A method and apparatus for active protection of a conveyor, and an electronic device

Abstract

The application provides a conveyor active protection method and device and electronic equipment, and relates to the field of conveyor active protection. In the application, after responding to shutdown demand information, a curve shutdown control strategy is used for shutdown operation, and after the shutdown operation is completed, the equipment shutdown response time of a specified device during the execution of the shutdown operation is obtained. If it is determined that the equipment shutdown response time meets a set time condition, active protection information is output, and thus corresponding active protection operation can be realized before the conveyor fails, the failure is avoided, and the operation reliability of the conveyor is improved. In addition, in the application, if the shutdown parameters at the last shutdown meet preset shutdown conditions, a curve shutdown control strategy is determined and used for the current shutdown operation, so that the conveyor can be slowly shut down during the current shutdown operation, and the stability of the shutdown control is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of conveyor active protection, and more particularly, to a conveyor active protection method, device and electronic equipment. BACKGROUND

[0002] The belt conveyor is a kind of mechanical equipment that transports materials in a continuous manner by friction drive. It mainly consists of a rack, a conveyor belt, a roller, a drum, a tensioning device, and a transmission device. It can form a material conveying process from the initial feeding point to the final discharging point on a certain conveying line.

[0003] In actual use, if there is a fault in the belt conveyor, it needs to be stopped to ensure the safety of the equipment operation. At present, when monitoring the fault of the belt conveyor, only the corresponding protection operation can be performed after the fault occurs, that is, passive protection, but active protection function cannot be realized. SUMMARY

[0004] Therefore, the present application provides a conveyor active protection method, device and electronic equipment to solve the problem of the urgent need to realize the active protection function of the belt conveyor.

[0005] To solve the above technical problems, the present application adopts the following technical solutions:

[0006] A conveyor active protection method comprises:

[0007] In response to the shutdown demand information, the shutdown parameters at the last shutdown are obtained, and the shutdown parameters include the required shutdown time and the cumulative number of shutdowns;

[0008] If the shutdown parameters meet the preset shutdown condition, the curve shutdown control strategy is determined;

[0009] The shutdown operation is performed according to the curve shutdown control strategy;

[0010] After determining that the shutdown operation is successfully executed, the device shutdown response time of the specified device during the execution of the shutdown operation is obtained;

[0011] If it is determined that the device shutdown response time meets the set time condition, the active protection information is output; wherein, before receiving the reset instruction corresponding to the active protection information, the conveyor is prohibited from starting again.

[0012] Optionally, the shutdown parameters meet the preset shutdown condition, comprising:

[0013] The required shutdown time is greater than the preset time or the cumulative number of shutdowns is greater than the target number.

[0014] Optionally, the accumulated number of shutdowns includes an accumulated number of active shutdowns, a first fault type shutdown number, and a second fault type shutdown number.

[0015] The determination process of the target number includes:

[0016] Calculating the proportion of the accumulated number of active shutdowns, the accumulated number of first fault type shutdowns, and the accumulated number of second fault type shutdowns;

[0017] Obtaining an initial number;

[0018] Adjusting the initial number using the proportion to obtain a target number.

[0019] Optionally, the specified device includes a motor and a brake;

[0020] Obtaining a device shutdown response time of the specified device during the execution of the shutdown operation includes:

[0021] Obtaining a first time of issuing a motor stop instruction and a second time of receiving a motor stop feedback signal;

[0022] Calculating the time difference between the first time and the second time, and taking the calculated time difference as the device shutdown response time of the motor;

[0023] Obtaining a third time of issuing a brake stop instruction and a fourth time of receiving a brake stop feedback signal;

[0024] Calculating the time difference between the third time and the fourth time, and taking the calculated time difference as the device shutdown response time of the brake.

[0025] Optionally, if it is determined that the device shutdown response time meets a set time condition, active protection information is output, including:

[0026] If the device shutdown response time is greater than a preset time threshold, it is determined that the device shutdown response time meets the set time condition, and response time protection information is output;

[0027] Or, the time change trend of the device shutdown response time compared to the historical device shutdown response time is determined, and if the time change trend is a preset trend, it is determined that the device shutdown response time meets the set time condition, and response time protection information is output.

[0028] Optionally, after it is determined that the shutdown operation is successfully executed, it further includes:

[0029] In the case where the first fault type shutdown cumulative number or the second fault type shutdown cumulative number corresponding to the current shutdown operation is greater than a preset number, shutdown cumulative number protection information is output.

[0030] Optionally, after outputting the active protection information, further comprising:

[0031] If a reset instruction is received, all stored shutdown parameters and all device shutdown response times are cleared.

[0032] Optionally, before responding to the shutdown demand information, further comprising:

[0033] Monitoring the conveyor operating current;

[0034] In the case that the conveyor operating current is greater than a preset current threshold, determining an operating adjustment strategy based on the conveyor operating current; the operating adjustment strategy comprises at least one of closing a feeding hole, reducing motor frequency and reducing material flow rate;

[0035] Adjusting the conveyor operating current according to the operating adjustment strategy.

[0036] An active protection device of a conveyor, comprising:

[0037] A parameter acquisition module, configured to acquire shutdown parameters at last shutdown in response to shutdown demand information, the shutdown parameters comprising shutdown required duration and shutdown cumulative number;

[0038] A strategy determination module, configured to determine a curve shutdown control strategy if the shutdown parameters meet preset shutdown conditions;

[0039] A shutdown control module, configured to perform shutdown operation according to the curve shutdown control strategy;

[0040] A time acquisition module, configured to acquire device shutdown response time of a specified device in the process of performing shutdown operation after determining that the shutdown operation is successfully performed;

[0041] An information output module, configured to output active protection information if it is determined that the device shutdown response time meets set time conditions; wherein, before receiving a reset instruction corresponding to the active protection information, the conveyor is prohibited from being started again.

