Automatic balance adjusting method for deviation rectifying device of belt conveyor

Abstract

The invention discloses an automatic balance adjusting method for a deviation rectifying device of a belt conveyor, and relates to the technical field related to conveyors. The method comprises the steps that basic information of a conveying belt of a target belt conveyor is obtained; correcting node optimization of the correcting device is carried out, and optimal correcting point location distribution is generated; a plurality of deviation rectifying devices located at a plurality of point positions are distributed and configured according to the optimal deviation rectifying point position; belt deviation monitoring is carried out at a plurality of point positions through a transmission roller, and deviation point positions, corresponding belt deviation amounts and corresponding target deviation correcting devices are generated; generating a balance pilot control vector; and driving the corresponding electric push rod to carry out deviation correction according to the balance guide control vector. The technical problems that due to the fact that deviation of a conveyor belt is difficult to accurately monitor in real time in an existing conveyor deviation rectifying device, the balance adjustment response speed is low, the adjustment precision is limited, and the deviation rectifying efficiency and accuracy of the conveyor deviation rectifying device are insufficient are solved, and the technical effect of improving the deviation rectifying efficiency and accuracy of the deviation rectifying device is achieved.

Description

Technical Field

[0001] The present application relates to the technical field related to conveyors, and in particular to an automatic balancing adjustment method for a deviation-correcting device of a belt conveyor. Background Art

[0002] In modern industrial automation and logistics transmission systems, belt conveyors are the core equipment for material handling. Their operating efficiency and stability are directly related to the efficiency of the entire production line. However, in actual applications, due to factors such as uneven material distribution, belt aging, installation errors, or dynamic interference during operation, the feeding belt of the belt conveyor often deviates, which not only reduces the conveying efficiency, but also may cause equipment failures and even safety accidents. How to effectively monitor and correct the belt deviation problem has become the key to improving the operating stability and safety of the belt conveyor. Existing methods for correcting belt deviation mostly use mechanical or hydraulic adjustment devices. These devices often require manual intervention, and it is difficult to achieve accurate monitoring and rapid correction of belt deviation, that is, it is difficult to capture the running status of the belt in real time, accurately judge whether the belt is deviating and the degree and direction of the deviation, and the balance adjustment accuracy and response speed are limited, and the maintenance cost is high, which reduces the correction efficiency and accuracy of the correction device, thereby affecting the operating stability and reliability of the belt conveyor.

[0003] At present, in the technologies related to the balance adjustment of conveyor correction devices, there is a technical problem that it is difficult to accurately and real-time monitor the conveyor belt deviation, which leads to slow balance adjustment response speed and limited adjustment accuracy, resulting in insufficient correction efficiency and accuracy of the conveyor correction device. Summary of the invention

[0004] The present application provides an automatic balancing adjustment method for a belt conveyor correction device, thereby solving the technical problem that it is difficult to accurately and in real time monitor the conveyor belt deviation in the existing conveyor correction device, which leads to slow balance adjustment response speed and limited adjustment accuracy, resulting in insufficient correction efficiency and accuracy of the conveyor correction device, thereby achieving the technical effect of improving the correction efficiency and accuracy of the correction device.

[0005] The present application provides an automatic balancing and adjustment method for a belt conveyor correction device, comprising: obtaining basic information of a feed belt of a target belt conveyor, wherein the basic information of the feed belt includes belt length, belt width, belt structure and running load; optimizing correction nodes of a correction device in combination with the belt length, belt width, belt structure and running load to generate an optimal correction point distribution; configuring a plurality of correction devices located at a plurality of points according to the optimal correction point distribution, wherein any correction device includes a conduction roller, a micro generator and an electric push rod; monitoring belt deviation at the plurality of points through the conduction rollers in the plurality of correction devices to generate offset points and corresponding belt deviation vectors, as well as corresponding target correction devices; performing deviation balance analysis on the electric push rod of the target correction device according to the belt deviation vector to generate a balance correction control vector; establishing a power generation module with the conduction roller and micro generator of the target correction device to drive the corresponding electric push rod to correct the deviation according to the balance correction control vector.

[0006] In a possible implementation, the correction nodes of the correction device are optimized in combination with the belt length, the belt width, the belt structure and the running load to generate an optimal correction point distribution, and the following processing is also performed: initialization correction points are configured; the belt length, the belt width, the belt structure and the running load are used as structural modeling data, and historical belt operation records are collected to establish a feed belt simulation model; the initialization correction points are loaded into the feed belt simulation model to perform belt operation simulation, and new points are established according to the simulation results; the optimal correction point distribution is generated using the new points and the initialization correction points.

