Abrupt corner tape anti-flow breaking method and device

Abstract

The application discloses a kind of steep corner belt anti-breaking flow method and device.Method includes: according to the material image on steep corner belt, judge whether the supply of bunker bottom belt is continuous;When judging discontinuous, output alarm prompt, judge whether the line speed of calculated active roller is consistent with the actual running speed of belt;If it is judged to be consistent, corresponding control signal is sent to the active roller frequency converter of bunker bottom belt, so that the frequency of active roller frequency converter is improved, to improve the speed of bunker bottom belt;If it is judged to be inconsistent, corresponding control signal is sent to direct current electric cylinder, so that the screw rod of upper part of direct current electric cylinder is continuously extended;When screw rod is extended, drive cylinder motor and cylinder are lifted;Judge whether the pressure signal of cylinder reaches preset pressure signal threshold;If it reaches, make the screw rod of direct current electric cylinder stop extending, and at the same time make servo controller drive cylinder motor to drive cylinder to rotate.The application can eliminate the breaking fault in the embryonic state, improve the intelligent level of single machine equipment.

Description

Technical Field

[0001] This application relates to the field of cigarette production technology, and in particular to a method and apparatus for preventing flow interruption in steep-angle bands. Background Technology

[0002] Constant flow control is one of the core aspects of silk refining process control. The constant flow control device mainly consists of three parts: a bin-type feeder, a metering tube 1, and a control-type electronic scale 2. Among them, for example... Figure 1 As shown, the bin-type feeder mainly consists of: a bin 3, a bin bottom belt 4 and a bin bottom belt motor, a material photocell 5, a steep-angle belt 6 and a steep-angle belt motor, and a material buffer zone 7; a high-level photocell 8, a medium-level photocell 9 and a low-level photocell 10 are installed on the metering tube 1; and an electronic scale belt 11 is installed on the control electronic scale 2.

[0003] Material in the bin-type feeder is conveyed to the steep-angle belt 6 by the bottom belt 4 of the bin. The steep-angle belt 6 controls its speed (low, medium, and high) according to the detection of the high, medium, and low photoelectric tubes of the metering tube 1 to fill the metering tube 1 with material. Material at a certain height in the metering tube 1 is then driven by the electronic scale belt 11 and passes through the controlled electronic scale 2. The controlled electronic scale 2 adjusts the belt speed of the electronic scale belt 11 in real time according to the set flow rate to ensure that the instantaneous material passing through the electronic scale reaches the set rated flow rate.

[0004] In other words, during the production process, the rotation speed of the steep-angle belt 6 is controlled by the on / off switching of the high, medium and low photoelectric tubes of the metering tube 1, thereby ensuring that the material in the metering tube 1 is kept at a certain height; at the same time, the detection signal of the material photoelectric tube 5 of the hopper feeder controls the operation of the hopper bottom belt motor, which drives the hopper bottom belt 4 to continuously transport the material from the feeding belt 12 to the steep-angle belt 6.

[0005] The width of the bottom belt 4 is roughly the same as the width of the steep-angle belt 6. However, the material height stored in the hopper 3 is four times the material height on the steep-angle belt 6. Therefore, during production, the bottom belt motor feeds material in a stepping mode under the control of the material photocell 5. According to statistics, even under optimized parameters, the bottom belt 4 starts and stops about 80 times per hour, with each start being a load start. After prolonged use, the belt tension decreases, leading to reduced friction between the belt and the drive roller. This can cause the bottom belt 4 to slip relative to the material at startup, commonly known as "slippage." In this case, the bottom belt 4 cannot carry the material forward to the steep-angle belt 6, causing a material flow interruption on the steep-angle belt 6. Consequently, the material flow rate on the control scale 2 decreases and fails to reach the set value. At this time, the material height in metering tube 1 is lower than the low material level phototube 10 of metering tube 1. The low material level phototube 10 controls the steep angle belt 6 to run at high speed. However, the bottom belt 4 of the hopper cannot transport the material to the steep angle belt 6, which eventually leads to the interruption of the flow of the control electronic scale 2.

[0006] The reasons for the flow interruption are as follows: Firstly, the belt is made of PVC, and after prolonged use, the belt tension decreases, reducing the friction between the drive roller and the belt contact surface, causing the belt conveyor to slip or lose rotation. Most importantly, there was no prediction or alarm when the slippage trend occurred, leading to further escalation of the fault. Secondly, the material in the grain bin is insufficient, resulting in inadequate feeding of the steep-angle belt 6, which may also cause the flow interruption of the steep-angle belt 6.

