards.

[0066] Embodiment 2: please refer to Figure 1 and Figure 2 An embodiment provided by the application: the buffer weight device 16 is provided with an upper and lower limit position detection module 20, comprising a Hall effect proximity switch 21 and a visual recognition system 22, the sensing distance is 50±2mm, a three-stage adjustable damping buffer 23 is provided, the main buffer cylinder stroke is 500mm, and the damping coefficient is 5000N·s / m, the auxiliary buffer cylinder stroke is 300mm, and the damping coefficient is 2000N·s / m;

[0067] The hydraulic servo actuator 17 communicates with the unmanned yard intelligent control system 1 through an OPC UA protocol, and adjusts the weight position in real time to make the concave arc segment tension fluctuation less than or equal to ±5%;

[0068] The variable frequency driving braking unit 18 adopts an S-shaped braking curve control, and the braking deceleration gradient is less than or equal to 0.15m / s 2 ;

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

[0070] Further, precise tension control and safe braking are realized by the multi-level buffer and intelligent braking system. The buffer weight device 16 adopts Hall effect proximity switch 21 and visual recognition system 22 double redundancy detection, cooperates with the gradient damping design of the main / auxiliary buffer cylinder, can play the effect of absorbing impact kinetic energy, cooperates with the hydraulic servo actuator 17 based on OPC UA protocol to realize tension fluctuation control, forms a dynamic tension closed loop, and the braking system adopts the composite scheme of S-shaped curve frequency braking and multi-level point emergency braking. The disc type emergency braking unit 19 calls the dynamic braking curve database 25 through speed closed loop control, can realize precise braking, and further ensures that the device can still maintain the material stability rate under a large angle.

[0071] Embodiment 3: please refer to Figure 2 、 Figure 3 、 Figure 4 、 Figure 5 and Figure 6 , the present application provides an embodiment: the conveyor frame 5 comprises a bottom plate 26, and the top of the bottom plate 26 is provided with a plurality of hydraulic adjusting idler groups 13, both ends of the top of the bottom plate 26 are provided with transmission rollers 27, and one side of the transmission roller 27 is provided with a first servo motor 28, and the first servo motor 28 is electrically connected with the start acceleration control unit 8;

[0072] The top of the hydraulic structure of the hydraulic adjusting idler group 13 is provided with a fixed plate 29, the bottom of the fixed plate 29 is provided with a lower protection roller 30, the middle of the inner bottom wall of the fixed plate 29 is provided with a first supporting plate 31, the top of the first supporting plate 31 is provided with a first upper adjusting roller 32, both ends of the first supporting plate 31 are provided with connecting grooves 33, the inner wall of the connecting groove 33 is hingedly connected with a second supporting plate 34, the top of the second supporting plate 34 is provided with a second upper adjusting roller 35, one end of the second supporting plate 34 is provided with a moving groove 49, the inner wall of the moving groove 49 is provided with a moving block 50, one end of the moving block 50 is provided with a belt pressing wheel 51 through a bearing, both ends of the top of the fixed plate 29 are provided with hydraulic cylinders 52, and the output ends of the hydraulic cylinders 52 are provided on the top of the moving block 50;

[0073] The inner bottom wall of the fixed plate 29 is provided with a sliding groove 36, one side of the fixed plate 29 is provided with a second servo motor 37, the output end of the second servo motor 37 is provided with a bidirectional screw 38, and the bidirectional screw 38 is provided in the inside of the sliding groove 36, the outer wall of the bidirectional screw 38 is threadedly connected with a sliding block 39, the top of the sliding block 39 is provided with a first rotating shaft 40, the outer wall of the first rotating shaft 40 is connected with a supporting rod 41, the other end of the supporting rod 41 is connected with a second rotating shaft 42, and the top of the second rotating shaft 42 is provided on the bottom of the second supporting plate 34;

[0074] Further, by adopting the modular hydraulic adjustment roller group 13 design on the bottom plate 26 of the conveyor frame 5, each roller group is driven by an independent hydraulic structure, the height of the adjustment device is adjusted, and the hinged support plate structure adjusted by the bidirectional screw 38 can adjust the included angle of the first upper adjustment roller 32 and the second upper adjustment roller 35 in real time, and cooperate with the hydraulic servo control of the belt pressing wheel 51 to form a three-dimensional adjustable conveyor belt constraint system, which can not only adapt to the complex curvature change of the concave arc segment, but also adjust the curvature of the conveyor belt to ensure the stability of the cargo transportation.

