High-efficiency energy-saving electric roller module

Abstract

The present application relates to a kind of high-efficiency energy-saving electric roller module, including the symmetrical distribution of plug-in slot in conveying line support inner side, electric roller is set up between plug-in slot by plug-in frame, conveying line support side is connected electric roller by cooling communication mechanism, conveying support other side is equipped with electricity connection box, electricity connection box is inserted into plug-in slot through the side plate of conveying line support and the side of plug-in frame close to electricity connection box side is equipped with electric contact, the position distribution of corresponding plug-in slot in the conveying line support close to electricity connection box side has indicator light, and the operation of electric roller is controlled based on multiple sensors of intelligent control system;The present application controls the start and stop of electric roller by the multiple sensors of intelligent control system detecting the load condition of electric roller, effectively avoids the phenomenon of electric energy waste caused by the no-load idling of electric roller, simultaneously, the whole electric roller is designed into modular, when conveying line appears electric roller failure, directly and quickly replace the electric roller module of failure, without conveying line overall shutdown maintenance.

Description

Technical Field

[0001] This invention relates to the field of electric roller technology, and in particular to a high-efficiency and energy-saving electric roller module. Background Technology

[0002] Electric rollers are automated actuators with built-in motors used in conveyor lines. Multiple electric rollers work together on the conveyor line to transport products. In logistics sorting or flexible production lines, the number and frequency of items on the conveyor line may be random. The conveyor line needs to ensure that the items do not squeeze each other during the transport process, that is, it needs to achieve its zero-pressure accumulation function.

[0003] When electric rollers are conveying materials on a conveyor line, there will be intervals in the conveying process, which may cause the electric rollers to run without load. This will result in a waste of electric energy. At the same time, the electric rollers may malfunction and stop during operation, causing the conveyor line to be unable to transport materials normally. Maintenance personnel need to stop the operation of the conveyor line to repair the electric rollers, which seriously affects the material transportation efficiency. Summary of the Invention

[0004] To address the shortcomings of existing production technologies, this applicant provides a high-efficiency and energy-saving electric roller module. This module uses multiple sensors in an intelligent control system to detect the load on the electric roller. When zero load is detected, the electric roller stops rotating; when load is detected, the electric roller starts conveying material. This effectively avoids the phenomenon of continuous rotation of electric rollers in traditional conveyor lines, which leads to idle running without load and wastes energy, thus achieving energy savings. Furthermore, the electric roller is designed as a modular unit, allowing for quick and easy replacement of faulty electric roller modules when a fault occurs on the conveyor line, eliminating the need for a complete shutdown of the conveyor line for maintenance.

[0005] The technical solution adopted in this invention is as follows:

[0006] A high-efficiency and energy-saving electric roller module includes a conveyor support frame. The inner side of the conveyor support frame has symmetrically distributed insertion slots. Electric rollers are installed between the insertion slots via insertion frames. One side of the conveyor support frame is connected to the electric rollers via a cooling and connecting mechanism. The other side of the conveyor support frame has an electrical connection box. The electrical connection box extends through the side plate of the conveyor support frame into the insertion slots and is equipped with electrical contacts. The side of the insertion frame near the electrical connection box also has electrical contacts that are electrically connected to the electric rollers. Indicator lights are distributed on the conveyor support frame near the electrical connection box corresponding to the insertion slot positions. The module also includes an intelligent control system that controls the operation of the electric rollers based on multiple sensors.

[0007] The cooling connection mechanism consists of an embedded connecting pipe, a through connecting pipe, a sealing adapter, and a circulation pipe. The embedded connecting pipe is located on the side of the plug-in frame away from the electrical box, and the through connecting pipe runs through the side of the conveyor support on the same side. One end of the embedded connecting pipe is connected to the internal liquid cooling structure of the electric roller, and the other end of the embedded connecting pipe corresponds to the through connecting pipe and is sealed and quick-released through the sealing adapter. The outer end of the through connecting pipe is connected to a circulation pipe.

[0008] As a further improvement to the above technical solution:

[0009] A tray frame is provided on the conveyor support on one side of the circulation pipe, and the circulation pipe is snapped and fixed on the tray frame. A control valve is provided on the through connecting pipe.

