Material conveying system interlocking control method, device, equipment and medium

Abstract

The application provides a material conveying system interlocking control method, device, equipment and medium, belonging to the technical field of material conveying equipment control. The method comprises: monitoring the fault input IO point state fault input IO point state, drive motor current and ultrasonic signal of the current belt conveyor, and the deflection angle of the material distribution mechanism of the upstream belt conveyor, and analyzing the running state of the belt conveyor. According to the analysis result, it is judged whether the belt conveyor exists fault, material state and material receiving state. At the same time, the current and ultrasonic signal of the upstream belt conveyor are monitored to evaluate the material state thereof. Comprehensive these information, the running of the current belt conveyor or the whole belt conveyor system is controlled to prevent fault or improper operation. The application can significantly improve the safety, flexibility and running efficiency of the material conveying system.

Description

Technical Field

[0001] This invention relates to the field of material conveying equipment control technology, specifically to a material conveying system interlocking control method, a material conveying system interlocking control device, an electronic device, and a computer-readable storage medium. Background Technology

[0002] Belt conveyors are widely used material conveying equipment in mines, ports, power plants, and other fields. A typical production line consists of multiple belt conveyors, transporting materials from source to destination. To ensure the safe and stable operation of the belt conveyor line, interlocking relationships need to be established between the belt conveyors to achieve coordinated control between upstream and downstream conveyors.

[0003] Currently, traditional belt conveyor interlocking systems control the operating path of the belt conveyors through preset process numbers. In this interlocking relationship, if the downstream belt conveyor stops due to a malfunction or other reasons, the upstream belt conveyor will immediately stop operating to prevent material blockage or further damage. The connection between belt conveyors is usually achieved through a transfer funnel, a device that can change the direction of material flow, typically with one inlet and two or three outlets. Baffles inside the funnel are used to control the flow direction of material. When the belt conveyor process starts or runs, the traditional interlocking logic monitors the position signals of the baffles between the upstream and downstream belt conveyors in real time. If the baffle position signal does not indicate a connected state, the system will immediately activate the interlocking shutdown mechanism to ensure safety and smooth process operation.

[0004] However, the existing belt conveyor interlocking system has the following problems: (1) Over-interlocking: Any failure of the downstream belt conveyor will cause all the upstream belt conveyors to stop immediately. Even if the failure is minor or there is no material upstream, this practice is unnecessary and affects production efficiency; (2) Rigid control: The interlocking method is fixed. When changing the process, all belt conveyors need to be stopped and the interlocking needs to be re-selected and established, which is inefficient; (3) Complex process switching: When switching between different processes, even if there are shared belt conveyors, it is necessary to stop the machines step by step according to the set cycle, wait for the motor to cool down, and then start the new process step by step. Online switching cannot be achieved, mainly due to the limitations of the traditional interlocking method.

[0005] In summary, existing belt conveyor interlocking systems suffer from problems such as excessive interlocking, lack of control flexibility, and complex process switching. Summary of the Invention

[0006] The purpose of this invention is to provide a method, device, equipment and medium for interlocking control of a material conveying system, so as to solve the problems of excessive interlocking, lack of control flexibility and complex process switching in existing belt conveyor interlocking systems.

[0007] To achieve the above objectives, embodiments of the present invention provide an interlocking control method for a material conveying system. The material conveying system includes multiple belt conveyors, and a material distribution mechanism is provided between each belt conveyor. Acquire the current status of the fault input I / O points of the belt conveyor, the drive motor current signal and ultrasonic signal, as well as the deflection angles of multiple material distribution mechanisms between the current belt conveyor and the upstream belt conveyor; Based on the current fault input I / O point status of the belt conveyor, the drive motor current signal, the ultrasonic signal, and the preset material receiving conditions, determine the current fault status, material status, and material receiving status of the belt conveyor. Based on the deflection angles of multiple material distribution mechanisms between the current conveyor and the upstream conveyor, the upstream conveyor interlocked with the current conveyor is determined, and the drive motor current signal and ultrasonic signal of the upstream conveyor interlocked with the current conveyor are acquired. Based on the drive motor current signal and ultrasonic signal of the upstream conveyor belt that is interlocked with the current conveyor belt, the material status of the upstream conveyor belt that is interlocked with the current conveyor belt is determined. Based on the current fault status of the belt conveyor, the current material status of the belt conveyor, the material status of the upstream belt conveyor interlocked with the current belt conveyor, and the receiving status of the current belt conveyor, control the current belt conveyor to stop running or control the current belt conveyor and all upstream belt conveyors of the current belt conveyor to stop running.

[0008] Optionally, based on the current fault input I / O point status of the belt conveyor, the drive motor current signal, the ultrasonic signal, and the preset material receiving conditions, the current fault status, material status, and material receiving status of the belt conveyor are determined, including: Determine the current fault status of the belt conveyor based on the current status of the fault input I / O points. Based on the current drive motor current signal and ultrasonic signal of the belt conveyor, the current material state of the belt conveyor is determined. The current material receiving status of the belt conveyor is determined by analyzing the preset material receiving conditions.

