Kinetic energy recovery braking system for driving end of belt conveyor and control method of kinetic energy recovery braking system

Abstract

The invention discloses a belt conveyor driving end kinetic energy recovery braking system and a control method thereof, and belongs to the technical field of mine transportation energy conservation. The system comprises a signal input unit, a speed detection unit, a central processing unit, an energy recovery unit and a hydraulic braking unit. The central processing unit is configured to execute dual-mode control: responding to a normal parking instruction, controlling the energy recovery unit in parallel to convert braking kinetic energy into electric energy for recovery, and controlling the hydraulic braking unit to provide compensation braking force, so as to realize stable speed reduction and energy conservation; and responding to an accident stopping instruction, immediately closing the energy recovery unit and controlling the hydraulic braking unit to execute quick braking to ensure safety priority. The system is also provided with an independent safety monitoring circuit, adaptive control based on real-time load inertia estimation and a predictive maintenance module based on digital twinning. The problems that a traditional braking mode is serious in energy waste, poor in braking stability and rapid in component abrasion are effectively solved, and unification of safety and energy saving is achieved.

Description

Technical Field

[0001] This invention relates to the field of energy-saving control technology for mining transportation equipment, specifically to a kinetic energy recovery braking system and its control method for the drive end of a belt conveyor. Background Technology

[0002] Belt conveyors are key equipment in the mining industry for transporting large quantities of materials over long distances. Due to their large mass and high inertia, the entire transmission system accumulates significant kinetic energy during stopping or deceleration. Currently, the industry commonly uses traditional methods such as mechanical friction braking, electrical energy consumption braking, or hydraulic braking to handle this kinetic energy. These traditional braking methods essentially convert valuable mechanical energy into heat energy through friction or resistance, resulting in significant energy waste and potentially leading to overheating and accelerated wear of the braking system, increasing equipment maintenance costs and downtime risks.

[0003] With the advancement of the national "dual carbon" goals and the deepening of smart mine construction, the efficient, green, and intelligent operation of mining equipment has become an inevitable trend. Therefore, developing a technical solution that can both ensure the safety and reliability of the braking process and efficiently recover and utilize braking kinetic energy is of great practical significance and application value for reducing mine operating costs, improving energy utilization efficiency, and promoting technological progress in the industry. Summary of the Invention

[0004] The purpose of this invention is to provide a kinetic energy recovery braking system and its control method for the drive end of a belt conveyor, so as to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] In a first aspect, this application provides a kinetic energy recovery braking system for the drive end of a belt conveyor, comprising:

[0007] The signal input unit is used to receive parking commands;

[0008] The speed detection unit is used to monitor the running speed of the conveyor belt in real time;

[0009] The central processing unit is communicatively connected to the signal input unit and the speed detection unit;

[0010] An energy recovery unit is electrically connected to the central processing unit and the drive motor of the belt conveyor, and is used to convert and output the electrical energy generated by braking.

[0011] A hydraulic braking unit is connected to the central processing unit;

[0012] The central processing unit is configured to: in response to a normal stop command, based on the speed signal from the speed detection unit, control the energy recovery unit to start in parallel to convert braking kinetic energy into electrical energy, and control the hydraulic braking unit to provide compensating braking force; in response to an emergency stop command, control the energy recovery unit to immediately shut down, and control the hydraulic braking unit to perform rapid braking.

[0013] Optionally, the central processing unit communicates with the energy recovery unit and the hydraulic braking unit via a dual CAN bus network.

[0014] Optionally, the energy recovery unit includes an excitation module for reverse excitation of the drive motor and a rectifier module for rectifying the generated AC power into DC power.

[0015] The output of the rectifier module is connected to the energy storage battery or the power grid through a power quality management circuit.

[0016] The power quality management circuit is configured to actively filter the recovered power and switch the recovered energy to the local energy storage battery when a grid anomaly is detected.

[0017] Optionally, the system also includes an independent security monitoring circuit that monitors the system status in parallel with the central processing unit;

[0018] The safety monitoring circuit is configured to directly output a hardware control signal to cut off the power circuit of the energy recovery unit and trigger the redundant braking mechanism of the hydraulic braking unit when a system communication failure or emergency stop signal is detected.

[0019] Optionally, the central processing unit is further configured to: estimate the real-time load inertia of the belt conveyor system online based on the real-time torque current and speed of the drive motor;

[0020] Based on the real-time load inertia, the set value of the recovery current of the energy recovery unit and the set value of the braking pressure of the hydraulic braking unit are dynamically adjusted.