[0042] An electronic device comprising at least one processor and a memory connected with the processor, wherein:

[0043] The memory is configured to store a computer program;

[0044] The processor is configured to execute the computer program, so that the electronic device can implement the active protection method of the conveyor.

[0045] Compared with the prior art, the present application has the following beneficial effects:

[0046] The application provides a conveyor active protection method and device and electronic equipment, in the application, after responding to the shutdown demand information, the shutdown operation is performed according to the curve shutdown control strategy, after the shutdown operation is completed, the equipment shutdown response time of the specified equipment in the process of performing the shutdown operation is acquired, if it is determined that the equipment shutdown response time meets the set time condition, the active protection information is output, and then the corresponding active protection operation can be realized before the conveyor fails, the failure is avoided, and the conveyor operation reliability is improved. In addition, in the application, the shutdown parameters at the last shutdown meet the preset shutdown condition, the curve shutdown control strategy is determined and used to perform the shutdown operation this time, so that the conveyor can be slowly shutdown during the shutdown operation this time, and the stability of the shutdown control is improved. In addition, before the reset instruction corresponding to the active protection information is received, the conveyor is prohibited from being started again, so that the safety of the next operation of the conveyor is ensured. BRIEF DESCRIPTION OF DRAWINGS

[0047] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or the prior art description. Obviously, the drawings in the following description only constitute the embodiments of the present application, and for those skilled in the art, other drawings can also be obtained without creative labor on the basis of the provided drawings.

[0048] Figure 1 A flowchart of a conveyor active protection method provided by the embodiment of the present application is provided.

[0049] Figure 2 A flowchart of a method for determining a target number provided by the embodiment of the present application is provided.

[0050] Figure 3 A flowchart of a method for determining an equipment shutdown response time provided by the embodiment of the present application is provided.

[0051] Figure 4 A flowchart of a current regulation method provided by the embodiment of the present application is provided.

[0052] Figure 5 A schematic diagram of an internal structure of a total controller provided by the embodiment of the present application is provided.

[0053] Figure 6 A structural schematic diagram of a conveyor active protection device provided by the embodiment of the present application is provided.

[0054] Figure 7 A structural schematic diagram of an electronic equipment provided by the embodiment of the present application is provided. DETAILED DESCRIPTION

[0055] With reference to the accompanying drawings, the technical solutions in the embodiments of the present application will be clearly and completely described below, obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative efforts belong to the protection scope of the present application.

[0056] The biggest fault of the belt conveyor is that it cannot stop when it needs to stop, thereby causing accidents. Therefore, in order to improve the safety of the belt conveyor, if there is a fault in the actual use process of the belt conveyor, the belt conveyor needs to be stopped for corresponding repair processing to ensure the safety of the equipment operation. At present, when monitoring the fault of the belt conveyor, only the corresponding protection operation corresponding to the fault can be performed after the fault occurs, that is, passive protection, but active protection function cannot be realized.

[0057] Therefore, the present application provides an active protection method and device of a conveyor and electronic equipment. After responding to stop demand information, the stop operation is performed according to a curve stop control strategy. After the stop operation is completed, the equipment stop response time of the specified equipment in the stop operation process is obtained. If it is determined that the equipment stop response time meets the set time condition, the active protection information is output, so that the corresponding active protection operation can be realized before the conveyor fails, the failure is avoided, and the operation reliability of the conveyor is improved. In addition, in the present application, the stop parameters at the last stop meet the preset stop condition, the curve stop control strategy is determined and used for the stop operation this time, so that the conveyor can be slowly stopped during the stop operation this time, and the stability of the stop control is improved. In addition, before the reset instruction corresponding to the active protection information is received, the conveyor is prohibited from being started again, so as to ensure the safety of the next operation of the conveyor.

[0058] On the basis of the above, an embodiment of the present application provides an active protection method of a conveyor. The execution subject of the active protection method of the conveyor can be a general controller of the conveyor.

[0059] With reference to Figure 1 , the active protection method of the conveyor can include:

[0060] S11, in response to stop demand information, obtaining stop parameters at the last stop.

[0061] In actual application, when the conveyor receives the stop demand information, the stop demand information is responded to, and the stop operation is started.

[0062] The source of the shutdown demand information in the embodiment can be in various modes, such as a user-initiated stop instruction, such as a user selecting a shutdown button on a touch screen or a control button of a host computer device, and the motor stops, and the general controller receives the stop instruction. This shutdown mode belongs to active control stop, and can be used to control the conveyor to stop when the conveyor does not need to work.

[0063] In addition, the general controller can also receive other light fault or heavy fault signals, and the information is the shutdown demand information. The light fault can be, for example, a motor temperature that is too high, a motor current that exceeds the standard, a fan damage, and the like, which have a lower impact. The heavy fault can be, for example, a protection device damage, a belt tearing, and the like, which have a higher impact on the safety of the conveyor operation.

[0064] When the shutdown demand information is received, a shutdown operation needs to be performed, and the general controller sends a stop instruction. When the shutdown is performed, it needs to be considered whether a direct shutdown strategy or a curve shutdown control strategy is used for this time of collection.

[0065] The direct shutdown strategy refers to directly controlling the motor frequency to be zero or directly emptying the gear, so that the conveyor is quickly stopped.

[0066] The curve shutdown control strategy refers to gradually reducing the motor frequency of the conveyor, so that the conveyor is gradually and slowly stopped. In this way, the conveyor needs a longer time to stop, but is not prone to the situation of overspeeding and is safer.