[0007] In a possible implementation, the initialization correction point is configured and the following processing is performed: if the transportation mode of the conveyor belt is one-way transportation, the initialization correction point is the end of the belt; if the transportation mode of the conveyor belt is two-way transportation, the initialization correction point is the beginning and end of the belt.

[0008] In a possible implementation, the initialization correction point is loaded into the feed belt simulation model to perform belt operation simulation, and a new point is established based on the simulation result, and the following processing is performed: in the feed belt simulation model, an immediate response correction mechanism is set for the initialization correction point, and then multiple belt operation simulations are performed; based on the simulation results, multiple fitting points whose deviation frequency is higher than a preset frequency are collected; the distances from the multiple fitting points to the initialization correction point are calculated, and the first fitting point with the farthest distance is extracted; after adding the first fitting point to the immediate response correction mechanism, the simulation result is updated through the feed belt simulation model, and so on, until the updated simulation results show that the deviation frequency of all points is less than the preset frequency.

[0009] In a possible implementation, a plurality of correction devices located at a plurality of points are configured with the optimal correction point distribution, and the following processing is also performed: the conduction roller includes a first conduction roller and a second conduction roller, which are symmetrically distributed on both sides of the belt at the plurality of points; the electric push rod includes a first push rod and a second push rod, which are symmetrically distributed on both sides of the belt at the plurality of points; the conduction roller serves as a power source, is connected to the micro generator to form a power generation module, and provides electrical energy to drive the electric push rod.

[0010] In a possible implementation, the belt deviation is monitored at the multiple points by the conductive rollers in the multiple deviation correction devices to generate offset points and corresponding belt deviation vectors, and the following processing is performed: multiple groups of preset deviation vector samples are established; the conductive rollers are operated with the multiple groups of preset deviation vector samples, and multiple groups of rotation sensor samples are obtained by testing the rotation sensors inside the conductive rollers; wherein any group of rotation sensor samples includes a rotation speed and a rotation direction; a deviation identification model is established with a mapping relationship between the multiple groups of preset deviation vector samples and the multiple groups of rotation sensor samples; the belt deviation is monitored according to the rotation sensors inside the conductive rollers by the deviation identification model to generate the offset points and the belt deviation vectors.

[0011] In a possible implementation, the belt deviation vector is used to perform a deviation balance analysis on the electric push rod of the target correction device to generate a balance correction control vector, and the following processing is also performed: taking the running load as a constraint, multiple groups of belt correction samples are collected for the feed belt, and any group of belt correction samples includes a deviation vector sample and a corresponding balance correction control vector sample; the correction control model is trained with the multiple groups of belt correction samples; the belt deviation vector is subjected to a deviation balance analysis by the correction control model to generate the balance correction control vector.

[0012] In a possible implementation, a power generation module is established with the conduction roller and micro-generator of the target deviation correction device to drive the corresponding electric push rod to correct the deviation according to the balance correction control vector, and the following processing is also performed: the target deviation correction device also includes an inverter rectifier controller; the conduction roller of the target deviation correction device rotates to drive the micro-generator to generate electrical energy, and a control signal is issued according to the balance correction control vector through the inverter rectifier controller; the control signal is used to control the corresponding electric push rod to correct the deviation.

[0013] Through the automatic balancing and adjustment method of the belt conveyor correction device proposed in this application, it is intended to obtain the basic information of the feed belt of the target belt conveyor; optimize the correction nodes of the correction device to generate the optimal correction point distribution; configure multiple correction devices located at multiple points with the optimal correction point distribution; monitor the belt deviation at multiple points through the conduction roller, generate the offset point and the corresponding belt deviation vector, and the corresponding target correction device; generate the balance correction control vector; drive the corresponding electric push rod to correct the deviation according to the balance correction control vector. The technical problem that it is difficult to accurately and real-time monitor the conveyor belt deviation in the existing conveyor correction device is solved, which leads to slow response speed of balance adjustment and limited adjustment accuracy, resulting in insufficient correction efficiency and accuracy of the conveyor correction device, and achieves the technical effect of improving the correction efficiency and accuracy of the correction device. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to more clearly illustrate the technical solution of the embodiment of the present invention, the accompanying drawings of the embodiment of the present invention will be briefly introduced below. A flow chart is used in the present application to illustrate the operations performed by the system according to the embodiment of the present application. It should be understood that the preceding or following operations are not necessarily performed accurately in order. On the contrary, various steps can be processed in reverse order or simultaneously as needed. At the same time, other operations can also be added to these processes, or one or more operations can be removed from these processes.

