Intelligent induction conveyor

Abstract

The application relates to the technical field of circuits, and discloses an intelligent induction conveying belt, which comprises a conveying belt module, a feeding mechanism, a sensor module, a control module, a signal processing unit, an alarm module, a fault grade judgment module and a manual reset switch, the conveying belt module is used for conveying materials, the feeding mechanism is arranged at the inlet end of the conveying belt, and the sensor module is used for detecting the running state of the conveying belt. The intelligent induction conveying belt is provided with the conveying belt module, the feeding mechanism, the control module and the fault grade judgment module, the control module realizes the hardware level time sequence control of the conveying belt module and the feeding mechanism through an RC delay circuit and a linkage control unit, the conveying belt is started first, and the feeding mechanism is started in delay; when the machine is stopped due to faults, the control module synchronously cuts off the power supply of the feeding mechanism, so that continuous feeding after the machine is stopped is avoided. The problem of material accumulation at the inlet caused by the asynchronization of starting and stopping in the traditional system is solved from the root, the system can be restarted without manual cleaning, and the production efficiency is improved.

Description

Technical Field

[0001] This application relates to the field of circuit technology, specifically to intelligent induction conveyor belts. Background Technology

[0002] A conveyor belt, also known as a transmission belt, is the transmission medium in a belt drive system. A belt drive system is a type of transmission system that includes two or more pulleys with a transmission belt on them. The pulleys can rotate freely, allowing the belt to move. One or more pulleys are powered to move the belt and the material it carries. The powered pulleys are called drive pulleys, and the others are called idler pulleys. Industrial applications of belt drive systems fall into two main categories: material handling in factories where materials or objects are placed in boxes or pallets, and bulk material handling where large quantities of goods or agricultural products (such as grain, salt, coal, ore, sand, or covering materials) are transported.

[0003] In existing bagged filling conveyor systems, the conveyor belt is typically equipped with a fault detection mechanism. When an anomaly is detected (such as packaging misalignment or jamming), the controller stops the conveyor belt. However, traditional systems have the following drawbacks: the feeding mechanism and the conveyor belt are not synchronized; after the conveyor belt stops, the front-end feeding mechanism continues to feed, causing raw materials to accumulate at the conveyor belt inlet, requiring manual cleaning before restarting, resulting in low efficiency; and it relies on manual intervention, requiring manual reset of the feeding mechanism and conveyor belt after troubleshooting, resulting in low automation. Therefore, there is an urgent need for an intelligent system that can coordinate and control the conveyor belt and feeding mechanism to improve the level of automation. Utility Model Content

[0004] To address the shortcomings of existing technologies, this application provides an intelligent sensor conveyor belt, which has the advantage of being able to restart without manual cleaning and improves production efficiency.

[0005] To achieve the above objectives, this application provides the following technical solution: an intelligent sensing conveyor belt, comprising a conveyor belt module, a feeding mechanism, a sensor module, a control module, a signal processing unit, an alarm module, a fault level determination module, and a manual reset switch. The conveyor belt module is used to transport materials, the feeding mechanism is located at the inlet end of the conveyor belt, the sensor module is used to detect the operating status of the conveyor belt, the control module is used to receive signals from the sensor module and synchronously control the start and stop of the motors inside the conveyor belt module and the feeding mechanism, the signal processing unit filters and performs threshold judgment on the sensor module signals, the alarm module is used to trigger an audible and visual alarm in case of a fault, the fault level determination module classifies faults into low-level faults and high-level faults based on the duration or amplitude of the fault signal, and the manual reset switch is used to restart the system after the fault is cleared.