[0067] When the specific strategy is used, it is necessary to analyze whether the shutdown parameters of the last shutdown meet the corresponding conditions. The shutdown parameters include a shutdown time and a shutdown cumulative number. The shutdown time is the shutdown time of the last shutdown. During the shutdown of the conveyor, the general controller first controls the motor to stop running, and then controls the brake to stop running, until the conveyor belt is stationary. The time from the time when the motor stop instruction is sent to the time when the conveyor belt is completely stationary is the shutdown time.

[0068] The accumulated number of shutdowns at the last shutdown refers to the accumulated number of shutdowns until the last shutdown. In practical applications, the accumulated number of shutdowns can be counted by a shutdown counting module. The shutdown counting module includes records of the number of shutdowns caused by the operation of the upper computer (which can be actively controlled by the user through the upper computer), the number of shutdowns caused by light faults, and the number of shutdowns caused by heavy faults. When the belt conveyor is in a running state, the number of shutdowns caused by the operation of the upper computer is incremented once upon receiving a stop instruction from the operation of the upper computer, the number of shutdowns caused by light faults is incremented once upon receiving a light fault summary signal, and the number of shutdowns caused by heavy faults is incremented once upon receiving a heavy fault summary signal. The time of occurrence is recorded. Therefore, after the last shutdown ends, the number counted by the shutdown counting module can be directly obtained, that is, the accumulated number of shutdowns at the last shutdown.

[0069] The number of shutdowns caused by the operation of the upper computer described above can be referred to as the number of active shutdowns, the number of shutdowns caused by light faults can be referred to as the number of shutdowns of the first fault type, and the number of shutdowns caused by heavy faults can be referred to as the number of shutdowns of the second fault type.

[0070] Therefore, the accumulated number of shutdowns includes the sum of the accumulated number of active shutdowns, the number of shutdowns of the first fault type, and the number of shutdowns of the second fault type.

[0071] S12, if the shutdown parameter meets the preset shutdown condition, a curve shutdown control strategy is determined.

[0072] In practical applications, when the required duration of the last shutdown is too long or the accumulated number of shutdowns is too large, the brake friction plate of the conveyor is worn out, and the braking effect of the brake friction plate is reduced. At this time, the curve shutdown control strategy can be used to slowly control the shutdown of the conveyor belt to reduce the occurrence of the speed runaway phenomenon caused by the poor braking effect of the brake friction plate.

[0073] Therefore, in this embodiment, a preset duration needs to be set in advance to determine whether the required duration of shutdown is greater than the preset duration. The preset duration can be configured manually according to experience. If the required duration of shutdown is greater than the preset duration, it means that the required time of the last shutdown is too long.

[0074] In addition, a target number also needs to be set to determine whether the accumulated number of shutdowns is greater than the target number to determine whether the number of shutdowns of the conveyor belt is too large. If the accumulated number of shutdowns is greater than the target number, it means that the number of shutdowns of the conveyor belt is too large.

[0075] In another implementation manner of the present application, with reference to Figure 2 , the determination process of the target number includes:

[0076] S21, the proportion of the accumulated number of active shutdowns, the accumulated number of shutdowns of the first fault type, and the accumulated number of shutdowns of the second fault type is calculated.

[0077] Taking 10 times of active stop accumulative times, 4 times of first fault type stop accumulative times and 2 times of second fault type stop accumulative times as an example, the ratio is 10:4:2=5:2:1.

[0078] In the embodiment, the purpose of calculating the ratio is to analyze the proportion of various stop types. If the active stop times account for a high proportion, it means that most of the stops are user-initiated stops, not because of the conveyor belt failure stop. At this time, a higher target number can be set. If the first fault type stop accumulative times account for a high proportion, it means that the conveyor belt often has small faults. Therefore, a medium target number can be set. If the second fault type stop accumulative times account for a high proportion, it means that the conveyor belt often has faults that affect the safety of the equipment operation, that is, the running safety reliability of the conveyor belt is low. At this time, a smaller target number should be set.

[0079] S22, obtaining an initial number.

[0080] In the embodiment, the initial number can be set manually according to experience, such as 20 times.

[0081] S23, adjusting the initial number by using the ratio to obtain a target number.

[0082] Specifically, if the active stop times account for a high proportion, it means that the probability of conveyor belt failure is low. At this time, the initial number can be adjusted to obtain a target number, such as setting the target number to 25 times.

[0083] If the first fault type stop accumulative times account for a high proportion, the initial number can be directly used as the target number at this time.

[0084] If the second fault type stop accumulative times account for a high proportion, the initial number can be adjusted to obtain a target number, such as setting the target number to 15 times.

[0085] In the embodiment, the target number can be adaptively set according to the historical stop situation of the conveyor belt, so as to match the target number with the actual running situation of the conveyor belt, and improve the accuracy and reliability of the target number setting.

[0086] In addition, a model such as a neural network model or a machine learning model can be constructed in advance in the present application. The ratio can be input into the model to obtain a suitable target number.

[0087] In this embodiment, the model needs to be trained by a large number of samples, and the samples can be, for example, various proportion samples and manually configured target number of times. The model is trained using the samples, and when the loss function is less than a preset threshold or the number of training times is greater than a preset number of times, the training is stopped, and the model is put into use. In the use process, the proportion is input into the model, and the model can output the corresponding target number of times.

[0088] After the preset time length and the target number of times are obtained, if the length of time required for shutdown is greater than the preset time length or the cumulative number of shutdowns is greater than the target number of times, it indicates that the frequency of use of the brake friction device is relatively high. In order to safely stop the conveyor belt, a curve shutdown control strategy can be used. At this time, a preset curve shutdown control strategy can be obtained. In actual application, the preset curve shutdown control strategy is a standard control strategy. The running frequency and / or running time length in the preset curve shutdown control strategy can be adjusted based on the actual situation of this shutdown to obtain a curve shutdown control strategy.