[0075] Embodiment 4: please refer to Figure 1 and Figure 3 An embodiment provided by the present application: the variable curvature bearing structure 12 adopts a gradually changing curvature design based on ANSYS transient analysis optimization, a high-damping rubber pad layer 43 with a thickness of 20 mm is arranged in the transition area of the concave arc segment, and the high-damping rubber pad layer 43 is made of butyl rubber and carbon nanotube composite modification;

[0076] The multi-stage tension cooperative adjustment unit 10 includes a MEMS wireless tension sensor 44, a data fusion processor 45, and a self-adaptive feedback controller 46. 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 greater than or equal to 100 Hz. The data fusion processor 45 processes tension data to generate a three-dimensional tension heat map by using an improved Kalman filtering algorithm. The self-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 less than or equal to 50 ms.

[0077] The unmanned yard intelligent control system 1 further includes a material sliding prediction model 47 and a dynamic risk early 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. When the predicted sliding amount exceeds a set threshold, the composite braking system 4 is triggered 50-100 ms in advance.

[0078] Further, by adopting the gradually changing curvature design of the variable curvature bearing structure 12 based on ANSYS transient analysis optimization and the butyl rubber-carbon nanotube composite modified pad layer, the structural bearing efficiency can be significantly improved and the dynamic impact can be reduced. The multi-stage tension cooperative adjustment unit 10 innovatively arranges the MEMS wireless tension sensor 44 at a golden section ratio of 0.618:1, cooperates with 100 Hz high-frequency sampling and an improved Kalman filtering algorithm to generate a three-dimensional tension heat map in real time, dynamically adjusts the hydraulic servo PID parameters by the self-adaptive feedback controller 46 at a period of less than or equal to 50 ms, and realizes high-precision tension control. The unmanned yard intelligent control system 1 integrates the material sliding prediction model 47 driven by a deep neural network to directly analyze three-dimensional laser radar 7 point cloud data, cooperates with the dynamic risk early warning module 48 to trigger the composite braking 50-100 ms in advance, and makes the system have fault pre-disposal capability.

[0079] Embodiment 5: please refer to Figure 7 An embodiment provided by the application: 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, ensuring that the initial tension of the conveyor belt meets the requirements of multi-stage tension cooperative adjustment;

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

[0082] The three-dimensional laser radar 7 scans the surface of the conveyor belt at a frequency of 10 Hz, generates point cloud data of the material accumulation form, and synchronously transmits to the material sliding prediction model 47;

[0083] S2, the distributed optical fiber strain sensor array 6 collects the dynamic tension distribution of the concave arc segment at the golden section interval, and the data is fed back to the concave arc segment adaptive adjustment unit 9;

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

[0085] The hydraulic adjusting roller group 13 feeds back the posture through the MEMS gyroscope 14 and the pressure sensor 15, dynamically adjusts the angle by ±3°, the response time is ≤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, the support rod 41 linkage mechanism makes the second support plate 34 produce ±3° angle adjustment, the curvature gradual change design based on ANSYS transient analysis automatically matches the conveyor belt form, and the high-damping rubber pad 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 generates a three-dimensional tension thermal map using an improved Kalman filter, the adaptive feedback controller 46 dynamically adjusts the PID parameters, and the buffer weight device 16 absorbs the impact load through the three-stage adjustable damper buffer 23;

[0088] S5, the multi-stage tension cooperative adjustment unit 10 integrates the data of the optical fiber sensor and the hydraulic roller group, dynamically adjusts the tension distribution of each section of the conveyor belt, and suppresses the centrifugal deviation of the material;

[0089] The material sliding prediction model 47 analyzes the laser radar point cloud based on a deep neural network, identifies material accumulation slope, volume and other features, 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, normal braking: the variable frequency drive braking unit 18 preferentially reduces the speed through motor reverse rotation or energy consumption braking;

[0091] Emergency braking: if the sliding risk is not removed, the disc type emergency braking unit 19 immediately clutches the brake;

[0092] S7, after braking, the unmanned stockyard intelligent control system 1 automatically detects the state of each sensor and resumes the start-up preparation after confirming that there is no fault;

[0093] In S6, the following steps are further included:

[0094] S61, during the braking process, the hydraulic servo actuator 17 compensates the real-time fluctuation of the conveyor belt tension to prevent relaxation or belt breakage.