[0006] The above solution, through the configuration of a conveyor belt module, feeding mechanism, control module, and fault level determination module, achieves hardware-level timing control of the conveyor belt module and feeding mechanism via an RC delay circuit and linkage control unit. This ensures that the conveyor belt starts first, and the feeding mechanism starts with a delay. In case of a fault shutdown, the control module synchronously cuts off the power to the feeding mechanism to prevent continuous feeding after shutdown. This fundamentally solves the problem of raw material accumulation at the inlet caused by asynchronous start-stop in traditional systems, allowing for restart without manual cleaning and improving production efficiency. The fault level determination module classifies faults into low-level and high-level faults based on the duration and amplitude of sensor signals. Low-level faults trigger PWM speed reduction and a slow flashing yellow alarm, while the system continues to operate. High-level faults immediately cut off power and trigger a fast flashing red alarm, avoiding production interruptions caused by the "one-size-fits-all" shutdown of traditional systems. Even under non-serious faults, the system can still operate at reduced speed, improving equipment utilization. The tiered alarm system allows operators to quickly locate the fault level, improving response efficiency.

[0007] Furthermore, the sensor module includes an infrared photoelectric sensor or a pressure sensor, which is installed in the middle section or at the outlet of the conveyor belt.

[0008] The above solution enables infrared photoelectric sensors to accurately detect material position shifts, while pressure sensors monitor accumulation pressure in real time, providing dual protection for comprehensive fault detection.

[0009] Furthermore, the control module includes an RC delay circuit, so that the feeding mechanism starts later than the conveyor belt module upon restart.

[0010] The above method forces the feeding mechanism to start late, ensuring that the conveyor belt reaches a stable speed in advance.

[0011] Furthermore, the control module integrates a linkage control unit, which automatically and synchronously restarts the conveyor belt and feeding mechanism after the fault is cleared.

[0012] With the above solution, after the fault is cleared, the linkage control unit automatically verifies the sensor status and synchronously sends start commands to the conveyor belt and feeding mechanism; no manual intervention is required to reset the process, realizing a closed loop of "fault clearing → automatic recovery".

[0013] Furthermore, the signal processing unit includes a voltage comparator for filtering noise interference and outputting a digital signal to the control module.

[0014] The above scheme allows the output digital signal to directly drive the control module, simplifying the signal processing link.

[0015] Furthermore, the control module controls the power supply to the motors inside the conveyor belt module and the feeding mechanism via relays.

[0016] The above solution provides hardware-level power failure protection, allowing for forced shutdown even if the main control chip fails.

[0017] Furthermore, the alarm triggering duration of the alarm module is positively correlated with the duration of the fault signal.

[0018] Through the above scheme, the alarm module can dynamically adjust the intensity of sound and light according to the duration of the fault.

[0019] Furthermore, the main control chip of the control module is a microcontroller, which receives input signals from the sensor module and outputs PWM waves to control the speed of the motors inside the conveyor belt module and the feeding mechanism. Low-level faults trigger PWM speed reduction control and start a slow flashing yellow light alarm. High-level faults trigger a relay to cut off the power supply and start a fast flashing red light and alarm module alarm. After the signal input of the manual reset switch, the control module first performs high-level fault reset. If the fault level has been reduced to low level, the PWM speed reduction control is restored to the preset speed.

[0020] The above solution prioritizes detecting advanced fault states during manual reset. If the fault is not cleared, the reset operation is locked to prevent accidental restart.

[0021] Compared with the prior art, the technical solution of this application has the following beneficial effects: 1. This intelligent sensor conveyor belt, through the configuration of a conveyor belt module, a feeding mechanism, a control module, and a fault level determination module, achieves hardware-level timing control of the conveyor belt module and the feeding mechanism via an RC delay circuit and a linkage control unit. This ensures that the conveyor belt starts first, and the feeding mechanism starts with a delay. In the event of a fault shutdown, the control module synchronously cuts off the power to the feeding mechanism to prevent continuous feeding after shutdown. This fundamentally solves the problem of raw material accumulation at the inlet caused by asynchronous start-stop in traditional systems, allowing for restart without manual cleaning and improving production efficiency. The fault level determination module classifies faults into low-level and high-level faults based on the duration and amplitude of sensor signals. Low-level faults trigger PWM speed reduction and a slow flashing yellow alarm, while the system continues to operate. High-level faults immediately cut off power and trigger a fast flashing red alarm, avoiding production interruptions caused by the "one-size-fits-all" shutdown of traditional systems. Even under non-serious faults, the system can still operate at reduced speed, improving equipment utilization. The tiered alarm system allows operators to quickly locate the fault level, improving response efficiency.