[0009] Optionally, the fault state of the belt conveyor is determined based on the current fault input I / O point status, including: If the current fault input IO point status of the belt conveyor is any one of the preset major fault input signals, and the current fault input IO point status of the belt conveyor meets the preset value, then the current fault status of the belt conveyor is determined to be a major fault; among which, the preset major fault input signals include: emergency stop of the control box, counterweight drop detection, material blockage, emergency stop of personnel pulling rope, belt misalignment detection, and belt tear detection. If the current fault input I / O point status of the belt conveyor is any one of the preset ordinary fault input signals, and the current fault input I / O point status of the belt conveyor meets the preset value, then the current fault status of the belt conveyor is determined to be an ordinary fault. Among them, the preset ordinary fault input signals include: the current belt conveyor downstream distribution mechanism fault, the current belt conveyor downstream distribution mechanism position error, the current belt conveyor downstream distribution mechanism is running, the current belt conveyor slippage fault, and the current belt conveyor start failure.

[0010] Optionally, based on the current drive motor current signal and ultrasonic signal of the current belt conveyor, the current material state of the belt conveyor is determined, including: If the current drive motor current signal of the current belt conveyor is greater than the preset drive motor current signal, and the current ultrasonic signal of the current belt conveyor is greater than the preset ultrasonic signal, then the material status of the current belt conveyor is determined to be "material present"; or If the current drive motor current signal of the current belt conveyor is less than the preset drive motor current signal or the current ultrasonic signal of the current belt conveyor is less than the preset ultrasonic signal, then the material status of the current belt conveyor is determined to be no material.

[0011] Optionally, the preset material receiving conditions include: belt conveyor failure, belt conveyor not running, average material flow rate overload, interlock stop command, downstream baffle failure of belt conveyor, and the current position of the downstream baffle of belt conveyor being inconsistent with the target position. The current material receiving status of the belt conveyor is determined based on preset material receiving conditions, including: If the current belt conveyor meets any of the preset conditions, then the current material receiving status of the belt conveyor is determined to be unfeedable. If the current belt conveyor does not meet the preset conditions, then the current material receiving status of the belt conveyor is determined to be that it can receive materials.

[0012] Optionally, the upstream belt conveyor includes: a first upstream belt conveyor and a second upstream belt conveyor; Based on the deflection angles of multiple material distribution mechanisms between the current conveyor and the upstream conveyor, the upstream conveyors interlocked with the current conveyor are determined, including: For each material distribution mechanism: Obtain the deflection angle of the material distribution mechanism; If the deflection angle of the material distribution mechanism is greater than the first deflection angle and less than the second deflection angle, then the second upstream conveyor belt is determined to be the upstream conveyor belt interlocked with the current conveyor belt. If the deflection angle of the material distribution mechanism is greater than the second deflection angle and less than the third deflection angle, then the first upstream conveyor belt is determined to be the upstream conveyor belt interlocked with the current conveyor belt; wherein, the first deflection angle < the second deflection angle < the third deflection angle.

[0013] Optionally, based on the current fault status of the conveyor belt, the current material status of the conveyor belt, the material status of the upstream conveyor belts interlocked with the current conveyor belt, and the receiving status of the current conveyor belt, control the current conveyor belt to stop operating or control the current conveyor belt and all upstream conveyor belts to stop operating, including: If the current conveyor belt is in a critical fault condition, then control the current conveyor belt and all conveyor belts upstream of the current conveyor belt to stop operating; If the current belt conveyor is in a normal fault state, and the upstream belt conveyor connected to the current belt conveyor is in a material state, then control the current belt conveyor and all upstream belt conveyors to stop running; If the current belt conveyor is in a normal fault state, and the upstream belt conveyor that is interlocked with the current belt conveyor is empty, then control the current belt conveyor to stop running; If the current material receiving status of the belt conveyor is "feedable", then replace the current belt conveyor with the downstream belt conveyor of the current belt conveyor, and return to the steps of obtaining the drive motor current signal and ultrasonic signal of the current belt conveyor, as well as the position status of the material distribution mechanism between the current belt conveyor and the upstream belt conveyor. If the current material receiving status of the belt conveyor is "unable to receive material" and the current material status of the belt conveyor is "material present", then control the current belt conveyor to stop running; If the current conveyor belt is empty and the upstream conveyor belt that is interlocked with the current conveyor belt is full, then control the current conveyor belt and all upstream conveyor belts to stop running. If the material status of the upstream conveyor belt in the current belt conveyor chain is empty, then replace the current conveyor belt with the downstream conveyor belt and return to the steps of obtaining the drive motor current signal and ultrasonic signal of the current conveyor belt, as well as the position status of the material distribution mechanism between the current conveyor belt and the upstream conveyor belt.

[0014] In a second aspect of the present invention, an interlocking control device for a material conveying system is provided. The material conveying system includes multiple belt conveyors, and a material distribution mechanism is provided between each belt conveyor. The data acquisition module is used to acquire the current status of the fault input IO points of the belt conveyor, the drive motor current signal and ultrasonic signal, as well as the deflection angle of multiple material distribution mechanisms between the current belt conveyor and the upstream belt conveyor. The first determination module is used to analyze the current belt conveyor based on the current fault input IO point status, drive motor current signal, ultrasonic signal and preset material receiving conditions, and determine the current fault status, material status and material receiving status of the belt conveyor. The interlocking determination module is used to determine the upstream conveyor interlocked with the current conveyor based on the deflection angles of multiple material distribution mechanisms between the current conveyor and the upstream conveyor, and to acquire the drive motor current signal and ultrasonic signal of the upstream conveyor interlocked with the current conveyor. The second determining module is used to determine the material status of the upstream conveyor belt that is interlocked with the current conveyor belt based on the drive motor current signal and ultrasonic signal of the upstream conveyor belt that is interlocked with the current conveyor belt. The control and operation module is used to control the current belt conveyor to stop running or to control the current belt conveyor and all belt conveyors upstream of the current belt conveyor to stop running based on the fault status of the current belt conveyor, the material status of the current belt conveyor, the material status of the upstream belt conveyor interlocked with the current belt conveyor, and the material receiving status of the current belt conveyor.