[0095] Working principle: through the unmanned stockyard intelligent control system 1, the distributed fiber strain sensor array 6 with golden section interval distribution is used to accurately monitor the dynamic tension distribution of the concave arc segment, combined with the 10Hz high-frequency three-dimensional laser radar 7 scanning the material accumulation form, a real-time three-dimensional point cloud model is constructed, and the acceleration is stabilized at 0.05-0.1m / s 2The interval deviation is controlled within ±5%, and the variable curvature bearing structure 12 and the hydraulic adjusting roller group 13 can reduce the risk of material centrifugal deviation during large-angle turning, thereby not only solving the bouncing problem of long-distance curved conveying, but also improving the stability and transportation efficiency of the equipment through full-state perception and multi-parameter collaborative control, which is suitable for high-intensity continuous operation scenarios in unmanned yards. The multi-level buffer and intelligent braking system realizes precise tension control and safe braking. The buffer hammer device 16 adopts Hall effect proximity switch 21 and visual recognition system 22 double-redundancy detection, and cooperates with the gradient damping design of the main / auxiliary buffer cylinder to absorb impact kinetic energy. The hydraulic servo actuator 17 based on OPCUA protocol realizes tension fluctuation control, forms a dynamic tension closed loop, and the braking system adopts an S-curve variable frequency braking and multi-stage point emergency braking composite scheme. The disc type emergency braking unit 19 calls the dynamic braking curve database 25 through speed closed loop control, which can realize precise braking and ensure the stability of the material under large angle. The bottom plate 26 of the conveyor belt frame 5 adopts a modular hydraulic adjusting roller group 13 design, each roller group is driven by an independent hydraulic structure to adjust the height of the device, and the hinged support plate structure adjusted by the bidirectional screw 38 can adjust the included angle of the first upper adjusting roller 32 and the second upper adjusting roller 35 in real time. The hydraulic servo control of the belt pressing wheel 51 forms a three-dimensional adjustable conveyor belt restraint system, which can not only adapt to the complex curvature change of the concave arc segment, but also adjust the curvature of the conveyor belt to ensure the stability of the cargo transportation. The variable curvature bearing structure 12 adopts the ANSYS transient analysis optimization of the gradual change curvature design, combined with the butyl rubber-carbon nanotube composite modified cushion layer, which can significantly improve the structural bearing efficiency and reduce the dynamic impact. The multi-stage tension collaborative adjustment unit 10 innovatively arranges the MEMS wireless tension sensor 44 according to the golden section ratio 0.618:1, and cooperates with the 100Hz high-frequency sampling and improved Kalman filtering algorithm to generate a three-dimensional tension thermal map in real time. The adaptive feedback controller 46 dynamically adjusts the hydraulic servo PID parameters with a period of ≤50ms to realize high-precision tension control. The unmanned yard intelligent control system 1 integrates a material sliding prediction model 47 driven by a deep neural network, which directly analyzes the three-dimensional laser radar 7 point cloud data, and cooperates with the dynamic risk early warning module 48 to trigger composite braking 50-100ms in advance, so that the system has fault pre-disposal capability.

[0096] It will be apparent to those skilled in the art that the application is not limited to the details of the above-exemplified embodiments and that the present application can be implemented in other particular forms without departing from the spirit or essential characteristics of the present application. The embodiments should therefore be considered in all respects as illustrative and not restrictive, the scope of the application being indicated by the appended claims rather than by the above description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. No reference signs in the claims should be considered as limiting the scope of the claims with respect to the figures of the patent document.