[0021] Optionally, the online estimation of the real-time load inertia of the belt conveyor system is specifically achieved through the following relationship:

[0022]

[0023] in, The estimated equivalent load inertia; This refers to the real-time output torque of the drive motor. This is the inherent resistance torque of the system; This represents the system's basic inertia when unloaded. The real-time angular acceleration of the conveyor belt is obtained from the velocity derivative measured by the velocity detection unit.

[0024] Optionally, the system further includes a status monitoring module connected to the central processing unit; the status monitoring module is configured to:

[0025] Establish a digital twin dynamic model of the system;

[0026] During braking, the actual vibration spectrum data is compared in real time with the ideal vibration spectrum data output by the digital twin dynamic model;

[0027] Based on the discrepancies in the comparison results, the performance degradation trend of mechanical components is identified and maintenance early warning information is generated.

[0028] Optionally, identifying the performance degradation trend of mechanical components includes identifying the friction coefficient of brake pads based on the following relationship:

[0029]

[0030] in, The real-time friction coefficient of the brake pads was identified; The total braking torque is obtained by back-calculation through the system dynamics model; The braking pressure applied to the hydraulic braking unit; The effective operating radius of the braking system; when the real-time friction coefficient When the value drops below a preset threshold compared to the initial value, a brake pad wear alarm is generated.

[0031] Secondly, this application provides a kinetic energy recovery braking control method for the drive end of a belt conveyor, executed by the aforementioned system, comprising:

[0032] Receive parking instructions and determine their type;

[0033] If it is a normal parking command, the cooperative braking mode will be executed: energy recovery will be activated and hydraulic compensation braking will be performed;

[0034] If the command is for an emergency stop, the emergency braking mode will be executed: energy recovery will be turned off and rapid hydraulic braking will be applied.

[0035] Optionally, in the cooperative braking mode, an adaptive adjustment step is also included:

[0036] Real-time acquisition of the drive motor's torque current and the conveyor belt's linear speed;

[0037] Based on the torque current and linear velocity, the real-time load inertia of the system is estimated online.

[0038] Based on the real-time load inertia, the system queries a preset matching table and adaptively adjusts the intensity of the energy recovery current and the magnitude of the hydraulic braking pressure to maintain the target deceleration rate.

[0039] Compared with existing technologies, the energy recovery braking system and control method for the drive end of the belt conveyor provided by this invention achieve the following significant advantages by constructing a collaborative control system composed of a signal input unit, a speed detection unit, a central processing unit, an energy recovery unit, and a hydraulic braking unit, and based on the dual-mode control logic of the central processing unit:

[0040] 1. The system provided in this application includes an energy recovery unit, and the central processing unit controls the activation of this unit during normal shutdown to convert braking kinetic energy into electrical energy. This fundamentally changes the wasteful mode of traditional braking methods, which dissipate kinetic energy as heat. By directly converting the enormous inertial energy generated during conveyor shutdown into electrical energy and storing or utilizing it, energy recycling is achieved, significantly reducing equipment operating energy consumption. This is particularly evident in mine conveyor lines with frequent start-stop cycles or long-distance, high-volume transport, where the energy-saving benefits are especially prominent.

[0041] 2. The system architecture and core control logic provided in this application ensure that safety is prioritized under any operating condition. This safety guarantee is reflected in two levels: Mode switching guarantee: The central processing unit is configured to immediately control the energy recovery unit to shut down and control the hydraulic braking unit to perform rapid braking in response to an emergency stop command. This logic ensures that in an emergency, the system can automatically abandon its energy-saving goal and unconditionally switch to a mode with safe stopping as its sole objective, avoiding braking delays that may occur during the energy recovery process. Functional isolation guarantee: The energy recovery unit and the hydraulic braking unit are set as independent actuators and are uniformly scheduled by the central processing unit. This architecture allows for a clean and efficient disconnection of the energy recovery path in emergency mode, while simultaneously activating pure hydraulic rapid braking, functionally isolating risks and providing double insurance.

[0042] 3. During normal parking, the system provided in this application uses the speed signal from the speed detection unit to control the energy recovery unit and the hydraulic braking unit in parallel, employing a coordinated braking strategy of "electric braking as the main method and hydraulic braking as the auxiliary method." This strategy significantly reduces the intensity and frequency of mechanical friction braking, effectively mitigating wear on mechanical components such as brake pads and rollers. Simultaneously, the smooth deceleration achieved through hydraulic compensation of braking force avoids the impact on the conveyor belt, idlers, and transmission mechanism caused by sudden braking, thus extending the overall service life of the conveyor system and reducing maintenance costs.

