Anti-deviation device of belt conveyor

Abstract

The invention relates to the technical field of belt conveyors, and discloses a belt conveyor deviation prevention device which comprises a rack. A conveyor belt; the first deviation preventing mechanisms are used for passively limiting the edge of the conveying belt. The at least one anti-deviation mechanism II is used for actively adjusting the running posture of the conveying belt; the bearing mechanisms are used for bearing the conveying belt; the at least one waste scraping mechanism is used for cleaning attachments on the surface of the conveying belt; the sensing unit extracts the belt deviation amount and the material mass center deviation degree; and the decision-making unit is electrically connected with the sensing unit and the anti-deviation mechanism II. Passive limiting is matched with the active adjusting deviation preventing mechanism, the waste scraping mechanism removes attachments, the sensing unit and the decision-making unit are combined for intelligent control, the deviation preventing device can adapt to working conditions to accurately rectify deviation, the deviation preventing stability of the belt conveyor is improved, and deviation is prevented from influencing conveying or causing equipment problems.

Description

Technical Field

[0001] This invention relates to the field of belt conveyor technology, specifically to a belt conveyor anti-deviation device. Background Technology

[0002] Belt conveyors are key equipment used in industrial production for the continuous transport of bulk and lumpy materials, especially in coal transportation, covering fields such as coal mining, processing, and transshipment. Anti-deviation devices are core supporting components of belt conveyors, mainly used to prevent the conveyor belt from deviating from the preset centerline during operation, avoiding problems such as coal spillage, conveyor belt tearing, and equipment wear caused by deviation, and ensuring the continuous operation of coal transportation.

[0003] Existing belt conveyor anti-deviation devices are mostly passive idler roller limiters or simple active adjustment devices. Passive devices limit the edge of the conveyor belt by fixing idler rollers, while active devices mostly rely on a single actuator and fixed control logic. Moreover, some devices are not designed for cleaning up common deposits in coal conveying or for multi-mechanism coordinated adjustment. They are more commonly used in coal mining, washing and other scenarios.

[0004] However, existing devices have obvious defects: passive devices can only deal with slight deviations and cannot correct serious deviations caused by uneven coal loading; active fixed control logic is difficult to adapt to changes in coal load and conveying speed, and is prone to correction lag or over-correction; at the same time, coal dust, fragments and other adhering materials accumulate on the conveyor belt and continuously induce deviations, and the lack of graded safety protection results in unstable anti-deviation effect of belt conveyors, frequently affecting coal conveying or causing equipment failure.

[0005] Therefore, this invention proposes a belt conveyor anti-deviation device to overcome the shortcomings of the prior art. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a belt conveyor anti-deviation device, which solves the problems of passive anti-deviation devices that can only handle slight deviations, active control logic that is difficult to adapt to working conditions, attachments that can easily induce deviations, and the lack of graded safety protection.

[0007] To achieve the above objectives, the present invention provides the following technical solution: A belt conveyor anti-deviation device includes: frame; A conveyor belt, which is mounted on the frame; Multiple anti-deviation mechanisms are installed on the inner side of the frame, and the anti-deviation mechanisms are used to passively limit the edge of the conveyor belt. At least one anti-deviation mechanism two is installed on the inner side of the frame, and the anti-deviation mechanism two is used to actively adjust the running posture of the conveyor belt; Multiple support mechanisms are mounted on the frame, and the support mechanisms are used to support the conveyor belt; At least one waste scraping mechanism is installed on the inside of the frame and is used to clean the adhering substances on the surface of the conveyor belt; The sensing unit is used to collect images of the conveyor belt in real time and extract the belt deviation and the deviation of the material's center of gravity from them. The decision unit is electrically connected to the sensing unit and the anti-deviation mechanism II. Based on the material centroid deviation, it generates a feedforward control quantity for predictive compensation; based on the belt deviation, it generates a feedback control quantity for real-time correction; and combines the feedforward control quantity and the feedback control quantity into a correction control command, which is then sent to at least one of the anti-deviation mechanisms II. The supporting mechanism includes two placement frames, and a supporting roller is rotatably connected between the two placement frames.

[0008] Preferably, the anti-deviation mechanism includes a first bracket and two second brackets. The first bracket is installed on the inner side of the frame, and the second bracket is installed on the top of the frame. A first roller is rotatably connected to the top of the first bracket, and a second roller is rotatably connected between the top of the first bracket and each of the two second brackets.

[0009] Preferably, the anti-deviation mechanism 2 includes a bracket 3, which is installed on the inner side of the frame. A bracket 4 is rotatably connected to the top of the bracket 3, and a roller 3 is rotatably connected to the top of the bracket 4. Brackets 5 are installed on both outer sides of the bracket 4, and a roller 4 is rotatably connected between the bracket 4 and the bracket 5. A mounting frame is fixedly connected to the outer side of the bracket 3, and a pneumatic telescopic rod is rotatably connected to the outer side of the mounting frame. The output end of the pneumatic telescopic rod is rotatably connected to the outer side of the bracket 4. A bracket 6 is installed on the outer side of the bracket 5, and a roller 5 is rotatably connected to the end of the bracket 6 away from the bracket 5.

[0010] Preferably, the second anti-deviation mechanism further includes two guide grooves and two guide rods. The two guide grooves are both opened on the inner side of the bracket three, and the two guide rods are both fixedly connected to the bottom of the bracket four. The guide rods are slidably connected to the guide grooves, and a guide plate is fixedly connected to the bottom of the guide rods. The guide plate is in contact with the bottom of the bracket three.

