Method for monitoring belt misalignment for a belt punching line

Abstract

The application provides a belt deviation monitoring method for a belt punching production line, a monitoring point is arranged at the far end of the belt punching mechanism in the feeding direction of the punching mechanism through a reference point at the rear of the belt punching mechanism, the monitoring point can detect the deviation of the far end belt, the controller obtains the deviation of the monitoring point, the belt deviation of the punching position can be calculated and predicted, when the predicted deviation exceeds a preset value, early warning or a parking instruction can be given, the monitoring method has high monitoring precision, effectively reduces the deviation of the belt punching position, and improves the punching precision and work efficiency.

Description

Technical Field

[0001] This invention relates to the field of belt misalignment monitoring technology, and specifically to a belt misalignment monitoring method for belt punching production lines. Background Technology

[0002] The belts on belt-driven bucket elevators are made of specially reinforced tear-resistant polyester canvas or steel wire tear-resistant layer material. As a crucial component of the equipment, the belts play a vital role. To secure the buckets to the belts, they must be pre-punched. Existing punching production lines use winding machines at both ends of the punching platform. The belt is released through one winding machine and enters the punching platform for punching. After punching, the belt is retrieved through the other winding machine. During the punching process, due to the belt's large mass and long length, slight belt misalignment can occur during continuous punching and conveying, leading to reduced punching accuracy and deviations. Workers need to correct these deviations promptly.

[0003] In existing technologies, measuring belt position changes using electronic devices has been widely applied. For example, patent announcement number CN214421602U discloses a coal conveyor belt misalignment early warning system for thermal power plants. This system uses laser emitters and receivers installed on both sides of the coal conveyor belt to measure the amount of laser beam obstruction at the belt's edges during operation. When the obstruction exceeds or falls below a preset standard value, a computer-controlled alarm is activated, sending an alarm signal to the outside world for easy maintenance. However, due to the high precision requirements of the belt punching process on the production line, the punching... Positional errors must be controlled within ±1mm. However, the above-mentioned detection methods have limited accuracy and are not suitable for belt punching production lines. To prevent belt misalignment during punching, the common practice is to manually measure after each punching cycle to determine the next punching position and confirm whether the belt is misaligned. If misalignment is found, the belt offset is corrected by adjusting the relative position of the drum. Therefore, the process of manually measuring and confirming misalignment is very cumbersome, requires high labor intensity and concentration from workers, and requires repeated verification to ensure accuracy. It may even require two people to work together to improve accuracy, which is time-consuming, labor-intensive, and results in low production efficiency. Summary of the Invention

[0004] Therefore, it is necessary to provide a belt misalignment monitoring method for belt punching production lines that has high monitoring accuracy and can provide early warning of belt misalignment.

[0005] A method for monitoring belt misalignment in a belt punching production line includes the following steps:

[0006] Step 1: Set up three monitoring base points A, B, and C on the belt conveyor frame of the belt punching production line. Point A is set as the reference point, behind the belt punching mechanism and located at the edge of one side of the belt. Point B is set at the center line of the belt punching mechanism, that is, the intersection of the punching position and the edge of the belt. Point C is set in front of the belt punching mechanism in the belt feeding direction and is located at the edge of the belt on the same side as point A. The center line distance between points A and B is a preset distance, and the straight line distance between points A and C is N times the preset distance between points A and B.

[0007] Step 2: Set up a belt offset monitoring device at point C to measure the belt offset D at point C;

[0008] Step 3: Set up the controller, which is electrically connected to the belt offset monitoring device. Receive the measurement signal from the belt offset monitoring device and obtain the belt offset D at point C based on the measurement signal. Calculate the belt offset E at the punching position at point B based on the belt offset D at point C. The formula for predicting and calculating the belt offset E is: Offset E = Offset D / N.