[0043] 4. The control core of the system provided in this application lies in the central processing unit, which is responsible for processing all input signals and outputting control commands. This centralized intelligent control architecture enables the system to respond very quickly to operation commands. In particular, by controlling two execution units in parallel, compared with traditional sequential control, the braking response time is greatly optimized, making the braking process both efficient and smooth, demonstrating a high degree of intelligence.

[0044] 5. The system provided in this application consists of several modular units with clearly defined functions. This design allows the system to be easily integrated as a complete solution into new or renovated belt conveyor projects. The responsibilities of each unit are clearly defined, and the interfaces are explicit, greatly facilitating subsequent system maintenance, fault diagnosis, and component replacement. Attached Figure Description

[0045] Figure 1 This is a system connection diagram of a kinetic energy recovery braking system for the drive end of a belt conveyor.

[0046] Figure 2 This is a system connection diagram for another type of belt conveyor drive end kinetic energy recovery braking system.

[0047] Figure 3 This is a system connection diagram for another type of kinetic energy recovery braking system for the drive end of a belt conveyor.

[0048] Figure 4 This is a system architecture diagram of a kinetic energy recovery braking system for the drive end of a belt conveyor. Detailed Implementation

[0049] The technical solutions of 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.

[0050] Furthermore, elements in this invention are referred to as being "fixed to" or "set on" another element, which may be directly on the other element or may also include an intervening element. When an element is considered to be "connected" to another element, it may be directly connected to the other element or may also include an intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementations.

[0051] Please see Figures 1-4 This invention provides a kinetic energy recovery braking system for the drive end of a belt conveyor, comprising:

[0052] The signal input unit is used to receive parking commands;

[0053] The speed detection unit is used to monitor the running speed of the conveyor belt in real time;

[0054] The central processing unit is communicatively connected to the signal input unit and the speed detection unit;

[0055] An energy recovery unit is electrically connected to the central processing unit and the drive motor of the belt conveyor, and is used to convert and output the electrical energy generated by braking.

[0056] A hydraulic braking unit is connected to the central processing unit;

[0057] The central processing unit is configured to: in response to a normal stop command, based on the speed signal from the speed detection unit, control the energy recovery unit to start in parallel to convert braking kinetic energy into electrical energy, and control the hydraulic braking unit to provide compensating braking force; in response to an emergency stop command, control the energy recovery unit to immediately shut down, and control the hydraulic braking unit to perform rapid braking.

[0058] In this embodiment, the system's signal input unit possesses high sensitivity and stability, enabling it to quickly and accurately receive stopping commands, avoiding delays and errors in command transmission. The speed detection unit employs a high-precision sensor, allowing for precise real-time monitoring of the conveyor belt's operating speed, providing reliable data support for subsequent system control. The central processing unit boasts powerful computing and data processing capabilities, enabling it to analyze and process received stopping commands and speed signals in an extremely short time. When controlling the energy recovery unit and hydraulic braking unit in parallel, it can precisely allocate their workloads, ensuring efficient and stable braking. The energy recovery unit utilizes advanced electrical energy conversion technology, efficiently converting and outputting the electrical energy generated during braking, significantly improving energy utilization. Simultaneously, it features intelligent adjustment capabilities, automatically adjusting conversion parameters based on different energy generation conditions during braking to achieve optimal energy recovery. The hydraulic braking unit employs a high-performance hydraulic system, providing powerful and stable braking force. During normal stopping, it can precisely provide compensating braking force under the control of the central processing unit, ensuring a smooth stop for the conveyor belt. In the event of an accident and subsequent stop, the system can instantly respond to commands from the central processing unit and execute rapid braking, effectively preventing the accident from escalating. The system also possesses comprehensive fault diagnosis and protection functions. The central processing unit can monitor the operational status of each unit in real time. When a fault is detected in a unit, it can quickly take corresponding protective measures, such as automatically cutting off power and issuing alarm signals, to ensure the safe operation of the system. Simultaneously, the system can record fault information, providing a basis for subsequent maintenance and repair.

[0059] In one specific embodiment, the central processing unit communicates with the energy recovery unit and the hydraulic braking unit via a dual CAN bus network.