[0015] In a third aspect of the present invention, an electronic device is provided, comprising: a processor and a memory, the memory storing machine-readable instructions executable by the processor, wherein the machine-readable instructions, when executed by the processor, perform the above-described material conveying system interlocking control method.

[0016] In a fourth aspect of the present invention, a computer-readable storage medium is provided, which stores computer instructions that, when executed on a computer, cause the computer to perform the above-described material conveying system interlocking control method.

[0017] The beneficial effects of this invention are: (1) Refinement of fault diagnosis: The new method can more accurately diagnose the fault status of the belt conveyor by analyzing the status of the fault input IO points, and classify them into ordinary faults and major faults, so that more precise countermeasures can be taken.

[0018] (2) Dual detection of material status: The new method not only uses the current signal of the drive motor, but also the ultrasonic signal to determine the current material status of the belt conveyor. Dual detection improves the accuracy of material status judgment.

[0019] (3) Intelligent judgment of material receiving status: The new method analyzes the current belt conveyor through preset material receiving conditions, and can intelligently judge the current material receiving status of the belt conveyor, thereby avoiding problems such as material blockage caused by poor material receiving status.

[0020] (4) Application of the deflection angle of the material distribution mechanism: The new method can determine the upstream belt conveyor that is interlocked with the current belt conveyor by analyzing the deflection angle of the material distribution mechanism, thereby achieving more precise interlock control.

[0021] (5) Intelligent interlocking control: The new method monitors the operating status of the belt conveyor in real time, including fault status, material and receiving conditions, and intelligently controls the start and stop of the belt conveyor or its upstream equipment, effectively preventing the risk of material blockage and further equipment damage, and significantly improving the safety of the system.

[0022] (6) Dynamic adjustment: The new method can monitor the operating status of the belt conveyor in real time and dynamically adjust the interlocking relationship, making the material conveying system more flexible and adaptable.

[0023] (7) Efficiency improvement: The new method can effectively reduce downtime due to faults and improve the operating efficiency of the material conveying system through accurate fault diagnosis and intelligent interlocking control.

[0024] Other features and advantages of the embodiments of the present invention will be described in detail in the following detailed description section. Attached Figure Description

[0025] The accompanying drawings are provided to further illustrate embodiments of the present invention and form part of the specification. They are used together with the following detailed description to explain the embodiments of the present invention, but do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic flowchart of the material conveying system interlocking control method provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the material conveying system provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of the interlocking control device for the material conveying system provided in an embodiment of the present invention. Detailed Implementation

[0026] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the scope of the present invention.

[0027] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit this application.

[0028] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0029] Example 1 Please refer to Figure 1 , Figure 1 This is a flowchart illustrating the interlocking control method for a material conveying system provided in an embodiment of the present invention. The method includes the following steps: S100: Obtain the current status of the fault input IO point of the belt conveyor, the drive motor current signal and ultrasonic signal, as well as the deflection angle of multiple material distribution mechanisms between the current belt conveyor and the upstream belt conveyor. The material conveying system includes multiple belt conveyors, such as Figure 2 As shown, multiple belt conveyors, including conveyors A1, B1, C1, D1, D2, and E1, are connected by a material distribution mechanism. Additionally, a transfer funnel is provided between each belt conveyor.

[0030] The current fault input I / O point status of the belt conveyor refers to the status of fault input I / O points that occur during the operation of the belt conveyor. It reflects the operating status and stability of the belt conveyor. By monitoring the fault input I / O point status, faults such as imbalance, misalignment, and looseness of the equipment can be detected in a timely manner, thereby ensuring the continuity and safety of production.

[0031] The drive motor current signal of a belt conveyor refers to the current signal generated by the motor driving the belt conveyor during operation. The motor current signal can reflect the motor's load condition and operating efficiency. By analyzing the current signal, it is possible to determine whether the motor is in an overload, underload, or normal operating state, thereby enabling equipment maintenance and adjustment.

[0032] The ultrasonic signals currently used in belt conveyors refer to the ultrasonic signals generated during belt conveyor operation. These signals can be used to detect internal defects in the belt conveyor, such as cracks and holes, as well as to monitor the operating status of bearings and gears. By analyzing the ultrasonic signals, potential equipment failures can be predicted, allowing for timely maintenance and replacement.

[0033] The deflection angle of the material distribution mechanism between the current conveyor belt and the upstream conveyor belt refers to the deflection angle of the material distribution mechanism when distributing materials between the two conveyor belts. By adjusting the deflection angle, the flow direction of the material can be controlled.