[0009] Step 4: Set the preset value of belt offset E. The controller monitors the predicted belt offset E and compares it with the preset value in real time. When the predicted belt offset E is greater than or less than the preset value, the controller will issue a warning or a stop command.

[0010] Preferably, the belt offset monitoring device is a light curtain sensor, installed on the belt conveyor frame. The light curtain sensor consists of a laser emitter and a laser receiver, which are electrically connected to the controller. The laser emitter is horizontally positioned above the belt, and the laser receiver is horizontally positioned below the belt. The laser emitter and laser receiver are perpendicular to each other. The laser receiver is used to receive infrared rays emitted by the corresponding side laser emitter to generate a protective light curtain that covers the edge of the belt and measures the belt offset D.

[0011] Preferably, the belt offset monitoring device is a laser rangefinder, which is installed on the belt conveyor frame, located on one side of the belt, perpendicular to the side edge of the belt. The laser rangefinder is electrically connected to the controller to measure the belt offset D.

[0012] Preferably, the controller is a PLC or an industrial computer.

[0013] The present invention adopts the above-mentioned technical solution, and its beneficial effects are as follows: by setting a monitoring point at the rear reference point of the belt punching mechanism and at the far end of the punching mechanism in the belt feeding direction, the monitoring point can detect the offset of the belt at the far end. By obtaining the offset of the monitoring point through the controller, the belt offset at the punching position can be predicted and calculated. When the predicted offset exceeds the preset value, an early warning can be given or a stop command can be issued. This monitoring method has high monitoring accuracy, effectively reduces the deviation of the belt punching position, and improves punching accuracy and work efficiency. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the monitoring base point layout of the belt punching production line of the invention.

[0015] Figure 2 This is a schematic diagram of the belt misalignment monitoring principle of the invention.

[0016] Figure 3 This is a schematic diagram of the installation of the belt offset monitoring device of the invention.

[0017] In the diagram: 1. Belt conveyor frame; 2. Belt; 3. Belt punching mechanism; 4. Belt offset monitoring device; 41. Laser emitter; 42. Laser receiver; 5. Controller. Detailed Implementation

[0018] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] This invention provides a method for monitoring belt misalignment in a belt punching production line, comprising the following steps:

[0020] Step 1: Set three monitoring base points A, B, and C on the belt conveyor frame 1 of the belt punching production line. Point A serves as the reference point, located behind the belt punching mechanism 3 and at the edge of one side of the belt 2. Point B is located at the center line of the belt punching mechanism 3, i.e., at the intersection of the punching position and the edge of one side of the belt 2. Point C is located in front of the belt punching mechanism 3 in the belt feeding direction and at the edge of the belt 2 on the same side as point A. The center line distance between points A and B is a preset distance, and the straight line distance between points A and C is N times the preset distance between points A and B. In this step, points B and A can be located at the edge of the belt 2 on the same side or at the edge of the belt 2 on opposite sides.

[0021] Step 2: Set up belt offset monitoring device 4 at point C to measure the offset D of belt 2 located at point C;

[0022] Step 3: Set up controller 5, which is electrically connected to belt offset monitoring device 4. Receive the measurement signal from belt offset monitoring device 4, obtain the belt offset D at point C based on the measurement signal, and predict and calculate the belt offset E at the punching position at point B based on the belt offset D at point C. The prediction and calculation formula for belt offset E is: offset E = offset D / N.

[0023] Step 4: Set the preset value of belt offset E. The controller 5 monitors the predicted belt offset E and compares it with the preset value in real time. When the predicted belt offset E is greater than or less than the preset value, the controller 5 issues a warning or a stop command.