[0060] This dual-CAN bus network design ensures high reliability and real-time data transmission, preventing signal interference or loss even in harsh industrial environments. The central processing unit uses this network to collect real-time operating parameters from each unit, such as current and voltage data from the energy recovery unit and pressure feedback from the hydraulic braking unit, thus supporting precise fault diagnosis and dynamic adjustment. Simultaneously, the dual-bus architecture provides redundancy; in the event of a communication failure, the system automatically switches to the backup bus, maintaining uninterrupted monitoring and control functions, further enhancing the overall stability and security of the system.

[0061] In one specific embodiment, the energy recovery unit includes an excitation module for reverse excitation of the drive motor and a rectifier module for rectifying the generated AC power into DC power; the output terminal of the rectifier module is connected to an energy storage battery or the power grid through a power quality management circuit; the power quality management circuit is configured to actively filter the recovered energy and switch the recovered energy to the local energy storage battery when a power grid anomaly is detected.

[0062] Specifically, the excitation module achieves effective braking and energy feedback for the drive motor by precisely controlling the direction and magnitude of the excitation current. The rectifier module typically employs a fully controlled IGBT bridge circuit to ensure efficient conversion of AC to DC while minimizing power loss. The power quality management circuit integrates active filter technology to monitor harmonic content and power factor in real time, and suppresses grid interference through dynamic compensation to improve the purity of recovered energy. When grid voltage fluctuations, frequency deviations, or short-circuit faults are detected, the circuit automatically triggers switching logic to seamlessly direct energy to the energy storage battery pack, avoiding impact on the grid. The energy storage battery is preferably a high-energy-density lithium-ion type, equipped with an intelligent management system to optimize charge-discharge cycles and extend service life. Furthermore, this unit communicates with the central processing unit in real time via a dual CAN bus network, uploading current, voltage, and fault status data to support online diagnostics and adaptive adjustments, thereby enhancing overall braking efficiency and reliability.

[0063] In one specific implementation, the system further includes an independent security monitoring circuit that monitors the system status in parallel with the central processing unit;

[0064] The safety monitoring circuit is configured to directly output a hardware control signal to cut off the power circuit of the energy recovery unit and trigger the redundant braking mechanism of the hydraulic braking unit when a system communication failure or emergency stop signal is detected.

[0065] Upon detecting a system communication failure or an emergency stop signal, the safety monitoring circuit immediately outputs a hardware control signal to forcibly disconnect the power circuit of the energy recovery unit. Simultaneously, it sends a highest-priority command to the hydraulic braking unit, activating its redundant braking mechanism. This mechanism directly drives the backup hydraulic valve group, ensuring that braking pressure can be rapidly established and maintained even if the central processing unit fails. The safety monitoring circuit has a built-in self-diagnostic function, capable of real-time verification of its own logic status and synchronously sending fault codes and action logs to the central processing unit via an independent channel. When redundant braking is triggered, the system continuously monitors the hydraulic circuit pressure feedback. If a delay or insufficiency in pressure establishment is detected, a three-level backup braking strategy will be automatically activated, linking the mechanical brake device to achieve multiple safety safeguards. All safety monitoring actions employ a hard-wired connection design to avoid potential software layer latency risks, ensuring a response time of less than 50 milliseconds. Simultaneously, the action trigger signal illuminates the independent audible and visual alarm on the control cabinet and sends an alarm signal to the remote monitoring center.

[0066] In one specific embodiment, the central processing unit is further configured to: estimate the real-time load inertia of the belt conveyor system online based on the real-time torque current and speed of the drive motor;

[0067] Based on the real-time load inertia, the set value of the recovery current of the energy recovery unit and the set value of the braking pressure of the hydraulic braking unit are dynamically adjusted.

[0068] In one specific implementation, the online estimation of the real-time load inertia of the belt conveyor system is achieved through the following relationship:

[0069]

[0070] in, The estimated equivalent load inertia; This refers to the real-time output torque of the drive motor. This is the inherent resistance torque of the system; This represents the system's basic inertia when unloaded. The real-time angular acceleration of the conveyor belt is obtained from the velocity derivative measured by the velocity detection unit.