[0015] Figure 1 A schematic flow chart of an automatic balancing adjustment method for a belt conveyor deviation correction device provided in an embodiment of the present application;

[0016] Figure 2 A schematic diagram of a flow chart for generating an optimal deviation correction point distribution in an automatic balancing adjustment method for a belt conveyor deviation correction device provided in an embodiment of the present application. DETAILED DESCRIPTION

[0017] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below.

[0018] In order to make the purpose, technical solutions and advantages of the present application clearer, the present application will be further described in detail below in conjunction with the accompanying drawings. The described embodiments should not be regarded as limiting the present application. All other embodiments obtained by ordinary technicians in the field without making creative work are within the scope of protection of this application.

[0019] In the following description, reference is made to "some embodiments", which describe a subset of all possible embodiments, but it is understood that "some embodiments" may be the same subset or different subsets of all possible embodiments, and may be combined with each other without conflict, and the terms "first\second" involved are merely to distinguish similar objects and do not represent a specific ordering of objects. The terms "including" and "having" and any variations are intended to cover non-exclusive inclusions, for example, a process, method, system, product, or server that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or modules that are not clearly listed or inherent to these processes, methods, products, or devices. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those generally understood by technicians in the technical field of this application. The terms used herein are for the purpose of describing the embodiments of the present application only.

[0020] The embodiment of the present application provides an automatic balancing adjustment method for a belt conveyor deviation correction device, such as Figure 1 As shown, the method includes:

[0021] Step S100, obtaining basic information of a feeder belt of a target belt conveyor, wherein the basic information of the feeder belt includes belt length, belt width, belt structure and running load.

[0022] Preferably, the deviation correction device of the target belt conveyor is an intelligent passive power generation automatic straightening device, which uses two conduction rollers installed on both sides of the belt of the feed belt support as a power source, and dynamically monitors the running condition of the belt in real time. When the belt deviates, it contacts the conduction roller, and its rotation drives the micro-high-efficiency generator to generate electricity. The control signal is sent out through the inverter rectifier controller to control the high-strength special electric push rod to perform self-guiding work and achieve balance adjustment. Obtain the basic information of the feed belt of the target belt conveyor, including belt length, belt width, belt structure and running load. Specifically, the belt length depends on the position and diameter of each roller in the actual structure of the belt conveyor, as well as the overall design of the conveyor and the material transportation requirements. In order to ensure the uniformity of size, the belt length generally refers to the circumference of the belt middle diameter (belt thickness center), rather than the circumference of the belt inner diameter or outer diameter, and the unit is generally millimeters; the belt width is usually between 500 mm and 2000 mm, but there are also some special specifications such as 2200 mm or larger width. Different materials have different particle sizes and shapes. It is necessary to select the appropriate belt width according to the characteristics of the material. For example, a narrower belt can be selected for materials with smaller particle sizes, while a wider belt needs to be selected for materials with larger particle sizes. The larger the conveying volume, the wider the belt needs to be selected to ensure uniform distribution of the material and conveying stability.

[0023] Preferably, the belt structure mainly includes the turning point, inclined section, uphill and downhill sections, etc. of the belt, which depends on the overall layout of the conveyor and the material transportation requirements. The turning point refers to the turning of the belt conveyor through a specially designed turning device to ensure that the material can remain stable during the turning process. The inclined section needs to consider the gravity of the material, the friction between the belt and the material, and the strength of the belt. Too large an inclination angle may cause the material to slip or increase the wear of the belt. In the uphill and downhill sections, the upper belt section is used to lift the material from a low place to a high place, while the lower belt section is used to transport the material from a high place to a low place; the operating load includes the weight and speed of the transported material. The weight of the material directly affects the carrying capacity of the belt and the operating stability of the conveyor. The belt speed has a great influence on the bandwidth, dead weight, cost and work quality of the belt conveyor. Under the same conveying capacity conditions, you can choose a large bandwidth and a low belt speed, or a small bandwidth and a high belt speed.

[0024] Step S200, optimizing the correction nodes of the correction device in combination with the belt length, the belt width, the belt structure and the running load to generate an optimal correction point distribution.

[0025] Preferably, the correction nodes are optimized in combination with the belt length, belt width, belt structure and running load to generate the optimal correction point distribution, and then determine at which positions on the belt to install the correction device in order to most effectively correct the belt deviation problem. Specifically, the correction nodes of the correction device are initialized according to the length, width, structure and load of the belt, and then the effect and stability of the correction device are evaluated through simulation operation of the belt, and new correction points are established according to the evaluation results, and the optimal correction point distribution is generated with these multiple correction points. The optimal correction point distribution refers to a solution that optimizes the layout and cost of the correction nodes of the correction device while meeting the requirements for stable operation of the belt, ensuring that the belt can detect and correct deviation problems in a timely and accurate manner throughout its entire length, thereby ensuring stable operation of the belt conveyor and improving production efficiency.