Claims

1. A large angle down-running long distance curved belt conveyor with anti-bounce, comprising an unmanned yard intelligent control system (1), an anti-bounce control module (2), an intelligent tensioning system (3), a composite braking system (4) and a conveyor belt rack (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), the optical fiber strain sensor array (6) is arranged along the longitudinal direction of the conveyor belt at a golden section interval, and the dynamic tension distribution of the concave arc segment is monitored in real time, and the three-dimensional laser radar (7) obtains the point cloud data of the material accumulation form on the surface of the conveyor belt at a sampling frequency of 10 Hz; The anti-bounce control module (2) comprises a start acceleration control unit (8), a concave arc segment adaptive adjustment unit (9), a multi-stage tension cooperative adjustment unit (10) and an emergency brake 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 interval, the starting time deviation is controlled within ±5%. The concave arc section self-adapting adjusting unit (9) comprises a variable curvature bearing structure (12) and a hydraulic adjusting roller group (13), the minimum curvature radius R min satisfies the formula: ； wherein K is a safety factor of 1.2-1.5, T is the belt tension in kN, W is the weight of the belt per unit length in kg / m, and g is the acceleration due to gravity in 9.81 m / s 2 , the actual radius of curvature is taken as 1.3-1.8 times R min ; The hydraulic adjusting roller group (13) is arranged at an interval of 20 m, is integrated with a MEMS gyroscope (14) and a pressure sensor (15), has a dynamic adjustment range of the adjusting angle of ±3°, and is coated with a 0.5 mm silicon nitride ceramic layer on the surface, the hydraulic driving working pressure of the hydraulic adjusting roller group (13) is 10-15 MPa, and the response time is less than or equal to 200 ms; The intelligent tensioning system (3) comprises a buffer weight device (16) and a hydraulic servo actuator (17), and the composite brake system (4) comprises a variable frequency drive brake unit (18) and a disc type emergency brake unit (19).

2. A long distance curved belt conveyor with large angle of descent and without bouncing according to claim 1, characterized in that: The buffer weight device (16) is provided with an upper and lower limit position detection module (20) comprising a Hall effect proximity switch (21) and a visual recognition system (22), and has an inductive distance of 50±2 mm; the buffer weight device (16) is provided with a three-stage adjustable damping buffer (23), a main buffer cylinder with a stroke of 500 mm and a damping coefficient of 5000 N·s / m, and an auxiliary buffer cylinder with a 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 an OPC UA protocol, and adjusts the position of the tensioning wheel in real time to make the tension fluctuation of the concave arc segment less than or equal to ±5%; The variable frequency drive brake unit (18) adopts S-shaped brake curve control, and the brake deceleration gradient is less than or equal to 0.15 m / s 2 ; The disc type emergency brake unit (19) is integrated with a speed closed-loop control system (24), has a built-in brake curve database (25) based on dynamic analysis, and implements multi-stage point brake, and the single brake time is less than or equal to 0.5 s, and the brake interval is adjustable in a range of 0.2-1.0 s.

3. A long distance curved belt conveyor with large angle of descent and without bouncing according to claim 1, characterized in that: The conveyor belt rack (5) comprises a bottom plate (26), a plurality of hydraulic adjusting roller groups (13) are arranged on the top of the bottom plate (26), drive rollers (27) are installed at both ends of the top of the bottom plate (26), a first servo motor (28) is installed on one side of the drive roller (27), and the first servo motor (28) is electrically connected with the start acceleration control unit (8).

4. A long distance curved belt conveyor with large angle of descent and without bouncing according to claim 1, characterized in that: The hydraulic structure top of the hydraulic adjusting roller group (13) is provided with a fixed plate (29), the bottom of the fixed plate (29) is provided with a lower protection roller (30), the middle of the inner bottom wall of the fixed plate (29) is provided with a first supporting plate (31), the top of the first supporting plate (31) is provided with a first upper adjusting roller (32), the two ends of the first supporting plate (31) are provided with connecting grooves (33), the inner wall of the connecting grooves (33) is hingedly connected with a second supporting plate (34), the top of the second supporting plate (34) is provided with a second upper adjusting roller (35), one end of the second supporting plate (34) is provided with a moving groove (49), the inner wall of the moving groove (49) is provided with a moving block (50), one end of the moving block (50) is provided with a belt pressing roller (51) through a bearing, the two ends of the top of the fixed plate (29) are respectively provided with hydraulic cylinders (52), and the output ends of the hydraulic cylinders (52) are arranged on the top of the moving block (50).