[0071] Based on estimated equivalent load inertia The central processing unit calculates the optimal recovery current setpoint for the energy recovery unit in real time. The specific relation is as follows: ,in The energy recovery coefficient, To compensate for the offset, This is the real-time linear speed of the conveyor belt. Simultaneously, the braking pressure setting of the hydraulic braking unit is dynamically adjusted. ,pass accomplish, This is the braking pressure coefficient. Based on the baseline pressure value, this ensures optimized braking response and energy recovery under different load conditions, avoiding overshoot or undershoot. This adjustment process is refreshed every 10 milliseconds, incorporating feedback from the speed detection unit. and This enables closed-loop control, improving system stability and energy efficiency.

[0072] In one specific embodiment, the system further includes a status monitoring module connected to the central processing unit; the status monitoring module is configured to:

[0073] Establish a digital twin dynamic model of the system;

[0074] During braking, the actual vibration spectrum data is compared in real time with the ideal vibration spectrum data output by the digital twin dynamic model;

[0075] Based on the discrepancies in the comparison results, the performance degradation trend of mechanical components is identified and maintenance early warning information is generated; the digital twin dynamic model integrates the real-time linear velocity of the conveyor belt. Equivalent load inertia Based on historical operating data, the model parameters are dynamically optimized using machine learning algorithms to ensure comparison accuracy. Real-time comparison employs a spectrum analysis algorithm to calculate the root mean square error between actual and ideal data. When the deviation exceeds a preset threshold, an early warning is automatically triggered. Identifying performance degradation trends includes analyzing the vibration characteristic frequency shift of key components such as bearings or brake discs, and predicting the remaining service life based on the degradation model. The generated maintenance early warning information is pushed to the central processing unit in real time, triggering the maintenance scheduling interface, and displaying specific degraded components, suggested maintenance times, and priorities through a human-machine interface, thus achieving a predictive maintenance closed loop.

[0076] In one specific embodiment, identifying the performance degradation trend of mechanical components includes identifying the friction coefficient of brake pads based on the following relationship:

[0077]

[0078] in, The real-time friction coefficient of the brake pads was identified; The total braking torque is obtained by back-calculation through the system dynamics model; The braking pressure applied to the hydraulic braking unit; The effective operating radius of the braking system; when the real-time friction coefficient When the value drops below a preset threshold compared to the initial value, a brake pad wear alarm is generated.

[0079] In addition, the system also monitors the friction coefficient in real time. Historical data is used, combined with machine learning algorithms, to analyze the wear rate and predict the remaining lifespan of the brake pads. When an accelerated decrease in the coefficient of friction is detected, the system can automatically adjust the braking pressure. The set value ensures braking torque. To maintain stability and prevent a decrease in braking efficiency due to wear. Simultaneously, upon triggering the alarm, the system records relevant parameter changes and outputs them to the maintenance log, facilitating subsequent diagnosis and preventative maintenance planning.

[0080] Secondly, this application provides a kinetic energy recovery braking control method for the drive end of a belt conveyor, executed by the aforementioned system, comprising:

[0081] Receive parking instructions and determine their type;

[0082] If it is a normal parking command, the cooperative braking mode will be executed: energy recovery will be activated and hydraulic compensation braking will be performed;

[0083] If the command is for an emergency stop, the emergency braking mode will be executed: energy recovery will be turned off and rapid hydraulic braking will be applied.

[0084] In the coordinated braking mode, energy recovery is initiated by converting the kinetic energy generated by the conveyor braking system into electrical energy via a generator and storing it in the energy storage unit; simultaneously, hydraulic compensation braking is applied based on the real-time friction coefficient. Dynamically adjust braking pressure To maintain a stable braking torque This ensures maximum energy recovery efficiency. In emergency braking mode, after energy recovery is deactivated, rapid hydraulic braking is performed: maximum braking pressure is applied directly. To achieve the shortest braking distance, and to monitor the braking torque in real time through a system dynamics model. This prevents overshoot or failure. Furthermore, the system continuously monitors the coefficient of friction during braking. The system tracks the historical degradation trend; if an abnormal decrease or accelerated degradation is detected, an early warning mechanism is triggered to optimize braking parameters or schedule maintenance in advance. After braking is completed, the system automatically resets to standby mode and records the operation log for subsequent performance analysis and preventative maintenance.

[0085] In one specific embodiment, the cooperative braking mode further includes an adaptive adjustment step:

[0086] Real-time acquisition of the drive motor's torque current and the conveyor belt's linear speed;

[0087] Based on the torque current and linear velocity, the real-time load inertia of the system is estimated online.

[0088] Based on the real-time load inertia, the system queries a preset matching table and adaptively adjusts the intensity of the energy recovery current and the magnitude of the hydraulic braking pressure to maintain the target deceleration rate.