[0011] Preferably, the waste scraping mechanism includes a bracket seven and a connecting plate. The bracket seven is installed on the inner side of the frame. A waste scraping plate is fixedly connected to the top of the connecting plate. One side of the waste scraping plate is an inclined surface. Limiting rods are fixedly connected to both sides of the top of the bracket seven. The limiting rods pass through the internal through holes of the connecting plate. A spring is sleeved on the outside of the limiting rods. The springs are fixedly connected between the bracket seven and the connecting plate. A limiting plate is fixedly connected to the top of the limiting rods. The diameter of the limiting plate is larger than the internal through holes of the connecting plate.

[0012] Preferably, the sensing unit includes: A high-definition video image acquisition sensor is used to acquire images of the conveyor belt in operation; A belt speed sensor is used to obtain the real-time speed of the conveyor belt; A motor current sensor is used to obtain the load information of the conveyor belt; The decision-making unit further adaptively adjusts the control parameters in the feedforward control quantity and the feedback control quantity based on the real-time speed and the load information.

[0013] Preferably, the formula for calculating the feedforward control quantity is: ; In the formula, For the current moment Generate feedforward control input; The feedforward control gain coefficient; For the current moment The deviation of the material's center of mass.

[0014] Preferably, the feedback control quantity is calculated using proportional-integral-derivative control, and the formula for calculating the feedback control quantity is: ; In the formula, For the current moment The generated feedback control quantity; This refers to the belt misalignment. For proportional gain, For integral gain; This is the differential gain; For integration variables; This is the integral of the belt misalignment from 0 to the current time. This represents the rate of change of belt misalignment with time.

[0015] Preferably, when there are multiple anti-deviation mechanisms, the decision unit further executes an adaptive cluster collaborative scheduling strategy. Specifically, the adaptive cluster collaborative scheduling strategy involves using the following formula to process the deviation correction control command... Decomposed into allocations to the first Sub-correction command of the second anti-deviation mechanism : ; In the formula, To be assigned to the The dynamic weighting coefficient of the second anti-deviation mechanism; The weight value assigned to any anti-deviation mechanism II located upstream of the material is greater than the weight value assigned to any of the anti-deviation mechanisms II located downstream of the material.

[0016] Preferably, the decision-making unit further executes graded response safety logic based on the absolute value of the belt misalignment: When the absolute value of the belt misalignment exceeds the first preset threshold, an alarm signal is sent. When the absolute value of the belt misalignment exceeds the second preset threshold, an interlocking shutdown command is output. Wherein, the second preset threshold is greater than the first preset threshold.

[0017] This invention provides a device to prevent belt conveyor from deviating from its designated path. It has the following beneficial effects: 1. This invention employs multiple passive anti-deviation mechanisms to physically limit the edge of a belt conveyor, while simultaneously using at least one active anti-deviation mechanism to adjust its posture upon receiving instructions from a decision-making unit, forming a dual anti-deviation mechanism. This mechanism can both limit minor deviations of the belt conveyor through passive mechanisms and correct significant deviations through active mechanisms, avoiding the limitations of a single anti-deviation method and effectively improving the comprehensiveness and operational stability of the belt conveyor's anti-deviation capabilities.

[0018] 2. This invention collects conveyor belt operation data through a sensing unit. The decision unit generates feedforward control quantities based on the material's center of gravity deviation and feedback control quantities based on the belt misalignment, synthesizing commands to drive the second anti-misalignment mechanism. It can also adaptively adjust control parameters. This intelligent control closed loop achieves dynamic and precise correction, adapts to different operating conditions, reduces correction lag, effectively ensures the anti-misalignment effect of the conveyor belt, and avoids repeated misalignment caused by inaccurate control.

[0019] 3. This invention uses a scraping mechanism to clean the surface of the conveyor belt, eliminating the cause of belt misalignment. Simultaneously, the decision-making unit executes tiered safety responses based on the amount of belt misalignment. This design reduces the source of misalignment through cleaning, and can trigger an alarm for minor misalignment and shut down the machine in severe cases, protecting the equipment while ensuring operational safety. It provides continuous and reliable operational assurance for preventing belt misalignment, avoiding problems caused by unresolved causes or escalating risks.

[0020] 4. This invention employs a decision-making unit to perform adaptive cluster collaborative scheduling of multiple anti-deviation mechanisms, allocating correction commands according to dynamic weights. Simultaneously, the anti-deviation mechanisms utilize a guiding structure to ensure smooth and precise adjustments. This design avoids conflicts between multiple mechanisms or excessive local adjustments, ensuring balanced force on the conveyor belt, improving overall correction consistency, effectively enhancing the reliability of anti-deviation measures, ensuring stable conveyor belt operation during transport, and reducing deviation problems caused by improper coordination among multiple mechanisms. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the device structure of the present invention. Figure 1 ; Figure 2 This is a front view of the present invention; Figure 3 This is a schematic diagram of a partial structure of the device of the present invention. Figure 1 ; Figure 4 This is a schematic diagram of the anti-deviation mechanism of the present invention; Figure 5 This is a schematic diagram of the second anti-deviation mechanism of the present invention; Figure 6 This is a three-section view of the bracket of the present invention; Figure 7 For the present invention Figure 7 Enlarged view of point A in the image; Figure 8 This is a schematic diagram of the guide groove structure of the present invention; Figure 9 This is a schematic diagram of a partial structure of the device of the present invention. Figure 2 ; Figure 10 This is a schematic diagram of the waste scraping mechanism of the present invention; Figure 11 This is a flowchart of the sensing unit operation of the present invention; Figure 12 This is a flowchart of the decision-making unit of the present invention; Figure 13 This is a schematic diagram of the device structure of the present invention. Figure 2 .