[0007] According to actual production statistics, there is a material buffer zone 7 between the bottom belt 4 and the steep-angle belt 6 of the hopper, which can store a portion of the material. By setting the material buffer zone 7, the bottom belt 4 of the hopper can be without material for 30 seconds. If the bottom belt 4 slips for more than 30 seconds, it will cause a production interruption, which will seriously affect the stability of product quality and increase energy consumption. However, existing constant flow control systems often cannot detect and handle the interruption in time. Summary of the Invention

[0008] Based on this, a steep-angle band anti-interruption method and device are provided to solve the technical problem that existing constant flow control systems cannot detect and handle interruptions in a timely manner.

[0009] To achieve the above objectives, this application provides the following technical solution:

[0010] Firstly, a method for preventing current interruption in steep-angle zones includes:

[0011] S1, acquire material images on the steep-angle belt collected by the image recognition sensor in real time, and determine whether the material supply to the bottom belt of the silo is continuous based on the material images;

[0012] S2, when it is determined that the material supply of the bottom belt of the hopper is discontinuous, an alarm prompt is output, the output signal of the first encoder is obtained, the linear speed of the drive roller of the bottom belt of the hopper is calculated based on the output signal of the first encoder, the first encoder is connected to the drive roller of the bottom belt of the hopper; and the actual running speed of the belt of the bottom belt of the hopper is obtained by the belt speed meter, and the linear speed of the drive roller is compared with the actual running speed of the belt.

[0013] S3, if the linear speed of the drive roller is consistent with the actual running speed of the belt, send a corresponding control signal to the drive roller frequency converter of the bottom belt of the silo to increase the frequency of the drive roller frequency converter in order to increase the speed of the bottom belt of the silo.

[0014] S4, if the linear speed of the drive roller is inconsistent with the actual running speed of the belt, a corresponding control signal is sent to the DC electric cylinder to continuously extend the screw rod at the top of the DC electric cylinder; the DC electric cylinder is located at the bottom of the belt, and a roller motor and a roller are mounted on the screw rod of the DC electric cylinder, the roller motor being connected to a servo controller; when the screw rod extends, it drives the roller motor and the roller to rise.

[0015] S5, acquire the pressure signal of the roller collected by the pressure sensor, and determine whether the pressure signal reaches the preset pressure signal threshold; if it is determined that the pressure signal reaches the preset pressure signal threshold, send a corresponding control signal to the DC electric cylinder to stop the screw rod of the DC electric cylinder from extending, and at the same time send a corresponding control signal to the servo controller to drive the roller motor to rotate the roller, and make the linear velocity of the roller consistent with the linear velocity of the drive roller, and the rotation direction of the roller is opposite to the rotation direction of the drive roller.

[0016] Optionally, determining whether the feeding of the hopper bottom belt is continuous based on the material image includes:

[0017] The material image is compared with a pre-stored standard steep-angle band material image to determine the uniformity of the material in the steep-angle band.

[0018] If the material on the steep-angle belt is determined to be uneven, then the material supply to the bottom belt of the silo is determined to be discontinuous; if the material on the steep-angle belt is determined to be uniform, then the material supply to the bottom belt of the silo is determined to be continuous.

[0019] Optionally, the preset pressure signal threshold is 10mA.

[0020] Optionally, step S5 further includes:

[0021] The output signal of the first encoder is continuously acquired, and the linear velocity of the drive roller of the bottom belt of the silo is calculated based on the output signal of the first encoder; and the actual running speed of the belt of the bottom belt of the silo is continuously acquired by the belt speed meter, and the linear velocity of the drive roller is compared with the actual running speed of the belt.

[0022] If the linear speed of the drive roller is consistent with the actual running speed of the belt, a corresponding control signal is sent to the servo controller to stop the servo controller from driving the roller motor to rotate the roller.

[0023] After a preset time interval, the linear speed of the drive roller is compared with the actual running speed of the belt; if the linear speed of the drive roller is still consistent with the actual running speed of the belt, a corresponding control signal is sent to the DC electric cylinder to retract the screw rod of the DC electric cylinder; when the screw rod retracts, it drives the roller motor and the roller to descend.

[0024] Alternatively, the preset time interval is 10 seconds.