[0089] The preset curve shutdown control strategy includes a plurality of shutdown running frequencies with gradually decreasing values and running time lengths corresponding to the shutdown running frequencies. For example, the preset curve shutdown control strategy includes:

[0090] F1, F2, F3, F4, and F5 are shutdown running frequencies with gradually decreasing values. The running time length of each shutdown running frequency is 20 ms. The shutdown running frequency can be a motor frequency.

[0091] After the preset curve shutdown control strategy is obtained, the shutdown running frequency and / or running time length can be adjusted based on the actual situation of this shutdown. For example, if the running current of the conveyor at the beginning of this shutdown is large, in order to avoid stalling caused by rapid stopping, the running time length of F1 can be increased. If the running current of the conveyor at the beginning of this shutdown is small, a large number of shutdown running frequencies are not needed, and F2 and F5 can be deleted to shorten the length of time required for shutdown.

[0092] S13, shutdown operation is performed according to the curve shutdown control strategy.

[0093] Specifically, after the curve shutdown control strategy is obtained through step S13, the conveyor belt can be controlled to stop according to the strategy.

[0094] During the stopping process of the conveyor belt, the total controller outputs a motor stop instruction to the motor, and the motor starts to execute a stop operation. After the motor stops running, the motor feeds back a motor stop signal to the total controller. Then, the total controller outputs a brake stop instruction to the brake, and the brake starts to execute a stop operation. After the brake stops running, the brake feeds back a brake stop signal to the total controller.

[0095] In actual application, the first time when the motor stop instruction is sent by the general controller and the second time when the motor stop signal feedback is received by the general controller, and the third time when the brake stop instruction is sent by the general controller and the fourth time when the brake stop feedback signal is received by the general controller, and the time when the belt conveyor stops finally can be recorded by the shutdown timing module.

[0096] S14, after determining that the shutdown operation is successfully executed, the equipment shutdown response time of the specified equipment in the process of executing the shutdown operation is acquired.

[0097] Specifically, after the conveyor is stationary, it is determined that the shutdown operation is successfully executed, at this time, the equipment shutdown response time of the specified equipment in the process of this shutdown from starting to stop running to completely stopping running can be analyzed.

[0098] In actual application, the two important control components in the conveyor are the motor and the brake, therefore, the specified equipment can be set to include the motor and the brake.

[0099] In an implementation manner of the present application, the equipment shutdown response time of the specified equipment in the process of executing the shutdown operation can include:

[0100] S31, the first time when the motor stop instruction is sent and the second time when the motor stop feedback signal is received are acquired.

[0101] In actual application, the first time and the second time can be acquired from the shutdown timing module.

[0102] S32, the time difference between the first time and the second time is calculated, and the calculated time difference is taken as the equipment shutdown response time of the motor.

[0103] In the embodiment, the time difference between the first time and the second time is the time required from receiving the motor stop instruction to the motor completely stopping, that is, the equipment shutdown response time of the motor in this response stop operation. The time can represent the running condition of the motor, in theory, the equipment shutdown response time of the motor should be similar each time, if the equipment shutdown response time becomes long, it indicates that the shutdown capability of the motor is reduced, and it also indicates that the motor may be about to fail and may need to be repaired.

[0104] S33, the third time when the brake stop instruction is sent and the fourth time when the brake stop feedback signal is received are acquired.

[0105] S34, the time difference between the third time and the fourth time is calculated, and the calculated time difference is taken as the equipment shutdown response time of the brake.

[0106] The third time, the fourth time and the determination process of the device shutdown response time are referred to the corresponding processes described above.

[0107] S15, if it is determined that the device shutdown response time meets the set time condition, output the active protection information.

[0108] Specifically, after determining the device shutdown response times of the motor and the brake, it is judged whether the device shutdown response time meets the set time condition. If it meets, it means that active protection operation is needed, and at this time, the active protection information is output to remind the user to perform active protection operation immediately.

[0109] In actual application, the set time condition can be that the device shutdown response time is greater than a preset time threshold, or that the time change trend of the device shutdown response time compared with the historical device shutdown response time is a preset trend.

[0110] When the set time condition includes the preset time threshold, it is directly analyzed from the value size whether the device shutdown response time meets the set time condition. When the set time condition includes the preset trend, it is analyzed from the time change trend of the device shutdown response time whether the device shutdown response time meets the set time condition.

[0111] Specifically, if the device shutdown response time is greater than the preset time threshold, it means that the shutdown process of the specified device is longer during this shutdown operation, that is, the performance of the specified device is lower, and active protection is needed. In actual application, it is considered that the device shutdown response time is greater than the preset time threshold when at least one of the device shutdown response time of the motor and the device shutdown response time of the brake is greater than the preset time threshold, and at this time, the response time protection information is output. The content of the response time protection information can be that the response time of the motor or the brake is too long, and active protection is needed.

[0112] In addition, the time change trend of the device shutdown response time compared with the historical device shutdown response time can also be determined. The historical device shutdown response time refers to the device shutdown response time stored before shutdown.

[0113] When determining the time change trend of the device shutdown response time compared with the historical device shutdown response time, a curve of all device shutdown response times can be drawn to judge whether the curve shows an upward trend, that is, whether the device shutdown response time gradually increases. If it gradually increases, it means that the braking time of the specified device is getting longer, and the performance of the specified device is getting lower.