[0089] This adaptive adjustment mechanism allows the system to dynamically adjust its braking strategy based on the actual load conditions. When the real-time load inertia is large, the energy recovery current intensity is appropriately increased to convert more kinetic energy into electrical energy for storage, while the hydraulic braking pressure is reasonably increased to ensure sufficient braking torque so that the conveyor belt decelerates at the target deceleration rate. Conversely, when the real-time load inertia is small, the energy recovery current intensity and hydraulic braking pressure are correspondingly reduced to avoid excessive braking that leads to energy waste and equipment damage.

[0090] During the adaptive adjustment process, the system continuously monitors the operating status of the conveyor belt. If a deviation is detected between the actual and target deceleration rates, the system will react quickly. If the actual deceleration rate is less than the target rate, the system will further increase the energy recovery current intensity and hydraulic braking pressure; if the actual deceleration rate is greater than the target rate, the system will decrease the corresponding parameters to ensure that the system always maintains a stable target deceleration rate.

[0091] The system records relevant data from each adaptive adjustment, such as real-time load inertia, adjusted energy recovery current intensity, and hydraulic braking pressure, in the operation log. This data is crucial for subsequent performance analysis. By analyzing a large amount of data, the optimal combination of braking parameters under different load inertia can be summarized, further optimizing the system's braking performance and energy recovery efficiency. This provides a more accurate basis for preventative maintenance, allowing for the early detection and handling of potential problems, and ensuring the long-term stable operation of the kinetic energy recovery braking system at the drive end of the belt conveyor.

[0092] Example 2

[0093] This invention system is implemented on a main conveyor belt in a mine. The signal input unit consists of control panel buttons installed in the control room, including a normal stop button and an emergency stop button. The speed detection unit uses a laser displacement sensor, installed above the return belt at the tail end of the conveyor, to accurately measure the belt speed non-contactly.

[0094] The central processing unit employs an industrial-grade PLC controller, which connects to the energy recovery unit, hydraulic braking unit, and status monitoring module via dual CAN bus interfaces. The core of the energy recovery unit is a control module for reverse excitation of the drive motor and a high-power rectifier cabinet. The rectified DC power passes through a power quality management circuit with active filtering and grid-connection switching functions, and is ultimately stored in an energy storage battery pack on the machine room side, or fed back to the mine's power grid under suitable conditions.

[0095] The hydraulic braking unit uses an electro-hydraulic system, in which an electronic booster controls the output pressure of the master cylinder, thereby applying braking force to the drive drum.

[0096] Work process:

[0097] When a normal stop is required, the operator presses the normal stop button. The signal is received by the PLC, which simultaneously reads the real-time belt speed from the laser sensor. Subsequently, the PLC sends two parallel commands via the CAN bus: one to the energy recovery unit to activate reverse excitation, causing the permanent magnet synchronous motor to operate as a generator and begin recovering kinetic energy; the other to the hydraulic braking unit, instructing it to output an initial braking pressure matching the current speed and load as compensation for electric braking, ensuring smooth deceleration. During braking, the PLC continuously monitors changes in motor torque and speed using the formula:

[0098]

[0099] Real-time estimation of load inertia and dynamic fine-tuning of generator current and hydraulic pressure enable adaptive optimized braking.

[0100] In case of an emergency, the operator presses the emergency stop button. The PLC responds immediately, cutting off the control signal to the energy recovery unit to stop it, and simultaneously sending a maximum braking pressure command to the hydraulic braking unit to stop the conveyor within the shortest distance. Meanwhile, an independent safety monitoring circuit also monitors the emergency stop signal; if it detects no response from the PLC or a communication interruption, it will take direct action to ensure that the safety logic is executed.

[0101] The condition monitoring module runs in the background and contains a built-in digital twin model of the conveyor. Each time braking occurs, it compares the actual vibration data with the model's predicted data. This is done using the formula:

[0102]

[0103] When the calculated brake pad friction coefficient μ remains below 80% of the initial value, the system will generate a warning message on the host computer suggesting that the brake pads be checked and replaced, prompting maintenance personnel.

[0104] It should be noted that this invention, while achieving braking safety control, effectively recovers inertial energy during equipment operation, improves energy efficiency, and has good prospects for industrial application, especially suitable for modern coal mines, smart mines and other fields.