[0034] S200 determines the current fault status, material status, and receiving status of the belt conveyor based on the current fault input IO point status, drive motor current signal, ultrasonic signal, and preset receiving conditions. In one embodiment, step S200 may include: S210, Determine the current fault status of the belt conveyor based on the current fault input IO point status; Specifically, step S210 includes: If the current fault input IO point status of the belt conveyor is any one of the preset major fault input signals, and the current fault input IO point status of the belt conveyor meets the preset value, then the current fault status of the belt conveyor is determined to be a major fault; among which, the preset major fault input signals include: emergency stop of the control box, counterweight drop detection, material blockage, emergency stop of personnel pulling rope, belt misalignment detection, and belt tear detection. If the current fault input I / O point status of the belt conveyor is any one of the preset ordinary fault input signals, and the current fault input I / O point status of the belt conveyor meets the preset value, then the current fault status of the belt conveyor is determined to be an ordinary fault. Among them, the preset ordinary fault input signals include: the current belt conveyor downstream distribution mechanism fault, the current belt conveyor downstream distribution mechanism position error, the current belt conveyor downstream distribution mechanism is running, the current belt conveyor slippage fault, and the current belt conveyor start failure.

[0035] S220, based on the current drive motor current signal and ultrasonic signal of the belt conveyor, determines the current material status of the belt conveyor; Specifically, an ultrasonic sensor is installed at the inlet of the conveyor belt. The sensor should be positioned above the inlet, at a certain height from the belt surface, to avoid interference or damage. The ultrasonic sensor is a wireless contact detection device that utilizes the principle of ultrasonic wave reflection. It emits ultrasonic waves of a specific frequency and receives the reflected signals. Based on the signal strength and time difference, it determines whether material is present in the detection area. The ultrasonic sensor's output signal can be a digital or analog signal. This invention uses a digital output signal, meaning it outputs a high level when material is detected and a low level otherwise.

[0036] Specifically, by collecting the drive motor current of the belt conveyor, it can be determined whether there is material on the operating belt conveyor. Drive motor current refers to the current consumed by the motor that drives the belt conveyor. It has a positive correlation with the material load on the belt conveyor; that is, when there is material on the belt conveyor, the drive motor current increases, and vice versa. By setting a reasonable current threshold, the magnitude of the drive motor current can be used to determine whether there is material on the currently operating belt conveyor. The drive motor current can be collected by installing a current transformer in the motor circuit. The current transformer converts the AC current in the motor circuit into a proportional AC voltage signal and outputs it to the PLC for processing.

[0037] In one embodiment, the presence of material on the conveyor belt can also be determined by means of detection such as belt scales, lidar, mercury level gauges, and cameras.

[0038] Specifically, step S220 includes: S221, if the current drive motor current signal of the current belt conveyor is greater than the preset drive motor current signal, and the current ultrasonic signal of the current belt conveyor is greater than the preset ultrasonic signal, then the material status of the current belt conveyor is determined to be "material present"; or S222, if the current drive motor current signal of the current belt conveyor is less than the preset drive motor current signal or the current ultrasonic signal of the current belt conveyor is less than the preset ultrasonic signal, then the material status of the current belt conveyor is determined to be no material.

[0039] In this embodiment, using two signals together to determine whether there is material on the belt conveyor can avoid the limitations caused by the failure of a single signal, thereby ensuring a more accurate determination of the material status.

[0040] S230, Analyze the current belt conveyor based on preset material receiving conditions to determine the current material receiving status of the belt conveyor; Preset material receiving conditions include, but are not limited to: belt conveyor failure, not running, average material flow rate overload, interlock stop command, downstream baffle failure of belt conveyor, and the current position of the downstream baffle of belt conveyor being inconsistent with the target position.

[0041] Understandably, by analyzing the current conveyor belt under preset material receiving conditions, it can be determined whether the current conveyor belt has the ability to transport materials normally.

[0042] Specifically, step S230 includes: S231, If ​​the current belt conveyor meets any of the preset conditions, then the current belt conveyor's material receiving status is determined to be unfeedable. S232, if the current belt conveyor does not meet the preset conditions, then the current material receiving status of the belt conveyor is determined to be that it can receive materials.

[0043] S300 determines the upstream conveyor belt interlocked with the current conveyor belt based on the deflection angles of multiple material distribution mechanisms between the current conveyor belt and the upstream conveyor belt, and acquires the drive motor current signal and ultrasonic signal of the upstream conveyor belt interlocked with the current conveyor belt. It is understandable that the current belt conveyor may have material distribution mechanisms with multiple upstream belt conveyors, but the logic of determining which upstream belt conveyor the current belt conveyor is interlocked with by the deflection angle of the material distribution mechanism is the same. Therefore, the following explanation focuses on a specific material distribution mechanism.

[0044] In one embodiment, step S300 may include: S310, obtain the deflection angle of the material distribution mechanism; In one specific embodiment, the material dispensing mechanism can be a baffle, such as... Figure 2As shown. The deflection angle of the baffle can be obtained by installing a tilt sensor on the baffle, and then measuring and outputting the deflection angle of the baffle in real time.

[0045] The upstream belt conveyors include: a first upstream belt conveyor and a second upstream belt conveyor. Specifically, as follows... Figure 2 As shown, D1 is the first upstream belt conveyor, and D2 is the second upstream belt conveyor.