[0114] If the time variation trend is a preset trend (time gradually increases), it is determined that the equipment shutdown response time meets the set time condition, and response time protection information is output. The content of the response time protection information can be, for example, that the response time of the motor or brake is too long and needs to be actively protected.

[0115] After the active protection ends, the reset button can be clicked, and at this time, a reset instruction can be received. Before the active protection ends, that is, before the reset instruction corresponding to the active protection information is received, the conveyor is prohibited from being started again to ensure the safety of the conveyor when it is next operated.

[0116] In the embodiment, after the response shutdown demand information is responded to, the shutdown operation is performed according to the curve shutdown control strategy. After the shutdown operation is completed, the equipment shutdown response time of the specified equipment during the execution of the shutdown operation is obtained. If it is determined that the equipment shutdown response time meets the set time condition, active protection information is output, and thus the corresponding active protection operation can be realized before the conveyor fails, the failure is avoided, and the operation reliability of the conveyor is improved. In addition, in the present application, the shutdown parameters at the last shutdown meet the preset shutdown condition, the curve shutdown control strategy is determined and used to perform the shutdown operation this time, so that the conveyor can be slowly shut down during the shutdown operation this time, and the stability of the shutdown control is improved. In addition, before the reset instruction corresponding to the active protection information is received, the conveyor is prohibited from being started again to ensure the safety of the conveyor when it is next operated.

[0117] In another implementation manner of the present application, after it is determined that the shutdown operation is successfully performed, the following steps are further included:

[0118] In the case where the first fault type shutdown cumulative number or the second fault type shutdown cumulative number corresponding to the shutdown operation this time is greater than a preset number, shutdown cumulative number protection information is output.

[0119] Similar to the monitoring of the equipment shutdown response time described above, the above embodiment is based on the equipment shutdown response time to output active protection information. In the present embodiment, the corresponding shutdown cumulative number protection information is output based on the shutdown cumulative number.

[0120] Specifically, after the shutdown operation this time ends, whether the first fault type shutdown cumulative number and the second fault type shutdown cumulative number are incremented by one is determined according to the actual situation. If the shutdown this time is a first fault type shutdown, the first fault type shutdown cumulative number is incremented by one. If the shutdown this time is a second fault type shutdown, the second fault type shutdown cumulative number is incremented by one, and the latest first fault type shutdown cumulative number and second fault type shutdown cumulative number are obtained.

[0121] When the first fault type stoppage cumulative number or the second fault type stoppage cumulative number is greater than a preset number (previously set according to actual conditions), it is indicated that the stoppage cumulative number due to fault stoppage is too large, and it is also indicated that the fault frequency of the conveyor is high, at this time, the stoppage cumulative number protection information can be output, reminding the user to pay attention to the fault condition of the conveyor in time, and corresponding active protection is performed.

[0122] In actual application, the stoppage cumulative number protection information can be as follows:

[0123] The stoppage cumulative number is too large, please perform corresponding active protection.

[0124] In the embodiment, the stoppage cumulative number protection information can be output when the first fault type stoppage cumulative number or the second fault type stoppage cumulative number is greater than a preset number, reminding the user to pay attention to the fault condition of the conveyor in time, and corresponding protection or repair operation is performed in time, so that the situation that the conveyor cannot be used due to fault is avoided.

[0125] In another implementation manner of the present application, after the active protection information is output, if the user performs corresponding active protection operation, a reset button such as a reset key can be clicked, at this time, the total controller receives a reset instruction, indicating that the conveyor returns to normal after the active protection control operation is performed, and thereafter, new active protection can be started.

[0126] In order to avoid the situation that no memory is caused by large data storage amount, in the embodiment, after the total controller receives the reset instruction, all stored stoppage parameters and all equipment stoppage response times can be cleared, and in addition, other information such as the contents of the active stoppage number, the first fault type stoppage number and the second fault type stoppage number, the proportion content, the target number content, the first time, the second time, the third time, the equipment stoppage response time and the like can be cleared, so as to reduce the storage data amount.

[0127] In the embodiment, after one active protection, useless information can be deleted, so that the situation that the total controller cannot run caused by the large data storage amount and the large memory occupied by data is avoided.

[0128] In another implementation manner of the present application, during the normal operation of the conveyor, the running current of the conveyor can also be adjusted in real time, so as to avoid the situation that the running current of the conveyor is too large and the conveyor is faulted.

[0129] Before the response stoppage demand information, the method further includes:

[0130] S41, monitoring the running current of the conveyor.

[0131] Specifically, the conveyor running current can be obtained through a current sampling operation, and in order to improve the accuracy of current collection, the collected current can be filtered.

[0132] The size of the current can reflect the load condition of the conveyor, and the load condition can be determined by a shutdown load module. The shutdown load module can perform load detection and load judgment operations. The load detection is based on the motor current. When the belt conveyor runs at rated speed, the current value is one grade when it is empty, and the current value is five grades when it is full. One quarter of the difference between the full load current and the empty load current is the reference value of the sub-grade. The load judgment records the current grade value of the current shutdown during the running process of the conveyor and at the shutdown. The empty load, light load, heavy load and overload are divided and recorded according to the shutdown current grade value.

[0133] Among them, the load condition is divided into four load types, and the current is divided into five categories. Two current classifications correspond to the same load type. For example, current grade one corresponds to empty load, current grade two and three correspond to light load, current grade four corresponds to heavy load, and current grade five corresponds to overload.

[0134] S42, in the case where the conveyor running current is greater than a preset current threshold, determining a running adjustment strategy based on the conveyor running current.

[0135] The preset current threshold in the embodiment can be the above-mentioned five grades. In actual application, the actual running current of the conveyor will not be limited within five grades of current, but can be changed according to actual conditions. The maximum value can be greater than five grades, for example, when the load is overload, a current greater than five grades is needed to run the overload goods. If the load is empty, the conveyor current is small.