[0022] The components include: 1. Frame; 2. Anti-deviation mechanism one; 201. Support one; 202. Idler roller one; 203. Support two; 204. Idler roller two; 3. Anti-deviation mechanism two; 301. Support three; 302. Support four; 303. Idler roller three; 304. Support five; 305. Idler roller four; 306. Support six; 307. Idler roller five; 308. Mounting frame; 309. Pneumatic telescopic rod; 3010. Guide groove; 3011. Guide rod; 3012. Guide plate; 4. Conveyor belt; 5. Support mechanism; 501. Placement frame; 502. Support roller; 6. Waste scraping mechanism; 601. Support seven; 602. Connecting plate; 603. Waste scraping plate; 604. Limiting rod; 605. Spring; 606. Limiting plate. Detailed Implementation

[0023] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] See attached document Figures 1-13 The present invention provides a belt conveyor anti-deviation device, which may include: a frame 1, multiple anti-deviation mechanisms 1 2, at least one anti-deviation mechanism 2 3, a conveyor belt 4, multiple supporting mechanisms 5, at least one scraping mechanism 6, a sensing unit, and a decision unit.

[0025] The frame 1 provides the basic installation and support structure for the entire device. The conveyor belt 4 is mounted on the frame 1 and is used to transport materials. To enable the movement of the conveyor belt 4, a drive unit is also installed on the frame 1. This drive unit may include a motor, a reducer, and a drive roller. The output end of the motor is connected to the input end of the reducer, and the output end of the reducer is drively connected to the drive roller. The conveyor belt 4 forms a closed loop and is wound around the drive roller and a redirecting roller (not shown) located at the other end of the frame 1. When the motor is working, it drives the drive roller to rotate through the reducer, which in turn drives the conveyor belt 4 to circulate by friction, thereby achieving the conveying of materials.

[0026] Multiple support mechanisms 5 are mounted on the frame 1 and located below the conveyor belt 4 to support and carry the conveyor belt 4 in operation. In one specific embodiment, the support mechanism 5 includes two placement frames 501, and a support roller 502 is mounted between the two placement frames 501 by means of a rotatable connection. The two ends of the support roller 502 are placed in grooves on the placement frames 501, and the roller surface of the support roller 502 contacts the surface of the conveyor belt 4 to support and carry the conveyor belt 4 in operation.

[0027] Multiple anti-deviation mechanisms 2 are installed at intervals along the running direction of the conveyor belt 4 on the inner side of the frame 1. The anti-deviation mechanism 2 is a passive structure, and its function is to physically and passively limit the running edge of the conveyor belt 4 to prevent it from deviating significantly.

[0028] At least one anti-deviation mechanism 3 is installed on the inner side of the frame 1. It is an active structure and its function is to receive instructions from the decision-making unit and actively adjust its own posture, thereby adjusting the running posture of the conveyor belt 4 to correct deviation.

[0029] At least one scraping mechanism 6 is installed on the inner side of the frame 1, between the two support mechanisms 5, and at the bottom of the conveyor belt 4 during rotation, for cleaning residual materials or other attachments on the working surface of the conveyor belt 4.

[0030] The sensing unit is the input module of the device, and it is located above the conveyor belt 4. The function of this sensing unit is to acquire images of the conveyor belt 4 in real time, and extract two key data parameters from the acquired images through internal image analysis algorithms: belt misalignment and material centroid deviation.

[0031] The decision-making unit is the core computing and command module of the device. In terms of connectivity, the decision-making unit is electrically connected to the sensing unit and the anti-deviation mechanism 23. Functionally, the decision-making unit receives belt deviation amount and material centroid deviation data from the sensing unit and performs the following operations: based on the material centroid deviation, it generates a feedforward control quantity for predictive compensation; based on the belt deviation amount, it generates a feedback control quantity for real-time correction; subsequently, it synthesizes the feedforward control quantity and the feedback control quantity to generate the final correction control command, and sends this command to at least one anti-deviation mechanism 23 to drive it to perform the correction action.

[0032] See attached document Figures 1-4 Anti-deviation mechanism 2 is a passive limiting device, and multiple of them are arranged along the running path of the conveyor belt 4 of the belt conveyor. The structure of each anti-deviation mechanism 2 includes a support 201, a roller 202, two supports 203, and two rollers 204.

[0033] Bracket 1 201 serves as the central support and is fixedly installed on the inner side of the frame 1 by bolting or welding. Two brackets 203 serve as the outer supports and are symmetrically fixedly installed on the crossbeam structure at the top of the frame 1.

[0034] Idler roller 202 is a horizontally arranged intermediate idler roller, with bearings at both ends inside. Through this bearing structure, idler roller 202 is rotatably mounted on the mounting base at the top of bracket 201. Two idler rollers 204 are symmetrically arranged side idler rollers. The inner end of each idler roller 204 is also rotatably mounted on the side mounting base at the top of bracket 201 through built-in bearings, and its outer end is rotatably mounted on the mounting base of a corresponding bracket 203.

[0035] In this embodiment, the axes of the two idler rollers 204 are inclined upwards at a predetermined trough angle relative to the horizontal axis of the idler roller 202. The specific value of this trough angle can be set according to the width, rigidity, and material characteristics of the conveyor belt 4, for example, it can be set in the range of 20 degrees to 45 degrees. With this arrangement, the idler roller 202 and the two idler rollers 204 together constitute a trough-shaped idler roller group with a defined trough angle, used to support and guide the conveyor belt 4.