[0010] The embedded connecting pipe, the through connecting pipe, and the circulation pipe are each provided in two sets, which are used for water inlet and water outlet circulation, respectively. The through connecting pipe is connected to the two sets of circulation pipes, and the end of the circulation pipe is connected to the coolant circulation equipment.

[0011] The intelligent control system includes a parameter acquisition module, an analysis and processing module, and a control module. The parameter acquisition module acquires various operating parameters of the electric roller based on multiple sensors installed in the electric roller. The analysis and processing module is used to analyze and process the acquired parameters and diagnose faults. The control module is used to adjust and control the operation of the electric roller based on the diagnostic results.

[0012] Multiple sensors are included, such as speed sensors, pressure sensors, and temperature sensors. The speed sensor is used to monitor the speed of the electric roller and its fluctuations. The pressure sensor is used to monitor the load pressure when the electric roller is running. The temperature sensor is used to monitor the internal operating temperature of the electric roller and the cooling connection mechanism is controlled by the control module.

[0013] The analysis and processing module includes a data processing submodule, an anomaly detection submodule, and a control calculation submodule. The data processing submodule is used to perform noise reduction and enhancement processing on the received sensor data. The anomaly detection submodule automatically judges and identifies operational anomalies based on a threshold judgment model and generates display reminder signals. The control calculation submodule calculates and outputs the compensation data of the operating parameters of several groups of electric rollers adjacent to the abnormal electric roller based on the abnormal operating data using a compensation calculation model.

[0014] The control module includes a fault indication submodule and a data conversion submodule. The fault indication submodule is used to control the indicator light to flash and change to indicate when the analysis and processing module determines an abnormality. The data conversion submodule is used to convert the data output by the analysis and processing module into control signals for the electric roller and send them to control its execution.

[0015] The beneficial effects of this invention are as follows:

[0016] This invention features a compact and rational structure, and is easy to operate. It uses multiple sensors in an intelligent control system to detect the load on the electric roller. When zero load is detected, the electric roller stops rotating; when load is detected, the electric roller starts conveying material. This effectively avoids the energy waste caused by the continuous rotation of electric rollers in traditional conveyor lines, resulting in idle running without load. Furthermore, the electric roller is designed as a modular unit, allowing for quick replacement of faulty modules in case of a malfunction, eliminating the need for a complete conveyor line shutdown for maintenance and preventing low material conveying efficiency due to downtime. This provides a stable and energy-efficient intelligent control electric roller for material conveying. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the installation of the conveyor line bracket of the present invention.

[0018] Figure 2 This is a side view of the present invention (showing the internal structure).

[0019] Figure 3 for Figure 2 A magnified view of part A in the middle.

[0020] Figure 4 for Figure 2 A magnified view of part B in the middle.

[0021] Figure 5 This is a schematic diagram of the control system of the present invention.

[0022] The components include: 1. Conveyor support; 2. Insertion slot; 3. Insertion frame; 4. Electric roller; 5. Electrical box; 6. Electrical contact; 7. Indicator light; 8. Embedded connecting pipe; 9. Through connecting pipe; 10. Sealing adapter; 11. Circulation pipe; 12. Pallet frame; 13. Control valve. Detailed Implementation

[0023] The specific embodiments of the present invention will now be described with reference to the accompanying drawings.

[0024] The specific structure and function of the high-efficiency and energy-saving electric roller module of the present invention are as follows:

[0025] It mainly includes a conveyor support 1, a plug slot 2, a plug frame 3, an electric roller 4, a cooling and connecting mechanism, an electrical box 5, an electrical contact 6, an indicator light 7, and an intelligent control system.

[0026] The conveyor support 1 has symmetrically distributed insertion slots 2 on its inner side. Electric rollers 4 are installed between the insertion slots 2 via insertion frames 3. The insertion frames 3 are installed between the insertion slots 2 distributed on opposite sides of the conveyor support 1. The electric rollers 4 are installed in the insertion frames 3. The electric rollers 4 are connected to one side of the conveyor support 1 via a cooling and connecting mechanism. The other side of the conveyor support 1 has an electrical box 5. The electrical box 5 extends through the side plate of the conveyor support 1 and into the insertion slots 2, and is equipped with electrical contact 6. The side of the insertion frame 3 near the electrical box 5 is also equipped with electrical contact 6, which is electrically connected to the electric rollers 4. When the insertion frame 3 is installed, the two sets of electrical contact 6 make contact to achieve electrical connection of the electric rollers 4. Indicator lights 7 are distributed on the conveyor support 1 near the electrical box 5 at the corresponding positions of the insertion slots 2. The intelligent control system controls the operation of the electric rollers 4 based on multiple sensors.