[0046] In this embodiment, as Figure 2 As shown, the deflection angle of the baffle refers to the angle between the baffle and one side of the first upstream conveyor belt D1 at different positions. When the baffle is on one side of the first upstream conveyor belt D1, the deflection angle is the first deflection angle, which is 0 degrees. When the baffle is in the middle position between the first upstream conveyor belt D1 and the second upstream conveyor belt D2, the deflection angle is the second deflection angle, which is 90 degrees. When the baffle is on one side of the second conveyor belt D2, the deflection angle is the third deflection angle, which is 180 degrees. The first deflection angle < the second deflection angle < the third deflection angle.

[0047] S320, if the deflection angle of the material distribution mechanism is greater than the first deflection angle and less than the second deflection angle, then the second upstream conveyor belt is determined to be the upstream conveyor belt interlocked with the current conveyor belt. Specifically, such as Figure 2 As shown, when the deflection angle of the baffle is greater than 0 degrees and less than 90 degrees, it means that the baffle is blocking the first upstream conveyor belt D1. Therefore, the first upstream conveyor belt D1 cannot be interlocked with the current conveyor belt E1. Thus, the second upstream conveyor belt D2 is the upstream conveyor belt interlocked with the current conveyor belt E1.

[0048] S330, if the deflection angle of the material distribution mechanism is greater than the second deflection angle and less than the third deflection angle, then the first upstream belt conveyor is determined to be the upstream belt conveyor interlocked with the current belt conveyor; wherein, the first deflection angle < the second deflection angle < the third deflection angle.

[0049] Specifically, such as Figure 2 As shown, when the deflection angle of the baffle is greater than 90 degrees and less than 180 degrees, it means that the baffle is blocking the second upstream conveyor belt D2. Therefore, the second upstream conveyor belt D2 cannot be interlocked with the current conveyor belt E1. Thus, the first upstream conveyor belt D1 is the upstream conveyor belt interlocked with the current conveyor belt E1.

[0050] It should be noted that the above definitions of the first deflection angle, the second deflection angle, and the third deflection angle are merely illustrative examples. The specific sizes can be reasonably set according to the actual application scenario (the situation of the baffle, the setting requirements of the personnel). Therefore, this invention does not impose any specific limitations on them.

[0051] S400 determines the material status of the upstream conveyor belt that is interlocked with the current conveyor belt based on the drive motor current signal and ultrasonic signal of the upstream conveyor belt that is interlocked with the current conveyor belt. Regarding how to determine the material status of the upstream conveyor belt that is interlocked with the current conveyor belt, please refer to the method for determining the material status of the current conveyor belt in step S220 above, which will not be repeated here.

[0052] S500, based on the current fault status of the belt conveyor, the current material status of the belt conveyor, the material status of the upstream belt conveyor interlocked with the current belt conveyor, and the current receiving status of the belt conveyor, controls the current belt conveyor to stop running or controls the current belt conveyor and all upstream belt conveyors to stop running.

[0053] Specifically, in step S500, the controller controlling the operation of the belt conveyor can be a PLC, DCS, or a high-level language program in an industrial control computer, etc. These controllers perform logical operations and control on various input signals through user-defined programs, and output corresponding control signals to the actuators to achieve automatic control of the equipment. In this embodiment of the invention, it is necessary to receive input signals from ultrasonic sensors and current transformers, as well as signals related to the belt conveyor's own operation, faults, and baffle positions. The interlocking relationships between belt conveyors are dynamically adjusted according to different material conditions and baffle positions, and corresponding control signals are output to start or stop the belt conveyor.

[0054] In one embodiment, step S500 may include: S510, if the current belt conveyor's fault status is a major fault, then control the current belt conveyor and all belt conveyors upstream of the current belt conveyor to stop running; Specifically, a major malfunction can affect the normal operation of a belt conveyor and may even lead to safety issues. Stopping all affected belt conveyors is to prevent the malfunction from spreading, protect equipment and personnel safety, and facilitate maintenance and inspection.

[0055] S520: If the current belt conveyor's fault status is a normal fault, and the material status of the upstream belt conveyor interlocked with the current belt conveyor is material, then control the current belt conveyor and all belt conveyors upstream of the current belt conveyor to stop running. Specifically, if there is material on the upstream conveyor belt, continued operation may exacerbate the malfunction or cause material accumulation, affecting production efficiency and product quality. Stopping operation can prevent the situation from worsening and provide conditions for maintenance.

[0056] S530: If the current belt conveyor's fault status is a normal fault, and the upstream belt conveyor interlocked with the current belt conveyor is out of material, then control the current belt conveyor to stop running. Specifically, if the upstream conveyor belt is out of material, the current conveyor belt stopping will not affect the material flow, and the fault can be handled separately without affecting the operation of other conveyor belts.

[0057] S540, if the current material receiving status of the belt conveyor is that it can receive material, then replace the current belt conveyor with the downstream belt conveyor of the current belt conveyor, and return to the step of obtaining the drive motor current signal and ultrasonic signal of the current belt conveyor, as well as the position status of the material distribution mechanism between the current belt conveyor and the upstream belt conveyor. Specifically, if the current conveyor belt can pick up material, the downstream conveyor belt may become the new control focus because material needs to continue flowing to maintain the continuous operation of the production line. Transferring control to the downstream conveyor belt and acquiring motor current and ultrasonic signals can help monitor the system status, ensuring the continuity of material flow and the normal operation of the equipment. At the same time, understanding the position and status of the material distribution mechanism helps adjust the material flow direction and optimize the efficiency of the entire conveying system.