[0022] 2. This intelligent induction conveyor belt, through the setting of a signal processing unit, an alarm module, and a manual reset switch, ensures accurate feeding delay time by using an RC delay circuit independently controlled by software. The signal processing unit filters noise through a voltage comparator to reduce false triggering rate, and the relay directly controls the power supply to avoid safety risks caused by software failure, thus significantly enhancing the system's anti-interference capability. After the manual reset switch is triggered, the control module prioritizes checking whether the advanced fault has been cleared. If it has been cleared, it automatically restores the preset speed. The alarm module dynamically adjusts the alarm intensity according to the fault duration, accurately indicating the operation priority. Thus, the problem of "multi-step operation for manual reset" in traditional systems is simplified to a one-button safe restart. The differentiated design of the audible and visual alarms reduces human error. The sensor module supports infrared photoelectric and pressure sensors, adapting to different material types. The voltage comparator threshold of the signal processing unit is adjustable, compatible with various industrial scenarios, allowing the system to be quickly deployed to production lines in multiple industries such as food and chemicals. Attached Figure Description

[0023] Figure 1 This is a diagram of the overall system architecture of this application; Figure 2 This is a block diagram of the control module circuit of this application; Figure 3 This is the linkage control flowchart for this application; Figure 4 This is a structural diagram of the signal processing unit of this application; Figure 5 This is the alarm and motor control logic diagram for this application.

[0024] In the picture: 1. Conveyor belt module; 2. Feeding mechanism; 3. Sensor module; 4. Control module; 5. Signal processing unit; 6. Alarm module; 7. Fault level determination module; 8. Manual reset switch. Detailed Implementation

[0025] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0026] Please see Figure 1 , Figure 2 and Figure 3The intelligent sensing conveyor belt in this embodiment includes a conveyor belt module 1, a feeding mechanism 2, a sensor module 3, a control module 4, a signal processing unit 5, an alarm module 6, a fault level determination module 7, and a manual reset switch 8. The conveyor belt module 1 is used to transport materials. The feeding mechanism 2 is located at the inlet end of the conveyor belt. The sensor module 3 is used to detect the operating status of the conveyor belt. The control module 4 is used to receive signals from the sensor module 3 and synchronously control the start and stop of the motors inside the conveyor belt module 1 and the feeding mechanism 2. The signal processing unit 5 filters and performs threshold judgment on the signals from the sensor module 3. The alarm module 6... Block 6 is used to trigger an audible and visual alarm in case of a fault. The fault level determination module 7 classifies faults into low-level and high-level faults based on the duration or amplitude of the fault signal. The manual reset switch 8 is used to restart the system after the fault is cleared. By setting up the conveyor belt module 1, the feeding mechanism 2, the control module 4, and the fault level determination module 7, the control module 4 realizes hardware-level timing control of the conveyor belt module 1 and the feeding mechanism 2 through the RC delay circuit and the linkage control unit, ensuring that the conveyor belt starts first and the feeding mechanism starts later. When the system stops due to a fault, the control module 4 synchronously cuts off the power supply to the feeding mechanism 2 to avoid continuous feeding after the system stops. This system fundamentally solves the problem of raw material accumulation at the inlet caused by asynchronous start-stop in traditional systems, allowing for restart without manual cleaning and improving production efficiency. The fault level determination module 7 classifies faults into low-level and high-level faults based on the duration and amplitude of sensor signals. Low-level faults trigger PWM speed reduction and a slow flashing yellow alarm, while the system continues to run. High-level faults immediately cut off power and trigger a fast flashing red alarm, avoiding production interruptions caused by the "one-size-fits-all" shutdown of traditional systems. Even under non-serious faults, the system can still operate at reduced speed, improving equipment utilization. The graded alarms enable operators to quickly locate the fault level, improving response efficiency.