[0136] Therefore, in the embodiment, when the above-mentioned conveyor running current is greater than the preset current threshold (such as five grades), the conveyor running current needs to be adjusted to avoid too large current causing conveyor failure.

[0137] When adjusting the current, a running adjustment strategy can be set, which can include at least one of closing the feeding hole, reducing the motor frequency and reducing the material flow rate. In addition, the running adjustment strategy can also add corresponding contents according to actual conditions.

[0138] In actual application, when the current is large, multiple of closing the feeding hole, reducing the motor frequency and reducing the material flow rate can be selected, and when the current is small, one of closing the feeding hole, reducing the motor frequency and reducing the material flow rate can be selected.

[0139] Among them, if the feeding hole is closed, no new material falls into the conveyor belt at this time, so the conveyor belt does not need a large current to run, and the running current will be reduced at this time.

[0140] If the motor frequency is reduced, the corresponding operating current will also be reduced.

[0141] If the material flow rate is reduced, the load of the conveyor belt will be reduced, so that the conveyor belt does not need a large current to operate, and the operating current is reduced.

[0142] S43, according to the operation adjustment strategy, adjusting the conveyor operating current.

[0143] In this embodiment, after determining the operation adjustment strategy, the corresponding operation is performed according to the strategy, so as to reduce the conveyor operating current, so that the operating current is within five grades.

[0144] In this embodiment, the current value is detected when the conveyor belt is running, and when the operating current value grade value is greater than 5, the overload protection is performed, and the active flow reduction operation is performed, so as to improve the running safety of the conveyor belt and avoid the failure of the conveyor belt.

[0145] In another embodiment of the present application, the internal module implementation of the main controller is introduced, specifically, referring to Figure 5 The total controller includes a shutdown counting module, a shutdown timing module, a shutdown load module, a shutdown trend analysis module, an active protection control module and a reset archiving module.

[0146] The shutdown counting module includes recording the upper computer operation shutdown count, the light fault shutdown count and the heavy fault shutdown count. When the belt conveyor is in the running state, the upper computer operation shutdown count is incremented once when receiving the stop instruction from the upper computer operation, the light fault shutdown count is incremented once when receiving the light fault summary signal, and the heavy fault shutdown count is incremented once when receiving the heavy fault summary signal, and the occurrence time is recorded.

[0147] The shutdown timing module includes recording the first time of sending the motor stop instruction and the second time of receiving the motor stop feedback signal, the third time of sending the brake stop instruction and the fourth time of receiving the brake stop feedback signal, and the last stop time of the belt conveyor.

[0148] The shutdown load module includes load detection and load judgment. The load detection is based on the motor current. When the belt conveyor is running at rated speed, the current value is one grade when it is empty, and the current value is five grades when it is full. One fourth of the difference between the full load current and the empty load current is the reference value of the sub-grade. The load judgment records the current grade value of the shutdown when the shutdown, and divides and records the empty load, the light load, the heavy load and the overload according to the shutdown current grade value.

[0149] The stoppage trend analysis module analyzes the stoppage time recorded by the stoppage timing module when the last stoppage occurred, and the stoppage cumulative number recorded by the stoppage counting module when the last stoppage occurred, and sends a protection control to the active protection control module if the stoppage time is greater than a preset time or the stoppage cumulative number is greater than a target number, switches to a curve stoppage control mode provided by the device during stoppage to avoid the possibility of stalling and flying, and sends an alarm to check the brake friction plate, realizes equipment fault protection, and waits for confirmation to reset to start a new round of active protection.

[0150] The stoppage trend analysis module calls the stoppage counting module, the stoppage timing module and the stoppage load module, calculates the time difference between the first time when the motor stop command is sent and the second time when the motor stop feedback signal is received, and the time difference between the third time when the brake stop command is sent and the fourth time when the brake stop feedback signal is received, and estimates whether the conveyor has a fault possibility based on the time difference and the trend of the time difference, and sends a prompt that the equipment has a safety hazard to the active protection control module if there is, realizes poor brake effect protection, and after the problem is found and cleared, receives a reset instruction, restores to normal, and then starts a new stage of active protection.

[0151] The stoppage trend analysis module can also detect that the operating current value is greater than five gears, that is, when overloaded, send an overload protection to the active protection control module, actively slow down, and prevent material from flying, and realize overload and overspeed protection.

[0152] In the embodiment, the stoppage counting module records the number of recent host computer operation stoppages, light fault stoppages and heavy fault stoppages, the stoppage timing module and the stoppage load analysis module are combined, the stoppage trend analysis module is used to analyze whether the stoppage time is too long, and a warning signal is given for active protection control to prevent accidents caused by uncontrolled braking, that is, the active protection in the application prevents accidents from occurring. Finally, the reset archiving module performs periodic data archiving and resets to start a new round of active protection control.

[0153] In addition, the stoppage timing module in the application can analyze the recorded data and trace the source when an accident occurs, and can also judge the brake effect change of the brake under the same working condition in combination with the load in the stoppage load module.

[0154] In addition, the time data in the stoppage counting module is used to analyze whether the belt conveyor is in good operation.

[0155] On the basis of the embodiment of the active protection method of the conveyor, another embodiment of the application provides an active protection device for a conveyor, which is described with reference toFigure 6 may comprise:

[0156] a parameter acquisition module 11 configured to acquire a shutdown parameter at a last shutdown in response to shutdown demand information, the shutdown parameter comprising a required duration of shutdown and a cumulative number of shutdowns;

[0157] a strategy determination module 12 configured to determine a curve shutdown control strategy if the shutdown parameter satisfies a preset shutdown condition;

[0158] a shutdown control module 13 configured to perform a shutdown operation according to the curve shutdown control strategy;

[0159] a time acquisition module 14 configured to acquire a device shutdown response time of a specified device during the execution of the shutdown operation after determining that the shutdown operation is successfully executed;

[0160] an information output module 15 configured to output active protection information if it is determined that the device shutdown response time satisfies a set time condition; wherein the conveyor is prohibited from being started again before a reset instruction corresponding to the active protection information is received.