[0058] S550: If the current material receiving status of the belt conveyor is "unable to receive material" and the current material status of the belt conveyor is "material present", then control the current belt conveyor to stop running. Specifically, if the conveyor belt is currently in a non-receiving state but there is still material present, continued operation may lead to material accumulation or overflow, affecting work environment safety and work efficiency. Stopping operation can prevent further material conveying until the receiving state returns to normal or the material is cleared.

[0059] S560, if the current material status of the belt conveyor is empty, and the material status of the upstream belt conveyor interlocked with the current belt conveyor is full, then control the current belt conveyor and all belt conveyors upstream of the current belt conveyor to stop running; Specifically, if the current conveyor belt is empty, but the upstream conveyor belt is still conveying material, the material may accumulate at the starting point of the current conveyor belt or damage the equipment. Meanwhile, if downstream equipment is unable to receive material for any reason, continuing to operate the entire production line is unnecessary and may result in wasted resources. Therefore, stopping the entire interlocking conveyor belt system can prevent these problems and allow operators to make necessary adjustments or maintenance.

[0060] S570, if the material status of the upstream conveyor of the current conveyor chain is no material, then replace the current conveyor with the downstream conveyor of the current conveyor, and return to the step of obtaining the drive motor current signal and ultrasonic signal of the current conveyor, as well as the position status of the material distribution mechanism between the current conveyor and the upstream conveyor.

[0061] Specifically, when the upstream conveyor belt is empty, the downstream conveyor belt may become the new control focus because material needs to continue flowing to maintain the continuous operation of the production line. Transferring control to the downstream conveyor belt and acquiring motor current and ultrasonic signals can help monitor the system status, ensuring the continuity of material flow and the normal operation of the equipment. Simultaneously, understanding the position and status of the material distribution mechanism helps adjust the material flow direction and optimize the efficiency of the entire conveying system.

[0062] The beneficial effects of this invention are: (1) Refinement of fault diagnosis: The new method can more accurately diagnose the fault status of the belt conveyor by analyzing the status of the fault input IO points, and classify them into ordinary faults and major faults, so that more precise countermeasures can be taken.

[0063] (2) Dual detection of material status: The new method not only uses the current signal of the drive motor, but also the ultrasonic signal to determine the current material status of the belt conveyor. Dual detection improves the accuracy of material status judgment.

[0064] (3) Intelligent judgment of material receiving status: The new method analyzes the current belt conveyor through preset material receiving conditions, and can intelligently judge the current material receiving status of the belt conveyor, thereby avoiding problems such as material blockage caused by poor material receiving status.

[0065] (4) Application of the deflection angle of the material distribution mechanism: The new method can determine the upstream belt conveyor that is interlocked with the current belt conveyor by analyzing the deflection angle of the material distribution mechanism, thereby achieving more precise interlock control.

[0066] (5) Intelligent interlocking control: The new method monitors the operating status of the belt conveyor in real time, including fault status, material and receiving conditions, and intelligently controls the start and stop of the belt conveyor or its upstream equipment, effectively preventing the risk of material blockage and further equipment damage, and significantly improving the safety of the system.

[0067] (6) Dynamic adjustment: The new method can monitor the operating status of the belt conveyor in real time and dynamically adjust the interlocking relationship, making the material conveying system more flexible and adaptable.

[0068] (7) Efficiency improvement: The new method can effectively reduce downtime due to faults and improve the operating efficiency of the material conveying system through accurate fault diagnosis and intelligent interlocking control.

[0069] Example 2 Based on the same inventive concept, such as Figure 3 As shown, this embodiment of the invention also provides a material conveying system interlocking control device 200. The material conveying system includes multiple belt conveyors, and a material distribution mechanism is provided between each belt conveyor, including: The data acquisition module 210 is used to acquire the current status of the fault input IO point of the belt conveyor, the drive motor current signal and ultrasonic signal, as well as the deflection angle of multiple material distribution mechanisms between the current belt conveyor and the upstream belt conveyor. The first determining module 220 is used to analyze the current belt conveyor based on the current fault input IO point status, drive motor current signal, ultrasonic signal and preset material receiving conditions, and determine the current fault status, material status and material receiving status of the belt conveyor. The interlocking determination module 230 is used to determine the upstream belt conveyor interlocked with the current belt conveyor based on the deflection angle of multiple material distribution mechanisms between the current belt conveyor and the upstream belt conveyor, and to acquire the drive motor current signal and ultrasonic signal of the upstream belt conveyor interlocked with the current belt conveyor. The second determining module 240 is used to determine the material status of the upstream belt conveyor that is interlocked with the current belt conveyor based on the drive motor current signal and ultrasonic signal of the upstream belt conveyor that is interlocked with the current belt conveyor. The control operation module 250 is used to control the current belt conveyor to stop running or to control the current belt conveyor and all belt conveyors upstream of the current belt conveyor to stop running based on the fault status of the current belt conveyor, the material status of the current belt conveyor, the material status of the upstream belt conveyor interlocked with the current belt conveyor, and the material receiving status of the current belt conveyor.

[0070] It should be understood that this device corresponds to the above-described material conveying system interlocking control method embodiment and is capable of executing the various steps involved in the above method embodiment. The specific functions of this device can be found in the description above, and detailed descriptions are omitted here to avoid repetition. The device includes at least one software function module that can be stored in memory or embedded in the device's operating system (OS) in the form of software or firmware.

