A closed-loop controlled tension forming conveyor belt machine

Abstract

This invention proposes a closed-loop tension-forming conveyor belt machine, belonging to the field of conveyor belt technology. The conveyor belt machine includes a force sensor, an automatic centering and deviation-correcting mechanism, a guide mechanism, and a laminating device. This invention can replace traditional forming machines, achieving closed-loop control of online constant-tension forming of layered belt cores. This improves interlayer adhesion of multi-layered tapes and addresses issues related to uniform flatness, tension, and tensile strength across the layers of layered conveyor belts. Furthermore, it improves production efficiency, reduces labor intensity, and contributes to a higher level of automation in tape production lines.

Description

Technical Field

[0001] The invention belongs to the technical field of conveyor belts and relates to a closed-loop controlled constant tension forming conveyor belt machine used in a conveyor belt calendering production line. Background Art

[0002] Conveyor belts are composite materials made of rubber, fiber, and metal, used in conveyor belts to carry and transport materials. They are widely used in agriculture, coal mining, mining, metallurgy, construction, and transportation. There are many types of conveyor belts, classified by their carcass material: fabric core conveyor belts, steel cord conveyor belts, and flame-retardant integral core conveyor belts. Fabric core conveyor belts are also known as layered conveyor belts, made by bonding three to six layers of rubberized canvas, covered with various top and bottom cover rubbers, and then vulcanized. Currently, layered conveyor belts are mostly formed on dedicated forming machines equipped with at least three material guides and multiple laminating devices. Three rolls of fabric must be placed simultaneously on the forming machine, and the forming process involves multiple fabric feeds, reverse laminating, and other operations, which can affect the overall strength and stability of the conveyor belt's tension cords. Furthermore, the forming machine lacks a closed-loop tension control unit, relying on manual control. This results in different tensions across the various guides, leading to uneven tension in each layer during forming. This affects the overall tensile strength and stability of the layered conveyor belt, making it prone to delamination during use and reducing its service life. Maintaining interlayer adhesion between multiple layers of tape for layered conveyor belts is a key technology for achieving simultaneous lamination. To improve interlayer adhesion and address the issue of unstable tensile strength through the full thickness of layered conveyor belts, the traditional concept of forming layered belts using conventional forming machines has been abandoned, with a new process for forming layered conveyor belts online on a calendering line. Based on this, the present invention proposes a closed-loop constant tension forming conveyor belt machine on a calendering line, which represents an inevitable trend in the development of the conveyor belt market. Summary of the Invention

[0003] To address the aforementioned issues, the present invention designs a closed-loop controlled constant tension forming conveyor belt machine for use in conveyor belt calendering production lines. The present invention utilizes a force sensor to detect and control the tape tension, enabling closed-loop control of the constant tension forming conveyor belt. A clutch is incorporated into the unwinding device, which is switched to achieve tape unwinding and rewinding. Two unwinding devices are employed to simultaneously position two rolls of tape, and two laminating devices are provided to enable laminating and forming of multiple layers of tape. Automatic centering and deviation correction ensures the edges of the layered conveyor belt formed by laminating multiple layers of tape are even.

[0004] The technical solution of the present invention is:

[0005] A closed-loop controlled tension forming conveyor belt machine comprises a 1# load cell 1, a 2# load cell 2, a 3# load cell 3, an automatic centering and deviation correcting mechanism 4, a 1# guide device 5, a 2# guide device 6, a 1# laminating device 7 and a 2# laminating device 8.

[0006] The 1# laminating device 7 and the 2# laminating device 8 are symmetrically arranged below the calender, and the 1# deflecting device 5 and the 2# deflecting device 6 are respectively provided on both sides of the calender.

[0007] The 1# unwinding device 5 and the 2# unwinding device 6 operate in opposite directions, with one used for rewinding the tape and the other for unwinding it. Both unwinding devices use a pneumatic brake to control the unwinding tension, switching between unwinding and rewinding via a clutch to achieve tape lamination. The specific structure is as follows: On one side of the mandrel of both the 1# unwinding device 5 and the 2# unwinding device 6, a pneumatic safety chuck II 13, a clutch II 14, a reducer II 15, an electro-hydraulic brake 16, and a motor 17 are sequentially connected; on the other side of the mandrel, a pneumatic safety chuck I 12, a clutch I 11, a reducer I 10, and a pneumatic brake 9 are sequentially connected. When used for rewinding, the clutch on the motor 17 side is engaged, while the clutch on the pneumatic brake 9 side is disengaged. When used for unwinding, the clutch on the pneumatic brake 9 side is engaged, while the clutch on the motor 17 side is disengaged. According to process requirements, the proportional valve of the pneumatic brake air circuit system of the unwinding device is adjusted to achieve closed-loop control of constant tension in the formed layered conveyor belt.