[0027] The cooling and connecting mechanism includes an embedded connecting pipe 8, a through connecting pipe 9, a sealing adapter 10, and a circulation pipe 11. The embedded connecting pipe 8 is provided on the side of the plug-in frame 3 away from the power box 5, and the through connecting pipe 9 is provided through the side of the conveyor support 1 on the same side. One end of the embedded connecting pipe 8 is connected to the internal liquid cooling structure of the electric roller 4, and the other end is connected to the through connecting pipe 9 through the sealing adapter 10 for quick and easy sealing. During installation, the sealing connection is achieved through two sets of sealing adapters. The outer ends of the through connecting pipe 9 are respectively connected to the circulation pipe 11, and the circulation pipe 11 is used to achieve the circulation heat exchange of the heat exchange medium in the internal liquid cooling structure of the electric roller 4.

[0028] A tray frame 12 is fixedly installed on the conveyor support 1 on one side of the circulation pipe 11. The circulation pipe 11 is snapped and fixed on the tray frame 12. A reinforcing rib is provided below the tray frame 12, and pipe clamps are symmetrically arranged above it to fix the circulation pipe 11 on the tray frame 12. A control valve 13 is provided on the through connecting pipe 9. The circulation of the heat exchange medium in the liquid cooling structure inside the electric roller 4 is closed by the control valve 13, which facilitates the quick replacement of the faulty electric roller 4.

[0029] The embedded connecting pipe 8, the through connecting pipe 9, and the circulation pipe 11 are each provided in two sets, which are used for water inlet and water outlet circulation, respectively. The through connecting pipe 9 is connected to the two sets of circulation pipes 11, and the end of the circulation pipe 11 is connected to the coolant circulation equipment.

[0030] The intelligent control system includes a parameter acquisition module, an analysis and processing module, and a control module. The parameter acquisition module acquires various operating parameters of the electric roller 4 based on multiple sensors installed in the electric roller 4. The analysis and processing module is used to analyze and process the acquired parameters and diagnose faults. The control module is used to adjust and control the operation of the electric roller 4 according to the diagnostic results.

[0031] Multiple sensors are included, such as speed sensors, pressure sensors, and temperature sensors. The speed sensor is used to monitor the speed of the electric roller 4 and its fluctuations. The pressure sensor is used to monitor the load pressure of the electric roller 4 during operation. The temperature sensor is used to monitor the internal operating temperature of the electric roller 4 during operation and the cooling connection mechanism is controlled by the control module.

[0032] The analysis and processing module includes a data processing submodule, an anomaly judgment submodule, and a control calculation submodule. The data processing submodule is used to perform noise reduction and enhancement processing on the received sensor data. The anomaly judgment submodule automatically judges and identifies operational anomalies based on a threshold judgment model and generates display reminder signals. The control calculation submodule calculates and outputs the operating parameter compensation data of several groups of electric rollers 4 adjacent to the abnormal electric roller 4 based on the abnormal operating data using a compensation calculation model.

[0033] The control module includes a fault indication submodule and a data conversion submodule. The fault indication submodule is used to control the indicator light 7 to flash and indicate when the analysis and processing module determines an abnormality. The data conversion submodule is used to convert the data output by the analysis and processing module into control signals for the electric roller 4 and send them to control its execution.

[0034] When using this high-efficiency and energy-saving electric roller module, the intelligent control system first monitors the operating status of the electric roller 4 on the conveyor support 1 in real time. The load of the electric roller 4 is detected by the pressure sensor. When zero load is detected, the electric roller 4 is controlled to stop rotating. When load is detected, the electric roller 4 is started to transfer material.

[0035] When a fault is detected in a certain electric roller 4, an alert is issued in a timely manner. Before the maintenance personnel arrive at the faulty electric roller 4, the analysis and processing module of the intelligent control system calculates the load change of the material conveying and calculates the operating change data of several electric rollers 4 adjacent to the faulty electric roller 4 based on the load weight to temporarily replace the conveying force of the faulty electric roller 4. Then, the control module issues an adjustment control signal to control the electric roller 4 to execute.