[0161] Further, the shutdown parameter satisfying the preset shutdown condition comprises:

[0162] the required duration of shutdown is greater than a preset duration or the cumulative number of shutdowns is greater than a target number.

[0163] Further, the cumulative number of shutdowns comprises a cumulative number of active shutdowns, a number of shutdowns of a first fault type, and a number of shutdowns of a second fault type.

[0164] The active protection device of the conveyor further comprises a number determination module, which comprises:

[0165] a proportion calculation sub-module configured to calculate proportions of the cumulative number of active shutdowns, the cumulative number of shutdowns of the first fault type, and the cumulative number of shutdowns of the second fault type;

[0166] a number acquisition sub-module configured to acquire an initial number;

[0167] a number adjustment sub-module configured to adjust the initial number by using the proportions to obtain a target number.

[0168] Further, the specified device comprises a motor and a brake; and the time acquisition module 14 comprises:

[0169] a first acquisition sub-module configured to acquire a first time at which a motor stop instruction is sent and a second time at which a motor stop feedback signal is received;

[0170] a first calculating sub-module, configured to calculate a time difference between the first time and the second time, and take the calculated time difference as a device shutdown response time of the motor;

[0171] a second acquiring sub-module, configured to acquire a third time when a brake stop instruction is sent, and a fourth time when a brake stop feedback signal is received;

[0172] a second calculating sub-module, configured to calculate a time difference between the third time and the fourth time, and take the calculated time difference as a device shutdown response time of the brake.

[0173] Further, the information output module 15 is specifically configured to:

[0174] if the device shutdown response time is greater than a preset time threshold, it is determined that the device shutdown response time meets a set time condition, and response time protection information is output;

[0175] or, a time change trend of the device shutdown response time compared with historical device shutdown response times is determined, and if the time change trend is a preset trend, it is determined that the device shutdown response time meets the set time condition, and the response time protection information is output.

[0176] Further, the device further comprises:

[0177] a frequency protection module, configured to output shutdown cumulative frequency protection information if a first cumulative frequency of shutdown of a first fault type or a second cumulative frequency of shutdown of a second fault type corresponding to a current shutdown operation is greater than a preset frequency.

[0178] Further, the device further comprises:

[0179] a reset control module, configured to clear all stored shutdown parameters and all device shutdown response times if a reset instruction is received.

[0180] Further, the device further comprises a current adjustment module, which comprises:

[0181] a current monitoring sub-module, configured to monitor a conveyor running current;

[0182] a strategy determining sub-module, configured to determine a running adjustment strategy based on the conveyor running current if the conveyor running current is greater than a preset current threshold; the running adjustment strategy comprises at least one of closing a feeding hole, reducing a motor frequency, and reducing a material flow rate;

[0183] a current adjusting sub-module, configured to adjust the conveyor running current according to the running adjustment strategy.

[0184] In the embodiment, after responding to the shutdown demand information, the shutdown operation is performed according to the curve shutdown control strategy, the equipment shutdown response time of the specified equipment during the shutdown operation is obtained after the shutdown operation is completed, and if it is determined that the equipment shutdown response time meets the set time condition, the active protection information is output, so that the corresponding active protection operation can be realized before the conveyor fails, the failure is avoided, and the operation reliability of the conveyor is improved. In addition, in the present application, the shutdown parameters at the last shutdown meet the preset shutdown condition, the curve shutdown control strategy is determined and used for the shutdown operation, so that the conveyor can be slowly shut down during the shutdown operation, and the stability of the shutdown control is improved. In addition, before the reset instruction corresponding to the active protection information is received, the conveyor is prohibited from being started again, so as to ensure the safety of the next operation of the conveyor.

[0185] It should be noted that the working processes of the various modules and sub-modules in the embodiment are described above, and will not be repeated here.

[0186] In the embodiment, an electronic device is also provided. The electronic device can be the general controller described above. Referring to Figure 7 The electronic device shown in the figure shows a structure diagram suitable for realizing the electronic device in the embodiment of the present application. The electronic device in the embodiment of the present application can include but is not limited to fixed terminals such as mobile phones, notebook computers, PDAs (personal digital assistants), PADs (tablet computers), desktop computers, etc. Figure 7 The electronic device shown is only an example, and should not limit the functions and use range of the embodiment of the present application.

[0187] As Figure 7 shown, the electronic device can include a processing device (such as a central processing unit, a graphics processing unit, etc.) 601, which can perform various appropriate actions and processes according to programs stored in a read-only memory (ROM) 602 or programs loaded from a storage device 608 to a random access memory (RAM) 603. In the state that the electronic device is powered on, various programs and data required for the operation of the electronic device are also stored in the RAM 603. The processing device 601, the ROM 602, and the RAM 603 are connected to each other through a bus 604. An input / output (I / O) interface 605 is also connected to the bus 604.

[0188] In general, the following devices can be connected to the I / O interface 605: input devices 606 including, for example, a touch screen, a touch pad, a keyboard, a mouse, a camera, a microphone, an accelerometer, a gyroscope, and the like; output devices 607 including, for example, a liquid crystal display (LCD), a speaker, a vibrator, and the like; storage devices 608 including, for example, a memory card, a hard disk, and the like; and communication devices 609. The communication devices 609 can allow the electronic device to communicate wirelessly or wiredly with other devices to exchange data. Although Figure 7 An electronic device having various devices is shown, but it is understood that all of the shown devices are not required to be implemented or possessed. More or less devices can be alternatively implemented or possessed.