[0105] Experimental Example: Performance Verification of Kinetic Energy Recovery Braking System

[0106] 1. Experimental Objective

[0107] This experiment aims to quantitatively demonstrate the significant advantages of the present invention in terms of energy efficiency, braking smoothness, and system life by comparing the braking performance and energy consumption of the traditional pure hydraulic braking system with the "kinetic energy recovery braking system" of the present invention under the same working conditions.

[0108] 2. Experimental Setup and Platform

[0109] Experimental subject: A fixed belt conveyor for mining with a length of 500 meters, a width of 1.2 meters, and a belt speed of 3.15 m / s.

[0110] Comparison System:

[0111] Control group: Original traditional pure hydraulic braking system.

[0112] Experimental group: The kinetic energy recovery braking system described in this invention is installed, while the original hydraulic system is retained as a backup and safety guarantee.

[0113] Measuring equipment:

[0114] Power quality analyzer: Installed at the output end of the drive motor distribution cabinet and energy recovery unit, it is used to measure energy consumption and recover electrical energy.

[0115] Accelerometer: Mounted on the drive roller bearing housing, it measures braking deceleration.

[0116] Data acquisition system: synchronously records belt speed, hydraulic pressure, recovery current, vibration data, etc.

[0117] High-precision noise meter: measures the noise level during braking.

[0118] 3. Experimental Design

[0119] Normal shutdown operations were performed on the conveyor under two conditions: no load (simulating light load) and rated load (400 tons / hour, simulating heavy load). Each experiment was repeated 5 times, and the average value was taken.

[0120] 4. Experimental Data and Results

[0121] Table 1: Comparison of Braking Performance and Energy Consumption under No-Load Conditions

[0122]

[0123] Table 2: Comparison of Braking Performance and Energy Consumption under Rated Load Conditions

[0124]

[0125] Table 3: Long-term operation simulation data (estimated based on experimental data)

[0126]

[0127] It should be noted that, compared to traditional systems, the system of this invention not only saves 4650 kWh of electricity consumed by traditional braking annually, but also recovers an additional 2100 kWh of energy. Therefore, the total energy saving benefit is 4650 + 2100 = 6750 kWh. This is equivalent to transforming a purely energy-consuming device into a small generator; the significant extension of brake pad life directly reduces equipment maintenance costs and downtime, further improving economic efficiency.

[0128] 5. Data Analysis and Conclusions

[0129] Experimental data clearly show that the system of this invention achieves net energy recovery under both no-load and heavy-load conditions (the "-" sign in the table indicates energy feedback). Traditional systems consume electrical energy with each braking action, while the system of this invention converts mechanical energy into electrical energy. Extrapolating to annual operation, the energy-saving effect is significant, directly reducing operating costs.

[0130] Significantly improved braking smoothness: The deceleration fluctuation range is a key indicator for measuring braking smoothness. The fluctuation range of the system in this invention is reduced by about 60% compared to traditional systems. This is due to the adaptive control based on real-time load inertia estimation described in this application. The system can dynamically adjust the electric braking force and hydraulic compensation force, avoiding the jerking sensation caused by the sluggish response of hydraulic valves and the instability of mechanical friction coefficient in traditional systems. The improved smoothness is also directly reflected in the significant reduction of braking noise, improving the working environment.

[0131] During braking, the system of this invention primarily relies on the electric braking of the energy recovery unit to bear the majority of the braking work, with the hydraulic system only providing fine compensation. This greatly reduces friction and wear between the brake pads and the brake disc; the inference that the brake pad life of the experimental group is expected to be extended by 3 times strongly demonstrates the beneficial effect of this invention in extending equipment life, significantly reducing spare parts costs and shortening downtime for maintenance.

[0132] Experimental data show that the braking time and average deceleration of the two systems are basically equivalent, indicating that the present invention achieves energy saving and smooth braking without sacrificing basic braking performance; the system of the present invention can reliably switch to pure hydraulic fast braking mode with a response time of less than 100ms, which fully meets the safety standard requirements.

[0133] Finally, this application provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps of the above-described kinetic energy recovery braking control method for the drive end of a belt conveyor.

[0134] According to one embodiment of the present invention, a server is provided, comprising: a processor; a memory for storing processor-executable instructions; wherein the processor is configured to invoke the instructions stored in the memory to execute a kinetic energy recovery braking control method for a belt conveyor drive end.

[0135] According to one embodiment of the present invention, a computer-readable storage medium is provided having computer program instructions stored thereon, which, when executed by a processor, implement a kinetic energy recovery braking control method for the drive end of a belt conveyor.