[0025] Secondly, a steep-angle anti-interruption device includes:

[0026] An image recognition sensor, installed on the steep-angle zone, is used to acquire images of the material on the steep-angle zone;

[0027] The first encoder is connected to the drive roller of the bottom belt of the hopper and is used to detect the rotational speed of the drive roller;

[0028] The belt speed meter comes into contact with the belt at the bottom of the silo and is used to detect the actual running speed of the belt at the bottom of the silo.

[0029] The active roller frequency converter is connected to the bottom belt motor of the hopper bottom belt and is used to control the speed of the hopper bottom belt; the bottom belt motor is connected to the active roller.

[0030] A DC electric cylinder is installed at the lower part of the belt at the bottom of the hopper; a screw rod is installed at the upper part of the DC electric cylinder, and a roller motor and a roller are installed on the screw rod;

[0031] A servo controller is connected to the roller motor;

[0032] A pressure sensor is installed on the roller to collect the pressure signal of the roller;

[0033] The PLC controller includes a memory and a processor. The memory stores a computer program, and the processor executes the computer program to implement the steps of the method described in the first aspect.

[0034] Optionally, the steep-angle anti-interruption device further includes a second encoder, which is connected to the drum motor and used to detect the rotational speed of the drum motor; the data output terminal of the second encoder is electrically connected to one data input terminal of the PLC controller.

[0035] Optionally, the steep-angle belt anti-interruption device further includes a constant pressure support mechanism, which is located at the lower part of the belt of the hopper bottom belt, and the belt speed measuring instrument is located on the constant pressure support mechanism.

[0036] Optionally, the distance between the roller and the drive roller is 7 times the thickness of the belt.

[0037] Optionally, the steep-angle anti-interruption device further includes an operation control panel, which is bidirectionally connected to the PLC controller.

[0038] The present invention has at least the following beneficial effects:

[0039] In the method provided in this embodiment of the invention, by using an image recognition sensor, encoder, and belt speed meter, when a flow interruption may occur on a steep-angle belt with discontinuous material supply at the bottom of the silo, it can promptly detect and issue an alarm. Simultaneously, it can intelligently identify whether the discontinuity in material supply is due to insufficient supply or belt slippage / loss of rotation, and execute different operations according to different abnormal situations. When it is identified that the discontinuity is due to insufficient material supply at the bottom of the silo, it can output a signal to control the frequency of the active roller inverter to increase the speed of the bottom belt, thereby increasing the material supply to the steep-angle belt and resolving the insufficient supply problem. When it is identified that the discontinuity is due to belt slippage / loss of rotation, it can quickly start the DC electric cylinder and roller motor, using the roller to forcibly tension the bottom belt, resolving the belt slippage / loss of rotation problem at the bottom of the silo and the material interruption problem on the steep-angle belt. Therefore, this invention can eliminate flow interruption faults at their inception, improving the intelligence level of single-machine equipment. Attached Figure Description

[0040] Figure 1 This is a schematic diagram of the constant flow control device;

[0041] Explanation of reference numerals in the attached figures:

[0042] 1. Measuring tube; 2. Control type electronic scale; 3. Hopper; 4. Hopper bottom belt; 5. Material feeding photocell; 6. Steep angle belt; 7. Material buffer zone; 8. High material level photocell; 9. Medium material level photocell; 10. Low material level photocell; 11. Electronic scale belt; 12. Feed belt conveyor.

[0043] Figure 2 A schematic flowchart of a steep-angle band anti-interruption method provided in one embodiment of the present invention;

[0044] Figure 3 This is a schematic diagram of a steep-angle anti-interruption device according to an embodiment of the present invention;

[0045] Figure 4 A schematic diagram of the circuit connection relationship of a steep-angle current interruption device provided in one embodiment of the present invention;

[0046] Figure 5 This is a schematic diagram of the complete circuit connection of a steep-angle anti-interruption device provided in one embodiment of the present invention.