[0189] The embodiments of the present application also provide a computer program product including computer readable instructions, which, when executed on an electronic device, cause the electronic device to implement any of the conveyor active protection methods provided by the embodiments of the present application.

[0190] The embodiments of the present application also provide a computer readable storage medium carrying one or more computer programs, which, when executed by an electronic device, can cause the electronic device to implement any of the methods provided by the embodiments of the present application.

[0191] The above description of disclosed embodiments enables a person skilled in the art to implement or use the present application. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method of active guarding of a conveyor, characterized in that, The method comprises the following steps: in response to the shutdown demand information, obtaining the last shutdown parameter, wherein the shutdown parameter comprises the required shutdown time and the cumulative number of shutdowns; if the shutdown parameter meets the preset shutdown condition, determining a curve shutdown control strategy; wherein the shutdown parameter meeting the preset shutdown condition comprises the required shutdown time being greater than a preset time or the cumulative number of shutdowns being greater than a target number; the cumulative number of shutdowns comprises the cumulative number of active shutdowns, the number of shutdowns of a first fault type, and the number of shutdowns of a second fault type; the target number is determined by calculating the proportion of the cumulative number of active shutdowns, the cumulative number of shutdowns of the first fault type, and the cumulative number of shutdowns of the second fault type; obtaining an initial number; adjusting the initial number by using the proportion to obtain the target number; performing a shutdown operation according to the curve shutdown control strategy; after determining that the shutdown operation is successfully performed, obtaining the equipment shutdown response time of the specified equipment during the shutdown operation; if it is determined that the equipment shutdown response time meets the set time condition, outputting active protection information; wherein the conveyor is prohibited from being started again before a reset instruction corresponding to the active protection information is received.

2. The active guarding method of a conveyor as claimed in claim 1, wherein, The specified equipment comprises a motor and a brake. Obtaining the equipment shutdown response time of the specified equipment during the shutdown operation comprises: obtaining a first time at which a motor stop instruction is sent and a second time at which a motor stop feedback signal is received; calculating the time difference between the first time and the second time, and taking the calculated time difference as the equipment shutdown response time of the motor; obtaining a third time at which a brake stop instruction is sent and a fourth time at which a brake stop feedback signal is received; calculating the time difference between the third time and the fourth time, and taking the calculated time difference as the equipment shutdown response time of the brake.

3. The active guarding method of a conveyor as claimed in claim 1, wherein, If it is determined that the equipment shutdown response time meets the set time condition, outputting active protection information comprises: if the equipment shutdown response time is greater than a preset time threshold, it is determined that the equipment shutdown response time meets the set time condition, and response time protection information is outputted; or, determining the time change trend of the equipment shutdown response time compared with the historical equipment shutdown response time, if the time change trend is a preset trend, it is determined that the equipment shutdown response time meets the set time condition, and response time protection information is outputted.

4. The active guarding method of a conveyor as claimed in claim 1, wherein, After it is determined that the shutdown operation is successfully performed, the method further comprises: if the cumulative number of shutdowns of a first fault type or the cumulative number of shutdowns of a second fault type corresponding to the current shutdown operation is greater than a preset number, outputting shutdown cumulative number protection information.

5. The active guarding method of a conveyor as claimed in claim 1, wherein, After the active protection information is outputted, the method further comprises: if a reset instruction is received, clearing all stored shutdown parameters and all equipment shutdown response times.

6. The active guarding method of a conveyor as claimed in claim 1, wherein, Before the shutdown demand information is responded to, the method further comprises: monitoring the running current of the conveyor; if the running current of the conveyor is greater than a preset current threshold, determining a running adjustment strategy based on the running current of the conveyor; the running adjustment strategy comprises at least one of closing the feeding hole, reducing the motor frequency, and reducing the material flow rate. According to the running adjustment strategy, the conveyor running current is adjusted.

7. A powered guard for a conveyor, characterized by, The method comprises the steps of: The parameter acquisition module is configured to acquire a last shutdown parameter in response to the shutdown demand information, the last shutdown parameter comprising a required shutdown duration and a cumulative number of shutdowns; The strategy determination module is configured to determine a curve shutdown control strategy if the last shutdown parameter meets a preset shutdown condition, wherein the last shutdown parameter meeting the preset shutdown condition comprises the required shutdown duration being greater than a preset duration or the cumulative number of shutdowns being greater than a target number; the cumulative number of shutdowns comprises a cumulative number of active shutdowns, a number of shutdowns of a first fault type, and a number of shutdowns of a second fault type; the target number is determined by calculating proportions of the cumulative number of active shutdowns, the number of shutdowns of the first fault type, and the number of shutdowns of the second fault type; acquiring an initial number; and adjusting the initial number by using the proportions to obtain the target number; The shutdown control module is configured to perform a shutdown operation according to the curve shutdown control strategy. The time acquisition module is configured to acquire a device shutdown response time of a specified device during the shutdown operation after determining that the shutdown operation is successfully performed. The information output module is configured to output an active protection information if it is determined that the device shutdown response time meets a set time condition; and the conveyor is prohibited from being started again before a reset instruction corresponding to the active protection information is received.

8. An electronic device, comprising: The electronic device comprises at least one processor and a memory connected to the processor, wherein: The memory is configured to store a computer program; The processor is configured to execute the computer program to enable the electronic device to implement the active protection method of the conveyor according to any one of claims 1 to 7.

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