[0027] Please see Figure 1 , Figure 4 and Figure 5 Sensor module 3 includes an infrared photoelectric sensor or a pressure sensor, installed in the middle or outlet of the conveyor belt. Control module 4 includes an RC delay circuit. When restarting, the starting time of feeding mechanism 2 is later than that of conveyor belt module 1. Control module 4 integrates a linkage control unit. After the fault is cleared, the conveyor belt and feeding mechanism 2 are automatically and synchronously restarted. The infrared photoelectric sensor accurately detects the material position deviation, and the pressure sensor monitors the accumulation pressure in real time, providing dual protection for comprehensive fault detection. The feeding mechanism is forced to delay its start to ensure that the conveyor belt reaches a stable speed in advance. After the fault is cleared, the linkage control unit automatically verifies the sensor status and synchronously sends start commands to the conveyor belt and feeding mechanism. No manual intervention is required for the reset process, realizing a closed loop of "fault clearing → automatic recovery".

[0028] Please see Figure 1 , Figure 4 and Figure 5The signal processing unit 5 includes a voltage comparator for filtering noise interference and outputting a digital signal to the control module 4. The control module 4 controls the power supply of the motors inside the conveyor belt module 1 and the feeding mechanism 2 via relays. The alarm trigger duration of the alarm module 6 is positively correlated with the duration of the fault signal. The main control chip of the control module 4 is a microcontroller, which receives the input signal from the sensor module 3 and outputs a PWM wave to control the speed of the motors inside the conveyor belt module 1 and the feeding mechanism 2. A low-level fault triggers PWM speed reduction control and starts a slow flashing yellow light alarm. A high-level fault triggers the relay to cut off the power supply and starts a fast flashing red light alarm and alarm module 6. After the signal input of the manual reset switch 8, the control module 4 prioritizes high-level fault reset. If the fault level has been reduced to low-level, it restores PWM speed reduction control to the preset speed and outputs a digital signal to directly drive the control module, simplifying the signal processing link. Hardware-level power failure protection ensures that even if the main control chip fails, it can still force a shutdown. The alarm module 6 can dynamically adjust the sound and light intensity according to the fault duration. During manual reset, it prioritizes detecting the high-level fault status. If it is not cleared, it locks the reset operation to prevent accidental restart.

[0029] In this embodiment, by setting up a conveyor belt module 1, a feeding mechanism 2, a control module 4, and a fault level determination module 7, the control module 4 achieves hardware-level timing control of the conveyor belt module 1 and the feeding mechanism 2 through an RC delay circuit and a linkage control unit, ensuring that the conveyor belt starts first and the feeding mechanism 2 starts with a delay. When a fault occurs and the system stops, the control module 4 synchronously cuts off the power to the feeding mechanism 2 to prevent continuous feeding after the system stops. This fundamentally solves the problem of raw material accumulation at the inlet caused by asynchronous start and stop in traditional systems, allowing for restart without manual cleaning and improving production efficiency. The fault level determination module 7 classifies faults into low-level and high-level faults based on the duration and amplitude of sensor signals. Low-level faults trigger PWM speed reduction and a slow flashing yellow light alarm, while the system continues to run. High-level faults immediately cut off power and trigger a fast flashing red light alarm, avoiding production interruptions caused by the "one-size-fits-all" shutdown of traditional systems. The system can still operate at reduced speed under non-serious faults, improving equipment utilization. The graded alarm allows operators to quickly locate the fault level, improving response efficiency.