[0047] Explanation of reference numerals in the attached figures:

[0048] 1. Image recognition sensor; 2. First encoder; 3. Drive roller; 4. Belt speed meter; 5. Belt; 6. Drive roller frequency converter; 7. Bottom belt motor; 8. DC electric cylinder; 9. Roller motor; 10. Roller; 11. Servo controller; 12. Pressure sensor; 13. PLC controller; 131. A / I module; 132. A / O module; 133. Image processing module; 14. Hopper; 15. Passive roller; 16. Second encoder; 17. Constant pressure support mechanism; 18. Operation control panel. Detailed Implementation

[0049] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0050] In one embodiment, such as Figure 2 As shown, a method for preventing current interruption in steep-angle zones is provided, which includes the following steps:

[0051] S1 acquires material images on the steep-angle belt collected by the image recognition sensor in real time, and determines whether the material supply to the bottom belt of the silo is continuous based on the material images.

[0052] Specifically, the image recognition sensor is a 3D image recognition sensor.

[0053] Furthermore, determining whether the material supply to the bottom belt of the silo is continuous based on the material image includes:

[0054] The material image is compared with a pre-stored standard steep-angle band material image to determine the uniformity of the material in the steep-angle band.

[0055] If the material on the steep-angle belt is determined to be uneven, then the material supply to the bottom belt of the silo is determined to be discontinuous; if the material on the steep-angle belt is determined to be uniform, then the material supply to the bottom belt of the silo is determined to be continuous.

[0056] In other words, during the production process, a 3D image recognition sensor is used to collect image signals of the material on the steep-angle conveyor belt in real time and transmit them to a pre-established image processing system. Based on a standard image of the material on a normal steep-angle conveyor belt, the uniformity of the material on the belt can be determined, thereby determining whether the material supply to the bottom conveyor belt of the hopper is continuous. By comparing the image with a standard image of the normal material on the steep-angle conveyor belt, an alarm signal is issued when it is determined that the material is decreasing or the material supply to the bottom conveyor belt of the hopper is discontinuous.

[0057] S2, when it is determined that the material supply of the bottom belt of the silo is discontinuous, an alarm prompt is output, the output signal of the first encoder is obtained, the linear speed of the drive roller of the bottom belt of the silo is calculated based on the output signal of the first encoder, the first encoder is connected to the drive roller of the bottom belt of the silo, and the actual running speed of the belt of the bottom belt of the silo is obtained by the belt speed meter, and the linear speed of the drive roller is compared with the actual running speed of the belt.

[0058] S3. If the linear speed of the drive roller is consistent with the actual running speed of the belt, send a corresponding control signal to the drive roller frequency converter of the bottom belt of the silo to increase the frequency of the drive roller frequency converter and thus increase the speed of the bottom belt of the silo.

[0059] S4, if the linear speed of the drive roller is inconsistent with the actual running speed of the belt, a corresponding control signal is sent to the DC electric cylinder to make the screw rod on the upper part of the DC electric cylinder continuously extend; the DC electric cylinder is set at the lower part of the belt, and a roller motor and a roller are set on the screw rod of the DC electric cylinder. The roller motor is connected to the servo controller; when the screw rod extends, it drives the roller motor and the roller to rise.

[0060] S5, acquire the pressure signal of the roller collected by the pressure sensor, and determine whether the pressure signal reaches the preset pressure signal threshold; if the pressure signal reaches the preset pressure signal threshold, send a corresponding control signal to the DC electric cylinder to stop the screw rod of the DC electric cylinder from extending, and at the same time send a corresponding control signal to the servo controller to drive the roller motor to rotate the roller, and make the linear speed of the roller consistent with the linear speed of the drive roller, and the rotation direction of the roller is opposite to the rotation direction of the drive roller.

[0061] The preset pressure signal threshold is 10mA.

[0062] Furthermore, step S5 also includes:

[0063] The output signal of the first encoder is continuously acquired, and the linear speed of the drive roller of the bottom belt of the silo is calculated based on the output signal of the first encoder; and the actual running speed of the belt of the bottom belt of the silo is continuously acquired by the belt speed meter, and the linear speed of the drive roller is compared with the actual running speed of the belt.

[0064] If the linear speed of the drive roller matches the actual running speed of the belt, a corresponding control signal is sent to the servo controller, causing the servo controller to stop driving the roller motor to rotate the roller.

[0065] After a preset time interval, the linear speed of the drive roller is compared with the actual running speed of the belt. If the linear speed of the drive roller is still consistent with the actual running speed of the belt, a corresponding control signal is sent to the DC electric cylinder to retract the screw rod of the DC electric cylinder. When the screw rod retracts, it drives the roller motor and the roller to descend.

[0066] The preset time interval is 10 seconds.