[0036] The working principle of the anti-deviation mechanism 2 is as follows: During normal operation of the belt conveyor, the central area of ​​the conveyor belt 4 is supported by a horizontal idler roller 202, while its two side edges are supported by two inclined idler rollers 204, causing the bearing section of the conveyor belt 4 to naturally form a groove shape. When the conveyor belt 4 tends to shift laterally to one side due to uneven load or other factors, the edge of the shifted side will move upward along the inclined surface of the idler roller 204 on that side. Due to gravity, the upward-moving portion of the conveyor belt 4 will generate a restoring force pointing towards the center line of the grooved idler roller group. This restoring force, as a passive corrective force, can automatically push the conveyor belt 4 back to the center position, thereby achieving passive limitation of deviation and maintaining the conveyor belt 4 running on the set center trajectory.

[0037] See attached document Figure 1 , Figure 3 , Figure 5 and Figure 6 The anti-deviation mechanism 2 (3) serves as the active adjustment unit of the anti-deviation device for this belt conveyor. The anti-deviation mechanism 2 (3) includes a fixed bracket 3 (301) and a rotatable bracket 4 (302). The bracket 3 (301) is fixed to the inner side of the frame 1 by welding or bolting, serving as the base of the entire active anti-deviation mechanism. The bracket 4 (302) is rotatably connected to the top of the bracket 3 (301), with its rotation axis perpendicular to the running plane of the conveyor belt 4. A horizontally positioned idler roller 3 (303) is rotatably mounted on the top of the bracket 4 (302) via bearings at both ends, supporting the middle section of the conveyor belt 4.

[0038] Supports 304 are mounted on both outer sides of support 4 302. A roller 305 is rotatably connected between support 4 302 and each roller 304. A support 306 is also mounted on the outer side of each roller 304, with a roller 307 rotatably connected to the end of the support 6 306 away from support 304. Thus, roller 303, two rollers 305, and two rollers 307 together constitute a complete trough-shaped roller assembly for supporting conveyor belt 4.

[0039] To drive bracket 302, a mounting bracket 308 is fixedly connected to the outside of bracket 301. The tail end of the cylinder of a pneumatic telescopic rod 309 is rotatably connected to the mounting bracket 308, and the end of its output piston rod is rotatably connected to the outside of bracket 302. The pneumatic telescopic rod 309 receives control signals from an external air source, and the extension or retraction of its piston rod will push bracket 302 to rotate horizontally around its central axis at a small angle. Since brackets 304 and 306 are both fixed to bracket 302, the rotation of bracket 302 will drive the side roller group composed of rollers 305 and 307 to rotate horizontally synchronously.

[0040] To ensure the stability and accuracy of bracket 4302 during rotation, refer to the attached... Figure 6 , Figure 7 and Figure 8 The anti-deviation mechanism 2 3 may further include two guide grooves 3010 formed on the inner side of the bracket 3 301. Two corresponding guide rods 3011 are fixedly connected to the bottom of the bracket 4 302. The rod body of each guide rod 3011 slides in engagement with a guide groove 3010, and this engagement strictly limits the movement of the bracket 4 302 to its preset rotation trajectory. A guide plate 3012 is also fixedly connected to the bottom of the guide rod 3011. The bottom surface of the guide plate 3012 is in contact with the upper bottom surface of the bracket 3 301 and can slide on it, providing stable support and a low-friction contact surface for rotation.

[0041] The operating principle of the anti-deviation mechanism 23 is as follows: When the decision unit determines that the conveyor belt 4 is deviating, it outputs a deviation correction control command to the pneumatic telescopic rod 309. The pneumatic telescopic rod 309 actuates, driving the support 4 302 to rotate. Since the supports 5 304 and 6 306 rotate with the support 4 302, and one end of the idler roller 4 305 is hinged to the fixed support 3 301, the rotation of the support 4 302 forces the axis of the entire side idler group, formed by idler rollers 4 and 5, to form an angle with the running direction of the conveyor belt 4. This angle generates a lateral deviation correction force on the conveyor belt 4, which pushes the conveyor belt 4 towards the centerline position until the deviation is eliminated. This is a controlled active adjustment process, which is a key link in achieving precise anti-deviation control of the belt conveyor.

[0042] See attached document Figure 2 , Figure 3 , Figure 9 and Figure 10 The scraping mechanism 6 is designed to continuously clean the material adhering to the working surface of the conveyor belt 4 after unloading. This is of great importance for maintaining the stable operation of the belt conveyor and preventing deviation caused by material sticking to the rollers.

[0043] The waste scraping mechanism 6 includes a bracket 601 serving as a fixed base and a connecting plate 602 that supports the scraper. The bracket 601 is fixedly installed on the inner side of the frame 1 by welding or bolting. On both sides of the top of the bracket 601, two limit rods 604 are vertically fixed upwards as guides and supports.

[0044] The connecting plate 602 has two through holes inside, which slide and engage with two limiting rods 604 respectively, allowing the connecting plate 602 to reciprocate up and down only along the axial direction of the limiting rods 604. A scraper 603 is fixedly connected to the top of the connecting plate 602. This scraper 603 can be made of wear-resistant materials such as polyurethane or hard alloy and directly contacts the surface of the conveyor belt 4. The side of the scraper 603 facing the material feeding direction of the conveyor belt 4 is machined into an inclined surface. This inclined surface design helps to cut into and peel off the attached material at an effective scraping angle, while guiding the cleaned material to fall smoothly.