[0008] The 1# force sensor 1 is arranged at the calender to measure the tension of the new tape currently produced by the calender; the 2# force sensor 2 and the 3# force sensor 3 are respectively arranged at the 1# deflection device 5 and the 2# deflection device 6 to measure the tension of the tape derived from the two workstations.

[0009] The automatic centering and deviation correction mechanism 4 includes a controller, a 1# sensor 18, a 2# sensor 19, a 3# sensor 20, a 1# actuator 21, and a 2# actuator 22. Among them, the 1# sensor 18 is located at the calender and is used to detect the edge position of the upper layer of new tape produced by the calender; the 2# sensor 19 is located at the 1# deflection device 5 and is used to detect the edge position of the tape participating in the control of the 1# deflection device; the 3# sensor 20 is located at the 2# deflection device 6 and is used to detect the edge position of the tape participating in the control of the 2# deflection device. When the width of the tape changes, the sensor of the automatic centering and deviation correction mechanism 4 will automatically find the edge of the tape for inspection and send a signal to the controller. The controller drives the 1# actuator 21 set below the 1# deflection device 5 and the 2# actuator 22 set below the 2# deflection device 6 according to the edge position signal, thereby pushing the movable bases of the two deflection devices to move left and right, correcting the center deviation of the tape and ensuring that the upper and lower layers of tape are centered before lamination.

[0010] The beneficial effects of the present invention are as follows: the present invention can replace the traditional forming machine, realize the closed-loop control of the online constant tension forming layered belt core, improve the adhesion between the multi-layer adhesive tape, and solve the problems of the flatness, tension and tensile strength uniformity of each layer of the layered conveyor belt; at the same time, it improves the production efficiency, reduces the labor intensity, and makes the automation level of the tape production line higher and higher. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 It is a structural diagram of a closed-loop controlled tension forming conveyor belt machine.

[0012] Figure 2 It is a structural schematic diagram of the deflection device.

[0013] Figure 3 The electrical control method of the closed-loop tension forming conveyor belt machine is shown in Figure 1, where (a) is the closed-loop control of the unwinding tension and (b) is the closed-loop control of the winding tension.

[0014] Figure 4 This is a schematic diagram of the automatic centering and deviation correction control method.

[0015] In the figure: 1-1# force sensor; 2-2# force sensor, 3-3# force sensor; 4-automatic centering and correcting mechanism; 5-1# guide device; 6-2# guide device; 7-1# bonding device; 8-2# bonding device; 9-pneumatic brake; 10-reducer I; 11-clutch I; 12-pneumatic safety chuck I; 13-pneumatic safety chuck II; 14-clutch II; 15-reducer II; 16-electro-hydraulic brake; 17-motor; 18-1# sensor; 19-2# sensor; 20-3# sensor; 21-1# actuator; 22-2# actuator. DETAILED DESCRIPTION

[0016] The following examples and drawings further explain the specific embodiments of the present invention, but are not intended to limit the present invention.

[0017] like Figure 1 As shown, a closed-loop controlled tension forming conveyor belt machine includes a 1# force sensor 1, a 2# force sensor 2, a 3# force sensor 3, an automatic centering and correcting mechanism 4, a 1# guide device 5, a 2# guide device 6, a 1# laminating device 7 and a 2# laminating device 8.

[0018] During the tape layer application process, the 1# unwinding device 5 and the 2# unwinding device 6 operate in opposite directions: one for rewinding the tape, the other for unwinding it. Because the 1# unwinding device 5 and the 2# unwinding device 6 perform both rewinding and unwinding functions, their mandrels are connected to the motor 17 via a clutch on one side and to the pneumatic brake 9 via a clutch on the other side. During layer application, when operating in the rewinding mode, the clutch on the motor 17 side is engaged, while the clutch on the pneumatic brake 9 side is disengaged. When operating in the unwinding mode, the clutch on the pneumatic brake 9 side is engaged, while the clutch on the motor 17 side is disengaged.