[0026] Further, such as Figure 2 As shown, step S200 also includes step S210, configuring the initialization correction point; step S220, using the belt length, the belt width, the belt structure and the running load as structural modeling data, and collecting historical belt operation records to establish a feed belt simulation model; step S230, loading the initialization correction point into the feed belt simulation model to perform belt operation simulation, and establishing a new point according to the simulation results; step S240, generating the optimal correction point distribution with the new point and the initialization correction point.

[0027] Preferably, the initialization correction point refers to the preset correction device installation position on the belt, which is determined based on the structural characteristics of the belt conveyor, material transportation requirements and common deviation patterns before any simulation and optimization is performed, such as the belt head, tail, tensioning roller, and convex points and concave arc segments of the belt frame and other positions that are prone to deviation. Initialization correction points may need to be set; then, the belt length, belt width, belt structure and operating load are used as structural modeling data, and historical belt operation records are collected, including the frequency, degree, position and other information of belt deviation, to construct a simulation model that can simulate the actual operating state of the belt, so as to more accurately evaluate the effect of the correction device and optimize the point distribution; then the initialization correction point is loaded into the feed belt simulation model to simulate the belt operation. Through simulation, the state of the belt under different operating conditions is observed, including whether it is deviating, the degree and direction of the deviation, etc. The effect of the initial correction point is evaluated according to the simulation results, and new points are added to the simulation model based on the hot spots or potential risk points of the belt deviation in the simulation results, that is, new points are added. By continuously adjusting and optimizing the point distribution, the probability of belt deviation is gradually reduced, and the efficiency and accuracy of the correction device are improved. After many simulations and optimizations, the relatively optimal correction point distribution is obtained, which not only takes into account the structural characteristics of the belt conveyor and the material transportation requirements, but also fully considers the historical records and potential risk points of the belt operation, ensuring that the correction device can play the greatest role on the belt, reducing the impact of belt deviation on production efficiency and safety, thereby improving production efficiency and safety.

[0028] Furthermore, step S210 also includes step S211, if the transport mode of the feed belt is one-way transport, the initialization correction point is the end of the belt; step S212, if the transport mode of the feed belt is two-way transport, the initialization correction point is the beginning and end of the belt.

[0029] Preferably, when the transport mode of the feed belt is one-way transport, the belt usually carries and transports materials in only one direction. The end of the belt (i.e., the material unloading point or the end point of transport) is the position where the belt deviation problem is more prominent. The initialization correction point is set at the end of the belt. Once the belt deviates at the end, the correction device can respond and correct it quickly to ensure that the material can be accurately unloaded and avoid problems such as material scattering or belt damage. When the transport mode of the feed belt is two-way transport, the belt needs to carry and transport materials in two directions. The belt may deviate at the starting end (i.e., the material loading point or the starting point of transport) and the end (i.e., the other material unloading point or the end point of transport). The initialization correction point is set at the starting end and the end of the belt. No matter in which direction the belt runs, once the deviation problem occurs, the corresponding correction device can respond and correct it in time, ensuring that the impact of the belt deviation on production efficiency and safety is minimized to the greatest extent, and the efficiency and accuracy of the correction device are improved.

[0030] Furthermore, step S230 also includes step S231, setting an immediate response correction mechanism for the initialization correction point in the feed belt simulation model, and then performing multiple belt operation simulations; step S232, collecting multiple fitting points whose deviation frequency is higher than a preset frequency according to the simulation results; step S233, calculating the distances from the multiple fitting points to the initialization correction point, and extracting the first fitting point with the farthest distance; step S234, adding the first fitting point to the immediate response correction mechanism, and then updating the simulation results through the feed belt simulation model, and so on, until the updated simulation results show that the deviation frequency of all points is less than the preset frequency.