5. A long distance curved belt conveyor with large angle of descent and without bouncing according to claim 4, characterized in that: The inner bottom wall of the fixed plate (29) is provided with a sliding groove (36), one side of the fixed plate (29) is provided with a second servo motor (37), the output end of the second servo motor (37) is provided with a bidirectional screw rod (38), and the bidirectional screw rod (38) is arranged in the inner part of the sliding groove (36), the outer wall of the bidirectional screw rod (38) is threadedly connected with a sliding block (39), the top of the sliding block (39) is provided with a first rotating shaft (40), the outer wall of the first rotating shaft (40) is connected with a supporting rod (41), the other end of the supporting rod (41) is connected with a second rotating shaft (42), and the top of the second rotating shaft (42) is respectively arranged on the bottom of the second supporting plate (34).

6. A long distance curved belt conveyor with large angle of descent and without bouncing according to claim 1, characterized in that: The variable curvature bearing structure (12) adopts a gradually variable curvature design based on ANSYS transient analysis optimization, a high-damping rubber pad layer (43) is arranged in the transition area of the concave arc segment, the thickness of the high-damping rubber pad layer (43) is 20 mm, and the high-damping rubber pad layer (43) is made of butyl rubber and carbon nanotube composite modification.

7. A long distance curved belt conveyor with large angle of descent and without bouncing according to claim 1, characterized in that: The multi-stage tension cooperative adjusting unit (10) comprises a MEMS wireless tension sensor (44), a data fusion processor (45) and a self-adaptive feedback controller (46), the MEMS wireless tension sensor (44) is arranged along the concave arc segment at a ratio of 0.618:1, the sampling frequency is greater than or equal to 100 Hz, the data fusion processor (45) processes tension data to generate a three-dimensional tension heat map by using an improved Kalman filtering algorithm, and the self-adaptive feedback controller (46) dynamically adjusts the PID parameters of the hydraulic servo actuator (17) according to the heat map characteristics, and the control period is less than or equal to 50 ms.

8. A long distance curved belt conveyor with large angle of descent and without bouncing according to claim 1, characterized in that: The unmanned yard intelligent control system (1) further comprises a material sliding prediction model (47) and a dynamic risk early warning module (48), the material sliding prediction model (47) analyzes laser radar point cloud data based on a deep neural network to predict a material sliding trend, and the dynamic risk early 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. A method of using a large angle under-running long distance curved belt conveyor with anti-bounce according to claim 8, 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 the preset tension, ensures that the initial tension of the conveying belt meets the multi-stage tension cooperative regulation requirement; 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 interval and the starting time deviation are controlled within ±5%, so that the instantaneous tension is prevented from being suddenly changed. The three-dimensional laser radar (7) scans the surface of the conveying belt at a frequency of 10 Hz, generates point cloud data of the material accumulation form, and synchronously transmits the point cloud data to the material sliding prediction model (47); S2, the distributed fiber strain sensor array (6) collects the dynamic tension distribution of the concave arc segment at the golden section interval, and feeds back the data to the concave arc segment adaptive adjustment unit (9); Variable curvature load bearing structure (12) calculates minimum radius of curvature R according to real-time tension min ; safety factor K = 1.2 - 1.5, actual radius of curvature is 1.3 - 1.8 times R min ; The hydraulic adjusting roller group (13) feeds back the posture through the MEMS gyroscope (14) and the pressure sensor (15), dynamically adjusts the angle by ±3°, the response time is less than or equal to 200 ms, and the surface silicon nitride ceramic layer reduces friction and wear; S3, the multi-stage tension cooperative regulation unit (10) integrates the data of the fiber sensor and the hydraulic roller group, dynamically adjusts the tension distribution of each section of the conveying belt, and suppresses 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 characteristics, predicts the sliding trend, and if the predicted sliding amount exceeds a threshold value, the dynamic risk early warning module (48) triggers the composite braking system (4) 50-100 ms in advance; S4, conventional braking: the variable frequency driving braking unit (18) preferentially reduces the speed through motor reverse rotation or energy consumption braking; Emergency braking: if the sliding risk is not removed, the disc type emergency braking unit (19) immediately engages the brake; S5, after braking, the unmanned stockyard intelligent control system (1) automatically detects the state of each sensor, and resumes the start-up preparation after confirming that there is no fault.

10. A method of using a large angle under-running long distance curved belt conveyor with anti-bounce according to claim 9, characterized in that, The S4 further includes the following steps: S41, during the braking process, the hydraulic servo actuator (17) compensates the tension fluctuation of the conveying belt in real time, prevents relaxation or belt breakage.

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