[0024] The specific monitoring principle of this monitoring method is as follows: the monitored belt 2 is in normal operating condition, such as... Figure 1 As shown, a monitoring base point A is set behind the belt punching mechanism 3, i.e., at the edge of the belt 2 in the output direction of the belt 2. A monitoring base point B is set at the intersection of the center line of the belt punching device, i.e., the punching position, and the edge of the belt 2. Monitoring base points B and A are located on the same side of the belt 2. A monitoring base point C is set in front of the belt punching mechanism 3 in the belt feeding direction, i.e., at the far end away from the belt punching mechanism 3. Point C is located on the edge of the belt 2 on the same side as point A. A belt offset monitoring device 4 is set at point C to measure the offset D of the belt 2 at point C. The distance between monitoring base point A and monitoring base point B is preset. The distance between monitoring base point C and monitoring base point A is N times the preset distance between monitoring base points A and B. Point A, as the reference point, can be set according to the detection accuracy requirements. For example, the preset distance from point A to point B is 30cm, and the distance from point C to point A is set to 300cm, that is, the distance from point C to point A is 10 times the preset distance from point A to point B. By monitoring the offset D of the belt at point C, the belt offset E at the punching position of point B is predicted and calculated. The prediction calculation formula for belt offset E is: offset E = offset D / N; that is, the value of offset E is obtained by dividing the belt offset D measured at point C by 10.

[0025] When the monitored belt 2 deviates from its designated path, such as Figure 2 As shown, with point A as the reference point, A, B, and C are the edges of the belt 2 under normal conditions, while A, E, and D are the edges of the belt 2 under monitoring when it deviates. The distance from D to C is the offset of the far end of the belt 2 being measured. With point A as the reference point, the distance from B to E is the belt offset E at the punching position that we are concerned with. The edges of the two states and the center lines of the belt punching mechanism 3 and the belt offset monitoring device 4 form two triangles △ABC and △ACD, which are similar triangles.

[0026] After the belt 2 is punched, it needs to be wound and collected by the belt 2 winding device located at the tail end of the belt conveyor frame 1. Belt guide plates are set on both sides of the belt conveyor frame 1 at the rear end of the belt punching mechanism 3 to guide the belt 2, so that the belt 2 winding device can wind and collect it. The belt guide plates have a guiding and positioning function to reduce the deviation of the belt 2. However, in the actual conveying process, a clearance needs to be reserved between the belt guide plate and the belt 2 so that the belt 2 can be smoothly conveyed by the belt conveyor frame 1. Since the deviation is larger at the far end of the belt 2 in the belt feeding direction from the punching position, the belt deviation monitoring device 4 can easily measure this deviation. However, at the near end of the belt 2 from the punching position, the deviation of the belt 2 will gradually decrease due to the influence of the belt guide plate. While the offset gradually decreases, a certain degree of deviation error still exists, which is very small, only ±1mm. It's difficult to guarantee the accuracy and precision of the measurement using only the belt offset monitoring device 4. Therefore, based on the principle of similar triangles, the ratio of side AB to side AC is equal to the ratio of side BE to side CD. This ratio is pre-set according to our accuracy requirements and is a known quantity. For example, the preset distance d between the center lines of points A and B is 30cm, and the straight-line distance between points A and C is N times the preset distance between points A and B. By measuring the offset from the far end C to D using the belt offset monitoring device 4, we can calculate the offset from side B to E, thus predicting the offset from side B to E at the near end punching position. The formula for calculating the belt offset E is: Offset E = Offset D / N.

[0027] The entire data processing and calculation process is completed by controller 5 without human intervention. The controller 5 is a PLC or industrial computer. Controller 5 is electrically connected to belt offset monitoring device 4, and can also be electrically connected to the power control terminal of belt conveyor frame 1 and belt punching mechanism 3. By preset the initial value of belt offset E in controller 5, controller 5 receives the detection signal of offset D from belt offset monitoring device 4, obtains offset D through the detection signal of offset D, predicts and calculates offset E through offset D, and compares the predicted offset E with the preset initial value of offset E. If the predicted offset E exceeds its initial value, controller 5 issues an audible or visual warning or issues a stop command to the power control terminal of belt conveyor frame 1 and belt punching mechanism 3.