[0045] To ensure that the scraper blade 603 can stably adhere to the surface of the conveyor belt 4, a spring 605 is fitted around the outside of each limiting rod 604. This spring 605 is a compression spring, with one end abutting against the top surface of the bracket 601 and the other end abutting against the bottom surface of the connecting plate 602. These springs 605 collectively provide a continuous thrust in the direction of the conveyor belt 4, acting on the connecting plate 602, thereby ensuring a constant contact pressure between the scraper blade 603 and the surface of the conveyor belt 4.

[0046] To prevent the connecting plate 602 from detaching from the limiting rod 604 during extreme vibration or maintenance, a limiting plate 606 is fixedly connected to the top of each limiting rod 604 away from the bracket 601. The diameter of the limiting plate 606 is larger than the diameter of the through hole inside the connecting plate 602, thus forming a mechanical limiting structure that limits the maximum upward stroke of the connecting plate 602.

[0047] The scraping mechanism 6 operates as follows: the preload of the spring 605 ensures close contact between the scraper blade 603 and the surface of the running conveyor belt 4. As the conveyor belt 4 passes, the blade of the scraper blade 603 scrapes away the adhered material. This mechanism has adaptive adjustment capabilities. When the scraper blade 603 wears due to long-term use, the spring 605 automatically extends to compensate for the wear and maintain effective scraping pressure. When there are uneven thickness areas such as joints on the surface of the conveyor belt 4, the connecting plate 602 can retract along the limit rod 604 and compress the spring 605 to absorb impact and protect the conveyor belt 4 and the scraper blade 603 from damage.

[0048] See attached document Figures 11-13 The intelligent control core of the belt conveyor anti-deviation device of the present invention relies on accurate real-time data perception.

[0049] The sensing unit, serving as the data input terminal of the device, is responsible for collecting operational status information and performing preliminary data extraction. By deploying multiple independent sensing units in key areas of the belt conveyor, comprehensive and real-time monitoring of belt misalignment is achieved. Specific deployment locations include the belt head and tail, with one unit deployed every 50-100 meters along the middle section.

[0050] The components of the sensing unit are distributed in different locations according to their functions. Specifically, it includes: a high-definition video image acquisition sensor, a belt speed sensor, and a motor current sensor.

[0051] A high-definition video image acquisition sensor is the core visual acquisition component of the sensing unit. In one specific embodiment of the invention, the sensor uses an industrial-grade high-definition intelligent camera that meets explosion-proof requirements. Its installation position is typically located approximately 3 to 5 meters above the belt conveyor section to be monitored, directly facing the working surface of the conveyor belt 4, ensuring that its field of view covers the entire width of the conveyor belt 4 and its edge areas on both sides. The sensor has a resolution of 2560x1440 (or higher) to ensure clear capture of details of the belt edges and material distribution. Its infrared distance is no less than 100 meters, supporting a minimum illumination of 0.0002 Lux for color and 0.0001 Lux for black and white, ensuring effective image acquisition even in dimly lit coal conveyor corridors or at night. To cope with the severe dust, humidity, and corrosive environment at the belt conveyor site, the sensor's enclosure meets IP68 (dustproof and waterproof), IK10 (shockproof), and C5-M corrosion resistance standards. To overcome the challenges of complex and variable lighting conditions and ensure consistent image acquisition quality, this invention equips the high-definition video image acquisition sensors with a specific light source. This light source typically employs a high-power LED array, coupled with a diffuser plate to form a uniform surface light source, illuminating the monitoring area on the conveyor belt surface at a specific angle. Its brightness can be automatically or manually adjusted according to ambient light intensity, aiming to eliminate shadows, suppress reflections, and enhance the contrast between the belt edge and background, and between the material and the belt surface. This provides high-quality raw images for subsequent visual analysis, meeting application requirements under various time periods and operating conditions. The images acquired by these high-definition video image acquisition sensors form the basis for analyzing deviation and material centroid deviation. The acquired image data is not remotely transmitted to a central server as raw video streams, but rather directly connected to a local GPU analysis device via gigabit Ethernet or fiber optic cable. This device is an embedded industrial control computer integrating powerful computing capabilities, its core consisting of two built-in heterogeneous AI chips integrating a CPU, GPU, and NPU. This device provides at least 4 TINT8 of AI computing power and is equipped with at least 4GB of DDR4 memory to meet the demands of high-bandwidth data exchange. It also has at least 8GB of built-in eMMC storage for storing the system and algorithms. It provides the necessary local computing power support for machine vision analysis algorithm models, enabling real-time edge computing of the belt conveyor's status.

[0052] The belt speed sensor is used to acquire the actual operating speed of the conveyor belt 4 in real time. The sensor can be installed on the shaft end of the drive roller or driven roller, and calculates the linear speed (real-time speed) of the conveyor belt 4 by measuring the rotational speed of the roller, and transmits the data to the local GPU analysis device.

[0053] A motor current sensor is installed in the power supply circuit of the motor driving the conveyor belt 4, for example, inside the motor's control cabinet. This sensor monitors and acquires the current value of the driving motor in real time, thereby indirectly obtaining the real-time load information of the conveyor belt 4. This information is then transmitted to the local GPU analysis device. Changes in the motor current reflect changes in the amount of material on the conveyor belt 4, providing a basis for subsequent adaptive adjustments to control parameters.