[0019] The 1# laminating device 7 and the 2# laminating device 8 are used to laminate the newly produced tape produced by the calendar with the tape discharged from the unwinding device. The two sets are used alternately during repeated lamination. Three sets of load cells measure the tension of the tape at three locations: the 1# load cell 1 measures the tension of the newly produced tape by the calendar, the 2# load cell 2 and the 3# load cell 3 measure the tension of the tape at the 1# unwinding device 5 and the 2# unwinding device 6, respectively. Because the laminating technology is implemented based on constant tension center winding, the tension provided by the rewinding is constant. The 1# unwinding device 5 is used for unwinding. After the discharged tape is laminated with the newly delivered tape from the rear traction device by the 1# laminating device 7, it is rewound by the 2# unwinding device 6. At this time, the rewinding tension is shared by both the discharged tape and the newly delivered tape from the rear traction device. The discharged tape tension is controlled by a pneumatic brake, and the tension is displayed by the load cells. The tension of the newly produced tape is the remainder of the rewinding tension minus the unwinding tension. For layer-by-layer conveyor belts, the process requires that the tension of the two tape layers at each layer correspond to the number of layers. Adjusting the force sensors at the pay-off position changes the pay-off tension so that the displayed tension of the tape output corresponds to the tension of the new tape. For example, if the fourth layer of tape is being applied, force sensor 2# is in the pay-off position and force sensor 3# is in the take-up position. This means that the new tape at the rear pull-off position is one layer, and the tape that is being paid out is three layers. Therefore, the tension ratio between force sensor 1# and force sensor 2# is adjusted to 1:3.

[0020] The above-mentioned closed-loop control tension forming conveyor belt machine can realize closed-loop control of constant tension lamination between layers and realize recipe management.

Claims

1. A closed-loop controlled tension forming conveyor belt machine, characterized in that: It includes a force sensor, an automatic centering and deviation correction mechanism (4), a guide device and a bonding device; Two laminating devices are symmetrically arranged below the calender, with a release device on each side. The two release devices always work in opposite ways, with one used to rewind the tape and the other to unwind the tape. Due to their dual functions of rewinding and unwinding, one side of the core shaft of the release device is connected to the motor through a clutch, and the other side is connected to the pneumatic brake through a clutch. When used for rewinding, the clutch on the motor side is engaged and the clutch on the pneumatic brake side is disengaged; when used for unwinding, the clutch on the pneumatic brake side is engaged and the clutch on the motor side is disengaged. According to process requirements, the proportional valve of the pneumatic brake air circuit system of the release device is adjusted to achieve constant tension closed-loop control of the formed layered conveyor belt. The force sensors include three, which respectively measure the tension of the new tape currently produced by the calender and the tension of the tape derived from the two unwinding devices; the 1# force sensor (1) is arranged at the calender, and is used to measure the tension of the new tape currently produced by the calender; the 2# force sensor (2) and the 3# force sensor (3) are respectively arranged at the 1# unwinding device (5) and the 2# unwinding device (6), and are used to measure the tension of the tape derived from the two workstations; the tension of the winding is shared by the unwinding tape and the new tape delivered by the rear traction; the tension of the unwinding tape is controlled by the pneumatic brake, and the magnitude of the tension is displayed by the force sensor; the tension of the new tape is the remainder of the winding tension minus the unwinding tension; it is required that the tension of the two tapes at the layer bonding locations has a corresponding relationship with the number of layers, and the force sensors at the unwinding devices are adjusted to change the unwinding tension so that the displayed tension of the unwinding tape and the tension of the new tape meet the corresponding relationship; The automatic centering and deviation correction mechanism (4) includes a controller, a sensor and an actuator; wherein the three sensors are respectively used to detect the edge position of the upper layer of new tape produced by the calender, and to detect the edge position of the tape involved in controlling the two unwinding devices; when the width of the tape changes, the sensor will automatically find the edge of the tape for inspection and send a signal to the controller, and the controller drives the actuator arranged below the two unwinding devices to move according to the edge position signal, thereby pushing the movable bases of the two unwinding devices to move left and right, correcting the center deviation of the tape, and ensuring that the upper and lower layers of the tape are centered before lamination.

2. A closed-loop controlled tension forming conveyor belt machine according to claim 1, characterized in that: The specific structure of the guide device is as follows: one side of the core shaft of the guide device is connected in sequence to the pneumatic safety chuck II (13), clutch II (14), reducer II (15), electro-hydraulic brake (16) and motor (17); the other side is connected in sequence to the pneumatic safety chuck I (12), clutch I (11), reducer I (10) and pneumatic brake (9).

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