[0036] After receiving the fault notification, the maintenance personnel prepare a new modular electric roller 4. Upon arrival at the site, they first close the control valve 13 on the through connecting pipe 9, and then quickly pull the faulty electric roller 4 out of the insertion slot 2 during the idle period when it is conveying materials. The new modular electric roller 4 is then correctly installed in the insertion slot 2, and the control valve 13 is then opened to complete the replacement.

[0037] The above description is an explanation of the present invention and not a limitation thereof. The scope of the present invention is defined by the claims. Within the scope of protection of the present invention, any form of modification may be made.

Claims

1. A high-efficiency and energy-saving electric roller module, characterized in that: The system includes a conveyor support (1), on which symmetrically distributed insertion slots (2) are provided on the inner side. An electric roller (4) is installed between the insertion slots (2) via an insertion frame (3). The electric roller (4) is connected to one side of the conveyor support (1) via a cooling and connecting mechanism. An electrical box (5) is provided on the other side of the conveyor support (1). The electrical box (5) extends through the side plate of the conveyor support (1) into the insertion slot (2) and is provided with an electrical contact (6). An electrical contact (6) is also provided on the side of the insertion frame (3) near the electrical box (5) and is electrically connected to the electric roller (4). An indicator light (7) is distributed on the conveyor support (1) near the electrical box (5) corresponding to the insertion slot (2). The system also includes an intelligent control system, which controls the operation of the electric roller (4) based on multiple sensors. The cooling connection mechanism has the following structure: it includes an embedded connecting pipe (8), a through connecting pipe (9), a sealing adapter (10), and a circulation pipe (11). The plug-in bracket (3) is provided with an embedded connecting pipe (8) on the side away from the electrical box (5). The through connecting pipe (9) is provided through the side of the conveyor support (1) on the same side. One end of the embedded connecting pipe (8) is connected to the internal liquid cooling structure of the electric roller (4). The other end of the embedded connecting pipe (8) corresponds to the through connecting pipe (9) and is sealed and quickly adapted by the sealing adapter (10). The outer end of the through connecting pipe (9) is connected to the circulation pipe (11). A tray bracket (12) is provided on the conveyor support (1) on one side of the circulation pipe (11). The circulation pipe (11) is clamped. The control valve (13) is provided on the through connecting pipe (9) and fixed on the tray frame (12); the embedded connecting pipe (8), the through connecting pipe (9) and the circulation pipe (11) are each provided in two sets, which are used for water inlet and water outlet circulation respectively. The through connecting pipe (9) is connected to the two sets of the circulation pipes (11), and the end of the circulation pipe (11) is connected to the coolant circulation equipment; the intelligent control system includes a parameter acquisition module, an analysis and processing module and a control module. The parameter acquisition module acquires various operating parameters of the electric roller (4) based on multiple sensors set in the electric roller (4). The analysis and processing module is used to analyze and process the acquired parameters and make fault judgments. The control module is used to control the electric roller (4) according to the judgment results. The operation of the roller (4) is regulated and controlled; multiple sensors include a speed sensor, a pressure sensor, and a temperature sensor. The speed sensor is used to monitor the speed and fluctuation of the electric roller (4). The pressure sensor is used to monitor the load pressure when the electric roller (4) is running. The temperature sensor is used to monitor the internal operating temperature of the electric roller (4) and the cooling connection mechanism is controlled by the control module. The analysis and processing module includes a data processing submodule, an anomaly judgment submodule, and a control calculation submodule. The data processing submodule is used to perform noise reduction and enhancement processing on the received sensor data. The anomaly judgment submodule automatically judges and identifies operating anomalies based on a threshold judgment model and generates display prompts. The control module calculates and outputs the operating parameter compensation data of several groups of electric rollers (4) adjacent to the abnormal electric roller (4) based on the compensation calculation model and the abnormal operating data. The control module includes a fault prompting submodule and a data conversion submodule. The fault prompting submodule is used to control the indicator light (7) to flash and change to issue a prompt when the analysis and processing module judges that there is an abnormality. The data conversion submodule is used to convert the data output by the analysis and processing module into the control signal of the electric roller (4) and send it to control its execution. The load of the electric roller (4) is detected by the pressure sensor. When zero load is detected, the electric roller (4) is controlled to stop rotating. When load is detected, the electric roller (4) is started to transfer material.

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