[0054] In the data extraction stage, the acquired high-definition video images are analyzed using a machine vision analysis algorithm model executed by an on-site GPU analysis device built into the perception unit. This algorithm model is the core analysis software embedded in the perception unit, essentially a deep learning network model trained on a large amount of image data (e.g., a semantic segmentation network based on an encoder-decoder structure like UNet, or a network based on keypoint detection). This algorithm model performs pixel-by-pixel analysis on the input high-definition video images, and its processing flow is as follows: First, image segmentation is performed. A single frame of high-definition video image is input into a pre-trained semantic segmentation network. This network classifies each pixel in the image and outputs two independent binary mask images: the first is a conveyor belt area mask, where pixels with a value of 1 identify the area of ​​conveyor belt 4; the second is a material area mask, where pixels with a value of 1 identify the area covered by material on conveyor belt 4.

[0055] Secondly, based on the conveyor belt region mask, edge detection and centerline calculation are performed. For the conveyor belt region mask image, an edge detection operator is applied to accurately extract the left and right edge pixel sets of conveyor belt 4. For each row of pixels in the image, the horizontal coordinates of its left edge point are recorded. and the horizontal coordinates of the right edge point The current time is calculated by averaging the coordinates of the left and right edge points of all rows within the field of view. Real-time centerline lateral position of conveyor belt 4 .

[0056] Next, based on the material region mask, the material centroid is calculated. For the material region mask image, image moment analysis is used to calculate the zeroth-order moment of the material region. (Total pixel area of ​​the material region) and the first moment about the vertical axis of the image Then, by dividing the first moment by the zeroth moment, the current moment is calculated precisely. Lateral position of the centroid of the material area on conveyor belt 4 .

[0057] Through the above processing, the algorithm model finally calculates and extracts two core data: one is the belt deviation, which quantifies the lateral deviation between the actual operating center line of conveyor belt 4 and its ideal center line; the other is the material centroid deviation, which quantifies the lateral deviation between the center of gravity of the material conveyed on conveyor belt 4 and its ideal center line.

[0058] Specifically, belt misalignment The calculation formula is as follows: ; In the formula, For the current moment The real-time lateral position of the center line of conveyor belt 4 is typically determined by identifying the left and right edges of conveyor belt 4. and The average value is obtained by calculating its value. ; The preset, calibrated ideal centerline lateral position of conveyor belt 4.

[0059] Material centroid deviation The calculation formula is as follows: ; In the formula, For the current moment The lateral position of the centroid of the material area on conveyor belt 4 is obtained by calculating the centroid of the material area identified in the image; The preset, calibrated ideal centerline lateral position of conveyor belt 4.

[0060] See attached document Figures 11-13 .

[0061] In addition to the aforementioned visual information extraction, the decision unit also receives data from the belt speed sensor and motor current sensor of the on-site GPU analysis device. Using the real-time speed and load information of conveyor belt 4, the decision unit dynamically adjusts the control parameters used to generate the feedforward and feedback control variables. In one specific implementation, this dynamic adjustment function is achieved through a preset two-dimensional look-up table (LUT).

[0062] The lookup table uses discretized conveyor belt speed ranges as the first dimension (e.g., row index) and discretized motor load ranges (derived from motor current values) as the second dimension (e.g., column index). Each cell in the lookup table... Internal storage contains a set of optimal control parameters pre-calibrated through experiments or simulations, which corresponds to the first... The speed range and the first Operating conditions under various load ranges. This set of control parameters may include gain coefficients for generating feedforward control quantities and proportional-integral-derivative (PID) parameters for generating feedback control quantities.

[0063] During the operation of the belt conveyor, the decision unit acquires the belt speed and motor current in real time, and maps these continuous measurements to the corresponding discrete interval indices in the lookup table. The system reads the corresponding set of control parameters from these parameters for current control calculations. To achieve smoother control parameter switching, when the measured value lies between two discrete intervals, algorithms such as bilinear interpolation can be used to calculate the interpolated control parameters based on the relative position of the measured value within the interval. In this way, the belt conveyor anti-deviation function in this invention can better adapt to different operating conditions, thereby optimizing the deviation correction effect and the stability of the belt conveyor.

[0064] The belt conveyor anti-deviation control in this invention adopts a feedforward + feedback dual-loop control strategy, with the decision unit responsible for synthesizing the core control commands. This strategy comprehensively considers the predictive deviation trend caused by material and the actual belt deviation amount to achieve a fast, accurate, and stable correction effect.

[0065] Generation of feedforward control input: The decision-making unit is based on the material centroid deviation provided by the sensing unit. Generate feedforward control variables for predictive compensation. The goal of feedforward control is to apply compensation before belt misalignment actually occurs, based on the known deviation trend of the material distribution, to reduce or eliminate belt misalignment caused by uneven material loading. The calculation formula is as follows: ; In the formula, For the current moment Generate feedforward control input; This is the feedforward control gain coefficient, whose value is adaptively adjusted based on real-time operating conditions (such as belt speed and load) through system debugging or a preset lookup table. This coefficient reflects the contribution of the material's centroid deviation to the required correction force. For the current moment The deviation of the material's center of mass.

[0066] Generation of feedback control variables: The decision-making unit is based on the belt misalignment amount provided by the sensing unit. Generate feedback control quantities for real-time correction. The goal of feedback control is to adjust the action of the belt misalignment actuator (pneumatic telescopic rod 309) in real time based on the actual measured belt misalignment deviation, maintaining the belt misalignment within the allowable range to correct potential deficiencies in feedforward control or respond to sudden disturbances. This invention employs the classic proportional-integral-derivative (PID) control algorithm as the feedback controller, and its calculation formula is as follows: ; In the formula, For the current moment The generated feedback control quantity; This refers to the belt misalignment. For proportional gain, For integral gain; This is the differential gain; For integration variables; This is the integral of the belt misalignment from 0 to the current time. This represents the rate of change of belt misalignment with time.