[0030] The working principle of the above embodiment is as follows: the feeding mechanism 2 delivers the material to the conveyor belt inlet. The conveyor belt module 1 conveys the material at a uniform speed under the PWM speed control of the control module 4. The sensor module 3 detects the running status of the conveyor belt in real time. The signal processing unit 5 performs low-pass filtering and voltage comparator threshold judgment on the original signal and outputs a stable digital signal to the control module 4. The low-level fault trigger condition is a brief material deviation or instantaneous pressure fluctuation. The high-level fault trigger condition is a continuous material accumulation or mechanical jamming. The level judgment logic is as follows: the fault level judgment module 7 dynamically classifies the faults according to the duration and amplitude of the sensor signal. Low-level fault → maintain operation and trigger a slow flashing yellow light alarm; high-level fault → immediately cut off the power to the feeding mechanism 2, trigger a fast flashing red light and a high-frequency buzzer alarm. The control module 4 transmits the alarm through a relay. The power supply to the motors of conveyor belt module 1 and feeding mechanism 2 is simultaneously cut off to avoid inlet accumulation caused by feeding delay. The RC delay circuit forces feeding mechanism 2 to delay its start during the restart phase to ensure that the conveyor belt reaches a stable speed in advance. After the operator troubleshoots the fault, press the manual reset switch 8. The control module 4 performs the following operations: high-level faults are detected first, and the pressure sensor signal is scanned to confirm that there is no continuous accumulation. If the high-level fault has been resolved, the conveyor belt motor is started, and the feeding mechanism relay is closed after a delay. If a low-level fault still exists, the PWM speed reduction mode is maintained and the yellow light alarm is retained. The alarm module 6 adjusts the intensity of the audible and visual alarm according to the duration of the fault. For low-level faults, the yellow light flashes slowly and the buzzer is turned off; for high-level faults, the red light flashes quickly and the buzzer sounds at a high frequency, and the alarm duration is positively correlated with the duration of the fault.

[0031] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0032] Although embodiments of this application have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An intelligent sensing conveyor belt, comprising a conveyor belt module (1), a feeding mechanism (2), a sensor module (3), a control module (4), a signal processing unit (5), an alarm module (6), a fault level determination module (7), and a manual reset switch (8), characterized in that: The conveyor belt module (1) is used to transport materials. The feeding mechanism (2) is located at the inlet end of the conveyor belt. The sensor module (3) is used to detect the running status of the conveyor belt. The control module (4) is used to receive the signal from the sensor module (3) and synchronously control the start and stop of the motor inside the conveyor belt module (1) and the motor inside the feeding mechanism (2). The signal processing unit (5) filters and performs threshold judgment on the signal from the sensor module (3). The alarm module (6) is used to trigger an audible and visual alarm when a fault occurs. The fault level determination module (7) classifies faults into low-level faults and high-level faults according to the duration or amplitude of the fault signal. The manual reset switch (8) is used to restart the system after the fault is cleared.

2. The intelligent sensor conveyor belt according to claim 1, characterized in that: The sensor module (3) includes an infrared photoelectric sensor or a pressure sensor, which is installed in the middle section or outlet of the conveyor belt.

3. The intelligent sensor conveyor belt according to claim 1, characterized in that: The control module (4) includes an RC delay circuit, and the starting time of the feeding mechanism (2) is later than that of the conveyor belt module (1) when restarting.

4. The intelligent sensor conveyor belt according to claim 1, characterized in that: The control module (4) integrates a linkage control unit, which automatically and synchronously restarts the conveyor belt and feeding mechanism (2) after the fault is cleared.

5. The intelligent sensor conveyor belt according to claim 1, characterized in that: The signal processing unit (5) includes a voltage comparator for filtering noise interference and outputting digital signals to the control module (4).

6. The intelligent sensor conveyor belt according to claim 1, characterized in that: The control module (4) controls the power supply of the internal motor of the conveyor belt module (1) and the internal motor of the feeding mechanism (2) through relays.

7. The intelligent sensor conveyor belt according to claim 1, characterized in that: The alarm trigger duration of the alarm module (6) is positively correlated with the duration of the fault signal.

8. The intelligent sensor conveyor belt according to claim 1, characterized in that: The main control chip of the control module (4) is a microcontroller. The microcontroller receives the input signal from the sensor module (3) and outputs a PWM wave to control the speed of the motor inside the conveyor belt module (1) and the motor inside the feeding mechanism (2). A low-level fault triggers PWM speed reduction control and starts a yellow light slow flashing alarm. A high-level fault triggers a relay to cut off the power supply and starts a red light fast flashing and alarm module (6) alarm. After the signal input of the manual reset switch (8), the control module (4) prioritizes high-level fault reset. If the fault level has been reduced to low level, the PWM speed reduction control is restored to the preset speed.

Images