[0071] Example 3 Based on the same inventive concept, embodiments of the present invention also provide an electronic device, including: a processor and a memory, wherein the memory stores machine-readable instructions executable by the processor, and when the machine-readable instructions are executed by the processor, the above-described material conveying system interlocking control method is performed.

[0072] In a typical configuration, an electronic device includes one or more processors (CPU), input / output interfaces, network interfaces, and memory.

[0073] Memory may include non-persistent memory in computer-readable media, such as random access memory (RAM) and / or non-volatile memory, such as read-only memory (ROM) or flash RAM. Memory is an example of computer-readable media.

[0074] Computer-readable media includes both permanent and non-permanent, removable and non-removable media that can store information using any method or technology. Information can be computer-readable instructions, data structures, modules of programs, or other data. Examples of computer storage media include, but are not limited to, phase-change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), other types of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technologies, CD-ROM, digital versatile optical disc (DVD) or other optical storage, magnetic tape, magnetic magnetic disk storage or other magnetic storage devices, or any other non-transferable medium that can be used to store information accessible by a computing device. As defined herein, computer-readable media does not include transient computer-readable media, such as modulated data signals and carrier waves.

[0075] Example 4 Based on the same inventive concept, embodiments of the present invention also provide a computer-readable storage medium storing computer instructions, which, when executed on a computer, cause the computer to perform the aforementioned material conveying system interlocking control method.

[0076] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0077] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0078] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0079] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0080] It should also be noted that the various specific technical features described in the above embodiments can be combined in any suitable manner without contradiction. To avoid unnecessary repetition, the embodiments of the present invention will not describe the various possible combinations separately.

[0081] In addition, the functional modules in the various embodiments of this application can be integrated together to form an independent part, or each module can exist independently, or two or more modules can be integrated to form an independent part.

[0082] It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0083] The above are merely embodiments of this application and are not intended to limit the scope of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.

Claims

1. A method for interlocking control of a material conveying system, the material conveying system comprising multiple belt conveyors, wherein a material distribution mechanism is provided between each belt conveyor, characterized in that, include: Acquire the current status of the fault input I / O points of the belt conveyor, the drive motor current signal and ultrasonic signal, as well as the deflection angles of multiple material distribution mechanisms between the current belt conveyor and the upstream belt conveyor; Based on the current fault input I / O point status of the belt conveyor, the drive motor current signal, the ultrasonic signal, and the preset material receiving conditions, determine the current fault status, material status, and material receiving status of the belt conveyor. Based on the deflection angles of multiple material distribution mechanisms between the current conveyor and the upstream conveyor, the upstream conveyor interlocked with the current conveyor is determined, and the drive motor current signal and ultrasonic signal of the upstream conveyor interlocked with the current conveyor are acquired. Based on the drive motor current signal and ultrasonic signal of the upstream conveyor belt that is interlocked with the current conveyor belt, the material status of the upstream conveyor belt that is interlocked with the current conveyor belt is determined. Based on the current fault status of the belt conveyor, the current material status of the belt conveyor, the material status of the upstream belt conveyor interlocked with the current belt conveyor, and the receiving status of the current belt conveyor, control the current belt conveyor to stop running or control the current belt conveyor and all upstream belt conveyors of the current belt conveyor to stop running.

2. The material conveying system interlocking control method according to claim 1, characterized in that, Based on the current fault input I / O point status of the belt conveyor, the drive motor current signal, the ultrasonic signal, and the preset material receiving conditions, determine the current fault status, material status, and material receiving status of the belt conveyor, including: Determine the current fault status of the belt conveyor based on the current status of the fault input I / O points. Based on the current drive motor current signal and ultrasonic signal of the belt conveyor, the current material state of the belt conveyor is determined. The current material receiving status of the belt conveyor is determined by analyzing the preset material receiving conditions.

3. The material conveying system interlocking control method according to claim 2, characterized in that, Based on the current fault input I / O point status of the belt conveyor, determine the current fault status of the belt conveyor, including: If the current fault input IO point status of the belt conveyor is any one of the preset major fault input signals, and the current fault input IO point status of the belt conveyor meets the preset value, then the current fault status of the belt conveyor is determined to be a major fault; among which, the preset major fault input signals include: emergency stop of the control box, counterweight drop detection, material blockage, emergency stop of personnel pulling rope, belt misalignment detection, and belt tear detection. If the current fault input I / O point status of the belt conveyor is any one of the preset ordinary fault input signals, and the current fault input I / O point status of the belt conveyor meets the preset value, then the current fault status of the belt conveyor is determined to be an ordinary fault. Among them, the preset ordinary fault input signals include: the current belt conveyor downstream distribution mechanism fault, the current belt conveyor downstream distribution mechanism position error, the current belt conveyor downstream distribution mechanism is running, the current belt conveyor slippage fault, and the current belt conveyor start failure.

4. The material conveying system interlocking control method according to claim 2, characterized in that, Based on the current drive motor current signal and ultrasonic signal of the belt conveyor, the current material state of the belt conveyor is determined, including: If the current drive motor current signal of the current belt conveyor is greater than the preset drive motor current signal, and the current ultrasonic signal of the current belt conveyor is greater than the preset ultrasonic signal, then the material status of the current belt conveyor is determined to be "material present"; or If the current drive motor current signal of the current belt conveyor is less than the preset drive motor current signal or the current ultrasonic signal of the current belt conveyor is less than the preset ultrasonic signal, then the material status of the current belt conveyor is determined to be no material.