[0067] With feedforward control gain similar, , , These three PID parameters are also dynamically adjusted. Their values ​​can be optimized based on the preset lookup table mentioned above, combined with real-time belt speed and motor load information, to ensure the optimal performance of the belt conveyor's anti-deviation device under different operating conditions.

[0068] Synthesis and output of correction control commands: The decision unit will generate feedforward control inputs. With feedback control quantity The commands are then synthesized to generate the final correction control commands. This synthesis method allows the device to simultaneously handle predictive processing of material eccentricity and real-time correction of actual belt misalignment, thereby improving the response speed and control accuracy of the belt conveyor in preventing belt misalignment. The synthesis formula is as follows: ; In the formula, This is the final correction control command sent to the actuator.

[0069] The decision-making unit also considers the belt misalignment. The absolute value executes hierarchical response security logic: Among them, belt misalignment The calculation formula is: ; When the absolute value of belt misalignment Exceeding the first preset threshold When the belt misalignment reaches a certain value, an alarm signal is sent to the monitoring center to provide a reminder; when the absolute value of the belt misalignment reaches a certain value... Exceeding the second preset threshold At that time, an interlocking stop command is output to the drive motor control system; Among them, the second preset threshold Greater than the first preset threshold That is, satisfying In a preferred embodiment, the first preset threshold Set to 50 mm, second preset threshold Set to 100 mm, that is: ; ; The mathematical expression for this security logic is: ; This graded response mechanism ensures that the belt conveyor's anti-deviation device can take corresponding safety measures according to the severity of the deviation. It can provide early warning when the deviation is slight, and take immediate protective shutdown when the deviation is severe, effectively preventing equipment damage and safety accidents that may be caused by further belt deviation.

[0070] If the deviation is within a safe range, the corrective control command should be executed. It is a drive signal whose value adjusts the extension and retraction of the pneumatic telescopic rod 309 in the anti-deviation mechanism 23 as needed. When When the value is greater than zero, the pneumatic telescopic rod 309 extends or retracts in one direction to generate a force that pushes the conveyor belt 4 toward the center position; when... When the value is less than zero, it indicates that the pneumatic telescopic rod 309 moves in the opposite direction; when... When the value approaches zero, it indicates that the conveyor belt 4 has basically returned to the ideal center position, and the pneumatic telescopic rod 309 will maintain its current state or return to the neutral position.

[0071] The decision-making unit will generate corrective control commands. The command is transmitted via electrical connection to at least one anti-deviation mechanism 3, specifically to the control valve group of the pneumatic telescopic rod 309. Upon receiving the command, the pneumatic telescopic rod 309 will perform the corresponding telescopic action, driving the side idler roller group of the anti-deviation mechanism 3 to deflect horizontally, thereby applying a lateral correction force to the conveyor belt 4 and achieving precise and active correction of belt deviation.

[0072] If the device is equipped with multiple anti-deviation mechanisms 2 and 3, the decision unit will execute an adaptive cluster collaborative scheduling strategy to meet the collaborative working requirements of these multiple anti-deviation mechanisms 2 and 3. The core of this adaptive cluster collaborative scheduling strategy is to achieve precise deviation control through instruction decomposition. Specifically, it involves using the following formula to decompose the total deviation correction control instruction... Decomposed into allocations to the first The sub-correction instructions of the anti-deviation mechanism 2 (3) are assigned using the following formula: ; In the formula, To be assigned to the The sub-correction command of the anti-deviation mechanism 2 (3); To be assigned to the The dynamic weighting coefficient of the anti-deviation mechanism 23; this coefficient is not a fixed value, but is dynamically calculated and adjusted in real time based on the physical position of each actuator on the belt conveyor, the current correction effect, historical load conditions, and the gradient distribution of belt deviation, and satisfies the following conditions. (in To prevent deviation of the mechanism (total number of 3), and to ensure the conservation of the total control quantity.

[0073] Meanwhile, this strategy strictly adheres to the rule of giving higher weight to upstream components than downstream components: the dynamic weight coefficient assigned to any anti-deviation mechanism 23 located upstream of the material is greater than the dynamic weight coefficient assigned to any anti-deviation mechanism 23 located downstream of the material. This is because when materials are conveyed along the belt, the upstream section will first encounter deviation-inducing factors such as uneven loading and impacts. Giving higher weight to upstream mechanisms allows the correction force to intervene earlier, curbing the accumulation of deviation downstream from the source and preventing the downstream deviation from worsening, thereby improving the overall efficiency and stability of the belt conveyor's anti-deviation measures.