[0028] In a further embodiment, an initial preset value for the offset D can be set in the controller 5. After receiving the detection signal of the offset D from the belt offset monitoring device 4, the controller 5 directly compares it with the initial preset value of the offset D. When the offset D exceeds its initial preset value, the controller 5 issues an audible or visual warning or issues a stop command to the power control end of the belt conveyor 1 and the belt punching mechanism 3.

[0029] like Figure 3 As shown, in the above embodiment, the belt offset monitoring device 4 is a light curtain sensor. The light curtain sensor is installed on the belt conveyor frame 1. The light curtain sensor consists of a laser emitter 41 and a laser receiver 42. The laser emitter 41 and the laser receiver 42 are electrically connected to the controller 5. The laser emitter 41 is horizontally arranged above the belt 2, and the laser receiver 42 is horizontally arranged below the belt 2. The laser emitter 41 and the laser receiver 42 are arranged perpendicular to each other. The laser receiver 42 is used to receive the infrared light emitted by the corresponding side laser emitter 41 to generate a protective light curtain. The protective light curtain covers the edge of the belt 2. When the light curtain is blocked by the edge of the belt 2, the device sends a light-blocking signal to measure the offset D of the belt 2.

[0030] In the above embodiments, the belt offset monitoring device 4 can also be a laser rangefinder, installed on the belt conveyor frame 1, located on one side of the belt 2, perpendicular to the side edge of the belt 2. The laser rangefinder is electrically connected to the controller 5 to measure the offset D of the belt 2. Laser rangefinders are widely used and technologically mature; their working principle will not be elaborated here.

[0031] The above-disclosed embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of the invention. Those skilled in the art will understand that implementing all or part of the above-described embodiments and making equivalent changes in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A method for monitoring belt misalignment in a belt punching production line, characterized in that: Includes the following steps: Step 1: Set up three monitoring base points A, B, and C on the belt conveyor frame of the belt punching production line. Point A is set as the reference point, behind the belt punching mechanism and located at the edge of one side of the belt. Point B is set at the center line of the belt punching mechanism, that is, the intersection of the punching position and the edge of the belt. Point C is set in front of the belt punching mechanism in the belt feeding direction and is located at the edge of the belt on the same side as point A. The center line distance between points A and B is a preset distance, and the straight line distance between points A and C is N times the preset distance between points A and B. Step 2: Set up a belt offset monitoring device at point C to measure the belt offset D at point C; Step 3: Set up the controller, which is electrically connected to the belt offset monitoring device. Receive the measurement signal from the belt offset monitoring device and obtain the belt offset D at point C based on the measurement signal. Based on the belt offset D at point C, predict and calculate the belt offset E at the punching position at point B. The prediction calculation formula for belt offset E is: Offset E = Offset D / N. Step 4: Set the preset value of belt offset E. The controller monitors the predicted belt offset E and compares it with the preset value in real time. When the predicted belt offset E is greater than or less than the preset value, the controller will issue a warning or a stop command. The controller is a PLC or an industrial computer.

2. The belt misalignment monitoring method for a belt punching production line as described in claim 1, characterized in that: The belt offset monitoring device is a light curtain sensor, installed on the belt conveyor frame. The light curtain sensor consists of a laser emitter and a laser receiver, which are electrically connected to the controller. The laser emitter is horizontally positioned above the belt, and the laser receiver is horizontally positioned below the belt. The laser emitter and laser receiver are perpendicular to each other. The laser receiver is used to receive infrared rays emitted by the corresponding side laser emitter to generate a protective light curtain that covers the edge of the belt and measures the belt offset D.

3. The belt misalignment monitoring method for a belt punching production line as described in claim 1, characterized in that: The belt offset monitoring device is a laser rangefinder, which is installed on the belt conveyor frame, located on one side of the belt, perpendicular to the side edge of the belt. The laser rangefinder is electrically connected to the controller to measure the belt offset D.

Images