5. The material conveying system interlocking control method according to claim 2, characterized in that, The preset material receiving conditions include: belt conveyor failure, belt conveyor not running, average material flow rate overload, interlock stop command, downstream baffle failure of belt conveyor, and the current position of the downstream baffle of belt conveyor being inconsistent with the target position. The current material receiving status of the belt conveyor is determined based on preset material receiving conditions, including: If the current belt conveyor meets any of the preset conditions, then the current material receiving status of the belt conveyor is determined to be unfeedable. If the current belt conveyor does not meet the preset conditions, then the current material receiving status of the belt conveyor is determined to be that it can receive materials.

6. The material conveying system interlocking control method according to claim 1, characterized in that, The upstream conveyor belts include: the first upstream conveyor belt and the second upstream conveyor belt; Based on the deflection angles of multiple material distribution mechanisms between the current conveyor and the upstream conveyor, the upstream conveyors interlocked with the current conveyor are determined, including: For each material distribution mechanism: Obtain the deflection angle of the material distribution mechanism; If the deflection angle of the material distribution mechanism is greater than the first deflection angle and less than the second deflection angle, then the second upstream conveyor belt is determined to be the upstream conveyor belt interlocked with the current conveyor belt. If the deflection angle of the material distribution mechanism is greater than the second deflection angle and less than the third deflection angle, then the first upstream conveyor belt is determined to be the upstream conveyor belt interlocked with the current conveyor belt; wherein, the first deflection angle < the second deflection angle < the third deflection angle.

7. The interlocking control method for a material conveying system according to any one of claims 1-6, characterized in that, Based on the current fault status of the conveyor belt, the current material status of the conveyor belt, the material status of the upstream conveyor belts interlocked with the current conveyor belt, and the receiving status of the current conveyor belt, control the current conveyor belt to stop operating or control the current conveyor belt and all upstream conveyor belts to stop operating, including: If the current conveyor belt is in a critical fault condition, then control the current conveyor belt and all conveyor belts upstream of the current conveyor belt to stop operating; If the current belt conveyor is in a normal fault state, and the upstream belt conveyor connected to the current belt conveyor is in a material state, then control the current belt conveyor and all upstream belt conveyors to stop running; If the current belt conveyor is in a normal fault state, and the upstream belt conveyor that is interlocked with the current belt conveyor is empty, then control the current belt conveyor to stop running; If the current material receiving status of the belt conveyor is "feedable", then replace the current belt conveyor with the downstream belt conveyor of the current belt conveyor, and return to the steps of obtaining the drive motor current signal and ultrasonic signal of the current belt conveyor, as well as the position status of the material distribution mechanism between the current belt conveyor and the upstream belt conveyor. If the current material receiving status of the belt conveyor is "unable to receive material" and the current material status of the belt conveyor is "material present", then control the current belt conveyor to stop running; If the current conveyor belt is empty and the upstream conveyor belt that is interlocked with the current conveyor belt is full, then control the current conveyor belt and all upstream conveyor belts to stop running. If the material status of the upstream conveyor belt in the current belt conveyor chain is empty, then replace the current conveyor belt with the downstream conveyor belt and return to the steps of obtaining the drive motor current signal and ultrasonic signal of the current conveyor belt, as well as the position status of the material distribution mechanism between the current conveyor belt and the upstream conveyor belt.

8. An interlocking control device for a material conveying system, the material conveying system comprising multiple belt conveyors, each belt conveyor being connected by a material distribution mechanism, characterized in that... include: The data acquisition module is used to acquire the current status of the fault input IO points of the belt conveyor, the drive motor current signal and ultrasonic signal, as well as the deflection angle of multiple material distribution mechanisms between the current belt conveyor and the upstream belt conveyor. The first determination module is used to analyze the current belt conveyor based on the current fault input IO point status, drive motor current signal, ultrasonic signal and preset material receiving conditions, and determine the current fault status, material status and material receiving status of the belt conveyor. The interlocking determination module is used to determine the upstream conveyor interlocked with the current conveyor based on the deflection angles of multiple material distribution mechanisms between the current conveyor and the upstream conveyor, and to acquire the drive motor current signal and ultrasonic signal of the upstream conveyor interlocked with the current conveyor. The second determining module is used to determine the material status of the upstream conveyor belt that is interlocked with the current conveyor belt based on the drive motor current signal and ultrasonic signal of the upstream conveyor belt that is interlocked with the current conveyor belt. The control and operation module is used to control the current belt conveyor to stop running or to control the current belt conveyor and all belt conveyors upstream of the current belt conveyor to stop running based on the fault status of the current belt conveyor, the material status of the current belt conveyor, the material status of the upstream belt conveyor interlocked with the current belt conveyor, and the material receiving status of the current belt conveyor.

9. An electronic device, characterized in that, include: A processor and a memory, the memory storing machine-readable instructions executable by the processor, which, when executed by the processor, perform the material conveying system interlocking control method according to any one of claims 1-7.

10. A computer-readable storage medium storing computer instructions, characterized in that, When the computer instructions are executed on the computer, the computer performs the material conveying system interlocking control method according to any one of claims 1-7.

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