[0074] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A belt conveyor anti-derailment device, characterized in that, The utility model relates to a kind of material conveying device, including: Rack (1); Conveying belt (4), the conveying belt (4) is located on the rack (1); Multiple anti-deviation mechanisms one (2), multiple the anti-deviation mechanisms one (2) are installed in the inner side of rack (1), the anti-deviation mechanism one (2) is used to limit the edge of the conveying belt (4) passively; At least one anti-deviation mechanism two (3), the anti-deviation mechanism two (3) is installed in the inner side of rack (1), the anti-deviation mechanism two (3) is used to actively adjust the running posture of the conveying belt (4); Multiple supporting mechanisms (5), multiple the supporting mechanisms (5) are installed on the rack (1), and the supporting mechanism (5) is used to support the conveying belt (4); At least one scrap mechanism (6), the scrap mechanism (6) is installed in the inner side of rack (1), and the scrap mechanism (6) is used to clean the adherend on the surface of the conveying belt (4); Sensing unit, for real-time acquisition the running image of the conveying belt (4), and extract the belt deviation and material centroid deviation from it; Decision unit, the decision unit is electrically connected with the sensing unit and the anti-deviation mechanism two (3), based on the material centroid deviation, generates the feedforward control quantity for predictive compensation;Based on the belt deviation, generate the feedback control quantity for real-time correction;The feedforward control quantity and the feedback control quantity are synthesized into correction control instruction, and are sent to at least one the anti-deviation mechanism two (3); The supporting mechanism (5) includes two placing racks (501), and the two placing racks (501) are rotatably connected with supporting rollers (502).

2. A belt conveyor off-tracking prevention device according to claim 1, characterized in that The anti-deviation mechanism one (2) includes support one (201) and two support two (203), support one (201) is installed in the inner side of rack (1), the support two (203) is installed on the top of rack (1), the top of support one (201) is rotatably connected with supporting roller one (202), and the top of support one (201) is rotatably connected with supporting roller two (204) between two support two (203).

3. A belt conveyor misalignment prevention device according to claim 1, wherein The anti-deviation mechanism two (3) includes support three (301), and the support three (301) is installed in the inner side of rack (1), the top of support three (301) is rotatably connected with support four (302), the top of support four (302) is rotatably connected with supporting roller three (303), the outside of support four (302) is installed with support five (304), and the support four (302) and support five (304) are rotatably connected with supporting roller four (305), the outside of support three (301) is fixedly connected with mounting bracket (308), the outside of mounting bracket (308) is rotatably connected with pneumatic telescopic rod (309), the output end of pneumatic telescopic rod (309) is rotatably connected with the outside of support four (302), and the outside of support five (304) is installed with support six (306), and the end, away from support five (304), of support six (306) is rotatably connected with supporting roller five (307).

4. A belt conveyor misalignment prevention device according to claim 3, characterized in that The second deviation preventing mechanism (3) further comprises two guide grooves (3010) and two guide rods (3011), the two guide grooves (3010) are both arranged on the inner side of the third bracket (301), the two guide rods (3011) are both fixedly connected to the bottom of the fourth bracket (302), the guide rod (3011) is in sliding connection with the guide groove (3010), and the bottom of the guide rod (3011) is fixedly connected with a guide plate (3012).

5. A belt conveyor misalignment prevention device according to claim 1, wherein The waste scraping mechanism (6) comprises a seventh bracket (601) and a connecting plate (602), the seventh bracket (601) is arranged on the inner side of the rack (1), the top of the connecting plate (602) is fixedly connected with a waste scraping plate (603), one side of the waste scraping plate (603) is an inclined surface, the top of the seventh bracket (601) is fixedly connected with a limiting rod (604) on each side, the limiting rod (604) penetrates through the inner through hole of the connecting plate (602), the outer portion of the limiting rod (604) is sleeved with a spring (605), the spring (605) is fixedly connected between the seventh bracket (601) and the connecting plate (602), and the top of the limiting rod (604) is fixedly connected with a limiting plate (606).

6. A belt conveyor misalignment prevention device according to claim 1, wherein The perception unit comprises: a high-definition video image acquisition sensor, configured to acquire a running image of the conveyor belt (4); a belt speed sensor, configured to acquire a real-time speed of the conveyor belt (4); a motor current sensor, configured to acquire load information of the conveyor belt (4); The decision unit further adaptively adjusts control parameters in the feedforward control quantity and the feedback control quantity according to the real-time speed and the load information.

7. A belt conveyor misalignment prevention device according to claim 1, wherein The calculation formula of the feedforward control quantity is as follows: ； wherein is the current time generates a feedforward control quantity; is a feedforward control gain coefficient; is the current time of the material mass center deviation.

8. A belt conveyor misalignment prevention device according to claim 1, wherein The feedback control quantity is calculated by using proportional-integral-derivative control, and the calculation formula of the feedback control quantity is as follows: ； In the formula, is the current time generated feedback control amount; is the belt deviation amount; is the proportional gain, is the integral gain; is the differential gain; is the integral variable; is the integral of the belt deviation amount from 0 to the current time; is the rate of change of the belt deviation amount with respect to time.

9. A belt conveyor misalignment prevention device according to claim 1, wherein When the number of the anti-deviation mechanisms two (3) is multiple, the decision unit further executes an adaptive cluster cooperative scheduling strategy, and the adaptive cluster cooperative scheduling strategy is specifically that the deviation correction control instruction is decomposed into sub-deviation correction instructions allocated to the anti-deviation mechanisms two (3) through the following formula: deviation correction control instruction = ∑sub-deviation correction instruction . ​ ； In the formula, is the dynamic weight coefficient assigned to the first anti-skew mechanism (3). The weight value allocated to any deviation preventing mechanism two (3) located upstream of the material is greater than the weight value allocated to any deviation preventing mechanism two (3) located downstream of the material.

10. A belt conveyor misalignment prevention device according to claim 1, characterized in that The decision unit also executes a hierarchical response safety logic according to the absolute value of the belt deviation amount: When the absolute value of the belt deviation amount exceeds a first preset threshold value, an alarm signal is sent; When the absolute value of the belt deviation amount exceeds a second preset threshold value, an interlocking shutdown instruction is output; The second preset threshold value is greater than the first preset threshold value.

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