[0067] In other words, when a discontinuous feeding is detected in the bottom belt of the hopper, comparing the linear speed of the drive roller with the actual running speed of the belt can determine the cause of insufficient feeding. There are two possible results:

[0068] One scenario is that the linear speed of the drive roller is consistent with the actual speed of the belt conveyor. This indicates that there is relatively little material stored or piled up in the hopper. In this case, the system output signal controls the frequency of the drive roller inverter to increase, thereby increasing the speed of the bottom belt of the hopper and improving the material supply of the steep-angle belt.

[0069] Another scenario is that the linear speed of the drive roller is inconsistent with the actual speed of the belt conveyor, indicating that the belt at the bottom of the silo is slipping or losing rotation. The system records each fault and alarms, while simultaneously starting the DC electric cylinder and roller motor to resolve the belt slippage problem at the bottom of the silo.

[0070] During production, the speed signal of the drive roller collected by the first encoder on the drive roller is input to the A / I module. The PLC system calculates the linear speed of the drive roller. If this linear speed is greater than the actual speed of the belt detected by the belt speed meter, it indicates that the belt is slipping. If the detection signal of the belt speed meter is "0", and the speed detected by the encoder 1 of the drive roller is "≠0", it means that the bottom belt has "lost rotation". At this time, the PLC system outputs a signal to control the extension of the screw rod of the DC electric cylinder, the roller motor and the roller rise, and the pressure sensor outputs a pressure signal. When the pressure sensor output signal reaches 10mA, the DC electric cylinder stops working, and the bottom belt is forcibly tensioned.

[0071] Simultaneously, under the control of the PLC system, the servo controller outputs a signal to drive the roller motor to start rotating. The rotational speed signal of the roller motor detected by the second encoder is input into the PLC system. After matching with the rotational speed of the active roller detected by the first encoder of the active roller, the servo controller is controlled to output different frequencies, ultimately achieving the same linear speed between the active roller and the roller motor. When these actions are completed within 30 seconds, two effects are achieved:

[0072] (1) The screw rod on the DC electric cylinder pushes the drum of the roller motor to rise, which tightens the belt and increases the friction between the belt and the drive roller;

[0073] (2) Driven by the servo controller, the roller motor rotates and the roller drives the belt to move from the bottom of the belt. That is, the belt is placed between two rollers with opposite rotation directions and equal linear speeds, pulling the inner and outer sides of the belt to be stressed at the same time, ensuring the bottom belt of the silo runs.

[0074] When the linear speed of the drive roller matches the speed detected by the belt speed meter, the roller motor stops first. After 10 seconds, if the linear speed of the drive roller continues to match the speed detected by the belt speed meter, the DC electric cylinder drives the roller motor to descend, at which point the belt auxiliary drive system stops working. During this process, the prerequisite for the DC electric cylinder to start is that the output signal of the encoder 1 of the drive roller is "≠0".

[0075] In the method provided in this embodiment of the invention, by using an image recognition sensor, encoder, and belt speed meter, when a flow interruption may occur on a steep-angle belt with discontinuous material supply at the bottom of the silo, it can promptly detect and issue an alarm. Simultaneously, it can intelligently identify whether the discontinuity in material supply is due to insufficient supply or belt slippage / loss of rotation, and execute different operations according to different abnormal situations. When it is identified that the discontinuity is due to insufficient material supply at the bottom of the silo, it can output a signal to control the frequency of the active roller inverter to increase the speed of the bottom belt, thereby increasing the material supply to the steep-angle belt and resolving the insufficient supply problem. When it is identified that the discontinuity is due to belt slippage / loss of rotation, it can quickly start the DC electric cylinder and roller motor, using the roller to forcibly tension the bottom belt, resolving the belt slippage / loss of rotation problem at the bottom of the silo and the material interruption problem on the steep-angle belt. Therefore, this invention can eliminate flow interruption faults at their inception, improving the intelligence level of single-machine equipment.

[0076] It should be understood that, although Figure 2 The steps in the flowchart are shown sequentially as indicated by the arrows, but these steps are not necessarily executed in the order indicated by the arrows. Unless otherwise specified herein, there is no strict order in which these steps are executed, and they can be performed in other orders. Figure 2At least some of the steps in the process may include multiple steps or multiple stages. These steps or stages are not necessarily completed at the same time, but may be executed at different times. The execution order of these steps or stages is not necessarily sequential, but may be executed in turn or alternately with other steps or at least some of the steps or stages in other steps.