[0136] This invention can be a method, apparatus, system, and / or computer program product. The computer program product may include a computer-readable storage medium having computer-readable program instructions loaded thereon for performing various aspects of the invention.

[0137] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0138] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A kinetic energy recovery braking system for the drive end of a belt conveyor, characterized in that, include: The signal input unit is used to receive parking commands; Speed ​​detection unit, used to monitor the running speed of the conveyor belt in real time; The central processing unit is communicatively connected to the signal input unit and the speed detection unit; An energy recovery unit is electrically connected to the central processing unit and the drive motor of the belt conveyor, and is used to convert and output the electrical energy generated by braking. A hydraulic braking unit is connected to the central processing unit; The central processing unit is configured to: in response to a normal stop command, based on the speed signal from the speed detection unit, control the energy recovery unit to start in parallel to convert braking kinetic energy into electrical energy, and control the hydraulic braking unit to provide compensating braking force; in response to an emergency stop command, control the energy recovery unit to immediately shut down, and control the hydraulic braking unit to perform rapid braking.

2. The system according to claim 1, characterized in that, The central processing unit communicates with the energy recovery unit and the hydraulic braking unit via a dual CAN bus network.

3. The system according to claim 1, characterized in that, The energy recovery unit includes an excitation module that reverse-excites the drive motor and a rectifier module that rectifies the generated AC power into DC power. The output of the rectifier module is connected to the energy storage battery or the power grid through a power quality management circuit. The power quality management circuit is configured to actively filter the recovered power and switch the recovered energy to the local energy storage battery when a grid anomaly is detected.

4. The system according to claim 1, characterized in that, The system also includes an independent security monitoring circuit that monitors the system status in parallel with the central processing unit; The safety monitoring circuit is configured to directly output a hardware control signal to cut off the power circuit of the energy recovery unit and trigger the redundant braking mechanism of the hydraulic braking unit when a system communication failure or emergency stop signal is detected.

5. The system according to claim 1, characterized in that, The central processing unit is also configured to: estimate the real-time load inertia of the belt conveyor system online based on the real-time torque current and speed of the drive motor; Based on the real-time load inertia, the set value of the recovery current of the energy recovery unit and the set value of the braking pressure of the hydraulic braking unit are dynamically adjusted.

6. The system according to claim 5, characterized in that, The online estimation of the real-time load inertia of the belt conveyor system is specifically achieved through the following formula: ； in, The estimated equivalent load inertia; This refers to the real-time output torque of the drive motor. This is the inherent resistance torque of the system; This represents the system's basic inertia when unloaded. The real-time angular acceleration of the conveyor belt is obtained from the velocity derivative measured by the velocity detection unit.

7. The system according to claim 1, characterized in that, The system further includes a status monitoring module connected to the central processing unit; the status monitoring module is configured to: Establish a digital twin dynamic model of the system; During braking, the actual vibration spectrum data is compared in real time with the ideal vibration spectrum data output by the digital twin dynamic model; Based on the discrepancies in the comparison results, the performance degradation trend of mechanical components is identified and maintenance early warning information is generated.

8. The system according to claim 7, characterized in that, The identification of performance degradation trends of mechanical components includes identifying the friction coefficient of brake pads based on the following relationship: ； in, The real-time friction coefficient of the brake pads was identified; The total braking torque is obtained by back-calculation through the system dynamics model; The braking pressure applied to the hydraulic braking unit; The effective operating radius of the braking system; when the real-time friction coefficient When the value drops below a preset threshold compared to the initial value, a brake pad wear alarm is generated.

9. A kinetic energy recovery braking control method for the drive end of a belt conveyor, executed by the system as described in any one of claims 1-8, characterized in that, include: Receive parking instructions and determine their type; If it is a normal parking command, the cooperative braking mode will be executed: energy recovery will be activated and hydraulic compensation braking will be performed; If the command is for an emergency stop, the emergency braking mode will be executed: energy recovery will be turned off and rapid hydraulic braking will be applied.

10. The method according to claim 9, characterized in that, The cooperative braking mode also includes an adaptive adjustment step: Real-time acquisition of the drive motor's torque current and the conveyor belt's linear speed; Based on the torque current and linear velocity, the real-time load inertia of the system is estimated online. Based on the real-time load inertia, the system queries a preset matching table and adaptively adjusts the intensity of the energy recovery current and the magnitude of the hydraulic braking pressure to maintain the target deceleration rate.

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