[0077] In one embodiment, such as Figure 3 As shown, a steep-angle anti-interruption device is provided, comprising:

[0078] Image recognition sensor 1 is set on the steep angle zone and is used to collect images of materials on the steep angle zone; specifically, image recognition sensor 1 can be a 3D image recognition sensor.

[0079] The first encoder 2 is connected to the drive roller 3 of the bottom belt of the hopper and is used to detect the rotational speed of the drive roller 3;

[0080] The belt speed meter 4 is in contact with the belt 5 at the bottom of the silo to detect the actual running speed of the belt 5 at the bottom of the silo.

[0081] The active roller frequency converter 6 is connected to the bottom belt motor 7 of the hopper bottom belt and is used to control the speed of the hopper bottom belt; the bottom belt motor 7 is connected to the active roller 3.

[0082] A DC electric cylinder 8 is located at the lower part of the belt 5 on the bottom belt of the hopper; a screw rod is provided on the upper part of the DC electric cylinder 8, and a roller motor 9 and a roller 10 are provided on the screw rod; the DC electric cylinder 8 specifically includes two cylinders.

[0083] Servo controller 11 is connected to roller motor 9;

[0084] Pressure sensor 12 is installed on roller 10 to collect pressure signals from roller 10;

[0085] PLC controller 13, such as Figure 4 As shown, the data output terminals of the image recognition sensor 1, the first encoder 2, the belt speed meter 4, and the pressure sensor 12 are all electrically connected to one data input terminal of the PLC controller 13. The control signal input terminals of the active roller frequency converter 6, the DC electric cylinder 8, and the servo controller 11 are all electrically connected to one control signal output terminal of the PLC controller 13. The PLC controller 13 includes a memory and a processor. The memory stores a computer program, and when the processor executes the computer program, it implements the steps of the steep-angle belt anti-interruption method provided in the above embodiment.

[0086] Alternatively, the PLC controller 13 can be described as including an A / I module 131, an A / O module 132, and an image processing module 133.

[0087] The bottom belt of the hopper is set at the bottom of the hopper 14. In the bottom belt of the hopper, the active roller 3 is wound around one end of the belt 5, and the passive roller 15 is wound around the other end of the belt 5. The rotation of the active roller 3 will drive the belt 5 and the passive roller 15 to rotate.

[0088] Furthermore, such as Figure 5 As shown, the steep-angle anti-interruption device also includes a second encoder 16, which is connected to the drum motor 9 and used to detect the rotational speed of the drum motor 9; the data output terminal of the second encoder 16 is electrically connected to one data input terminal of the PLC controller 13.

[0089] Furthermore, the steep-angle belt anti-interruption device also includes a constant pressure support mechanism 17, which is located at the lower part of the belt 5 on the bottom belt of the hopper, and the belt speed meter 4 is mounted on the constant pressure support mechanism 17. The constant pressure support mechanism 17 supports the belt speed meter 4 by applying a constant pressure to ensure its stability.

[0090] Furthermore, such as Figure 5 As shown, the steep-angle anti-interruption device also includes an operation control panel 18, which is bidirectionally connected to the PLC controller 13.

[0091] Furthermore, the distance between the roller 10 and the drive roller 3 is 7 times the thickness of the belt 5.

[0092] in other words:

[0093] Pressure sensor 12: used to control the extension length of the screw rod of DC electric cylinder 8. When the pressure signal detected by pressure sensor 12 reaches 10mA, it indicates that the roller 10 of roller motor 9 has risen to the position, the belt 5 is lifted by roller 10, and the belt 5 is forcibly tensioned to meet the design requirements. At the same time, the distance between roller 10 of roller motor 9 and drive roller 3 is 21mm, which is 7 times the thickness of the belt.

[0094] First encoder 2: Used to detect the rotational speed of drive roller 3. After the signal is input to PLC, the linear speed of drive roller 3 is calculated, which is the theoretical speed of belt 5.

[0095] The second encoder 16 is used to detect the rotational speed of the roller motor 9. After the signal is input to the PLC, the servo controller 11 controls the rotational speed of the roller motor 9 so that the linear speed of the roller motor 9 is equal to the linear speed of the drive roller 3.

[0096] DC electric cylinder 8: The signals collected by various detection devices and image processing systems are input into the PLC control system. According to the preset analysis program, when it is determined that the actual speed of the belt 5 at the bottom of the discharge bin is less than the linear speed of the drive roller 3, the screw rod of the DC electric cylinder extends, driving the roller 10 of the roller motor 9 to forcibly tension the belt 5.

[0097] Constant pressure support mechanism 17: ensures that the detection roller of the belt speed meter 4 is tightly attached to the surface of the belt conveyor during the movement and up-and-down movement of the belt 5, so as to avoid mis-detection and loss of rotation.

[0098] Operation control panel 18: The length of the extended screw of the DC electric cylinder 8 can be set through the operation control panel 18; during the operation of the equipment, fault information such as slippage and loss of rotation of the bottom belt, and the number of times the DC electric cylinder 8 is started can be queried through the fault information catalog of the operation control panel 18, and maintenance personnel can adjust and maintain the equipment through the fault information.

[0099] In this embodiment, based on the causes of flow interruption during the material feeding process of the silo bottom belt in the constant flow system, a silo bottom belt speed synchronization detection and belt auxiliary drive device is designed. This device can solve the problems of untimely material tracking and flow interruption caused by slippage of the silo bottom belt. The device mainly consists of: a 3D image recognition sensor, an encoder, a belt speed meter, a DC electric cylinder, a pressure sensor, a roller motor, a servo controller, and a PLC control system. The system composed of the DC electric cylinder, pressure sensor, roller motor, and belt speed meter constitutes the auxiliary drive system for the bottom belt.

[0100] Through image recognition sensors, encoders, speedometers, and PLC control programs, abnormal conditions such as material feeding and belt slippage of the feeder can be intelligently identified and alarmed. When slippage or loss of rotation occurs on the bottom belt, the intelligent identification control system can quickly resolve the slippage problem and address insufficient or interrupted material feeding on steep-angle belts, improving the intelligence level of individual equipment. Intelligent control analysis and fault information statistics from the alarm system provide accurate data support for preventative maintenance, eliminating faults in their early stages.

[0101] In one embodiment, a computer device is provided, including a memory and a processor, wherein the memory stores a computer program relating to all or part of the processes in the steep-angle band anti-interruption method provided in the above embodiments.

[0102] In one embodiment, a computer-readable storage medium is provided having a computer program stored thereon relating to all or part of the process of a steep-angle band anti-interruption method provided in the above embodiments.

[0103] Those skilled in the art will understand that all or part of the processes in the methods of the above embodiments can be implemented by a computer program instructing related hardware. The computer program can be stored in a non-volatile computer-readable storage medium, and when executed, it can include the processes of the embodiments of the above methods. Any references to memory, storage, databases, or other media used in the embodiments provided in this application can include at least one of non-volatile and volatile memory. Non-volatile memory can include read-only memory (ROM), magnetic tape, floppy disk, flash memory, or optical storage, etc. Volatile memory can include random access memory (RAM) or external cache memory. By way of illustration and not limitation, RAM can be in various forms, such as static random access memory (SRAM) or dynamic random access memory (DRAM), etc.

[0104] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0105] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A method for preventing current interruption in steep-angle zones, characterized in that, include: S1, acquire material images on the steep-angle belt collected by the image recognition sensor in real time, and determine whether the material supply to the bottom belt of the silo is continuous based on the material images; S2, when it is determined that the material supply of the bottom belt of the hopper is discontinuous, an alarm prompt is output, the output signal of the first encoder is obtained, and the linear speed of the drive roller of the bottom belt of the hopper is calculated based on the output signal of the first encoder. The first encoder is connected to the drive roller of the bottom belt of the hopper. The actual running speed of the belt at the bottom of the silo, detected by the belt speed meter, is obtained, and the linear speed of the drive roller is compared with the actual running speed of the belt. S3, if the linear speed of the drive roller is consistent with the actual running speed of the belt, send a corresponding control signal to the drive roller frequency converter of the bottom belt of the silo to increase the frequency of the drive roller frequency converter in order to increase the speed of the bottom belt of the silo. S4, if the linear speed of the drive roller is inconsistent with the actual running speed of the belt, a corresponding control signal is sent to the DC electric cylinder to continuously extend the screw rod at the top of the DC electric cylinder; the DC electric cylinder is located at the bottom of the belt, and a roller motor and a roller are mounted on the screw rod of the DC electric cylinder, the roller motor being connected to a servo controller; when the screw rod extends, it drives the roller motor and the roller to rise. S5, acquire the pressure signal of the roller collected by the pressure sensor, and determine whether the pressure signal reaches the preset pressure signal threshold; if it is determined that the pressure signal reaches the preset pressure signal threshold, send a corresponding control signal to the DC electric cylinder to stop the screw rod of the DC electric cylinder from extending, and at the same time send a corresponding control signal to the servo controller to drive the roller motor to rotate the roller, and make the linear velocity of the roller consistent with the linear velocity of the drive roller, and the rotation direction of the roller is opposite to the rotation direction of the drive roller.

2. The steep-angle band anti-interruption method according to claim 1, characterized in that, Determining whether the material supply to the hopper bottom belt is continuous based on the material image includes: The material image is compared with a pre-stored standard steep-angle band material image to determine the uniformity of the material in the steep-angle band. If the material on the steep-angle belt is determined to be uneven, then the material supply to the bottom belt of the silo is determined to be discontinuous; if the material on the steep-angle belt is determined to be uniform, then the material supply to the bottom belt of the silo is determined to be continuous.

3. The steep-angle band anti-interruption method according to claim 1, characterized in that, The preset pressure signal threshold is 10mA.

4. The steep-angle band anti-interruption method according to claim 1, characterized in that, Step S5 also includes: The output signal of the first encoder is continuously acquired, and the linear velocity of the drive roller of the bottom belt of the silo is calculated based on the output signal of the first encoder; and the actual running speed of the belt of the bottom belt of the silo is continuously acquired by the belt speed meter, and the linear velocity of the drive roller is compared with the actual running speed of the belt. If the linear speed of the drive roller is consistent with the actual running speed of the belt, a corresponding control signal is sent to the servo controller to stop the servo controller from driving the roller motor to rotate the roller. After a preset time interval, the linear speed of the drive roller is compared with the actual running speed of the belt; if the linear speed of the drive roller is still consistent with the actual running speed of the belt, a corresponding control signal is sent to the DC electric cylinder to retract the screw rod of the DC electric cylinder; when the screw rod retracts, it drives the roller motor and the roller to descend.

5. The steep-angle band anti-interruption method according to claim 4, characterized in that, The preset time interval is 10 seconds.

6. A steep-angle anti-interruption device, characterized in that, include: An image recognition sensor, installed on the steep-angle zone, is used to acquire images of the material on the steep-angle zone; The first encoder is connected to the drive roller of the bottom belt of the hopper and is used to detect the rotational speed of the drive roller; The belt speed meter comes into contact with the belt at the bottom of the silo and is used to detect the actual running speed of the belt at the bottom of the silo. The active roller frequency converter is connected to the bottom belt motor of the hopper bottom belt and is used to control the speed of the hopper bottom belt; the bottom belt motor is connected to the active roller. A DC electric cylinder is installed at the lower part of the belt at the bottom of the hopper; a screw rod is installed at the upper part of the DC electric cylinder, and a roller motor and a roller are installed on the screw rod; A servo controller is connected to the roller motor; A pressure sensor is installed on the roller to collect the pressure signal of the roller; The PLC controller includes an image recognition sensor, a first encoder, a belt speed meter, and a pressure sensor, whose data output terminals are all electrically connected to one data input terminal of the PLC controller. The control signal input terminals of the active roller frequency converter, the DC electric cylinder, and the servo controller are all electrically connected to one control signal output terminal of the PLC controller. The PLC controller includes a memory and a processor. The memory stores a computer program, and the processor executes the computer program to implement the steps of the method described in claim 1.

7. The steep-angle anti-interruption device according to claim 6, characterized in that, The steep-angle anti-interruption device also includes a second encoder, which is connected to the drum motor and used to detect the rotational speed of the drum motor; the data output terminal of the second encoder is electrically connected to one data input terminal of the PLC controller.

8. The steep-angle anti-interruption device according to claim 6, characterized in that, The steep-angle belt anti-interruption device also includes a constant pressure support mechanism, which is located at the lower part of the belt of the hopper bottom belt, and the belt speed measuring instrument is installed on the constant pressure support mechanism.

9. The steep-angle anti-interruption device according to claim 6, characterized in that, The distance between the roller and the drive roller is 7 times the thickness of the belt.

10. The steep-angle anti-interruption device according to claim 6, characterized in that, The steep-angle anti-interruption device also includes an operation control panel, which is bidirectionally connected to the PLC controller.

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