[0031] Preferably, in the feed belt simulation model, an immediate response correction mechanism is set for the determined initialization correction points (such as the end of the belt or the beginning and the end), and the immediate response correction mechanism simulates the behavior of the actual correction device to immediately correct the belt when it detects that the belt is deviating, ensuring that the belt can quickly return to the correct running track. The simulation model with the immediate response correction mechanism is used to perform multiple belt operation simulations to observe whether the belt will still deviate under different operating conditions, as well as the frequency and degree of the deviation. In the simulation results, all multiple points whose deviation frequency is higher than the preset frequency, i.e., multiple fitting points, are recorded. These fitting points are positions where the belt is prone to deviation under specific conditions, wherein the preset frequency refers to a threshold value of the frequency or number of belt deviations in the feed belt simulation operation, which is used to measure the severity of the belt deviation problem and serve as a basis for whether the correction mechanism needs to be optimized and adjusted.

[0032] Preferably, the distance between these fitting points and the initialization correction point is calculated, and the one farthest from the initialization correction point is extracted as the first fitting point. The selection of this point is based on the assumption that if the farthest point can be effectively corrected, then other closer points should also be able to be better controlled; the first fitting point is added to the immediate response correction mechanism, that is, a correction device is also set at this point or the parameters of the existing device are adjusted, and the simulation model is used again to simulate and observe whether the updated correction mechanism can reduce the deviation frequency of the point, and then repeat the above steps, that is, after each simulation, new fitting points are collected, the distance is calculated, the farthest point is extracted, the correction mechanism is updated, and the simulation is performed again until the deviation frequency of all points is less than the preset frequency, and it is considered that a relatively optimal correction point distribution has been found. By gradually optimizing the correction point distribution and the correction mechanism efficiency in the feed belt simulation model, not only the accuracy and efficiency of the correction device are improved, but also the impact of belt deviation on production efficiency and safety is reduced.

[0033] Step S300, configuring a plurality of correcting devices located at a plurality of points according to the optimal correcting point distribution, wherein any correcting device includes a conductive roller, a micro generator and an electric push rod.

[0034] Preferably, multiple correction devices located at multiple points are configured according to the optimal correction point distribution, which means that at each determined optimal correction point, a corresponding correction device is installed and configured to monitor the running status of the belt in real time and make timely adjustments when the belt deviates, so as to ensure that the belt always maintains a stable and accurate position during transportation. Specifically, each correction device includes a conduction roller, a micro generator and an electric push rod to achieve effective control and prevention of belt deviation problems. Among them, the conduction roller is one of the core components in the correction device, which is usually in direct contact with the belt and is used to sense the running status and position information of the belt and adjust it during the operation of the belt. In the process, the conductive roller will sense the deviation of the belt in real time and transmit this information to the micro generator; the micro generator is the energy conversion component in the deviation correction device, which uses the belt deviation information transmitted by the conductive roller to convert it into electrical energy or mechanical energy to drive the electric push rod to perform deviation correction operations and ensure that it can respond quickly and accurately and generate sufficient deviation correction force when the belt is deviated; the electric push rod is the executive component in the deviation correction device. According to the signal and energy provided by the micro generator, it pushes the conductive roller or related mechanical structure through telescopic movement to realize the deviation correction operation of the belt, so as to ensure that it can be quickly and accurately corrected to the normal position when the belt is deviated. The conductive roller, micro generator and electric push rod and other components in each deviation correction device work together to realize real-time monitoring and precise deviation correction of the belt deviation, thereby ensuring the stable operation and efficient production of the belt conveyor.

[0035] Furthermore, step S300 also includes step S310, wherein the conduction roller includes a first conduction roller and a second conduction roller, which are symmetrically distributed on both sides of the belt at the plurality of points; step S320, wherein the electric push rod includes a first push rod and a second push rod, which are symmetrically distributed on both sides of the belt at the plurality of points; and step S330, wherein the conduction roller serves as a power source and is connected to the micro generator to form a power generation module to provide electrical energy to drive the electric push rod.

[0036] Preferably, the conductive roller includes a first conductive roller and a second conductive roller, which are respectively located at symmetrical positions on both sides of the belt, and are used to sense the running state of the belt in real time, especially the deviation of the belt. When the belt deviates, the conductive roller will rotate or deviate accordingly, and this mechanical movement can be converted into electrical energy or other forms of energy for subsequent deviation correction operations; the electric push rod includes a first push rod and a second push rod, which are also located at symmetrical positions on both sides of the belt, corresponding to the conductive roller. The electric push rod is an actuator of the deviation correction device, and performs telescopic movement according to the received control signal, thereby pushing or pulling the belt to return to the correct position; the conductive roller is connected with a micro generator to form a power generation module, wherein the mechanical movement of the conductive roller during the operation of the belt can be used as a power source for power generation. When the belt deviates, the conductive roller will rotate accordingly, and the mechanical energy generated by the rotation of the conductive roller will be transmitted to the micro generator, and the micro generator will convert this mechanical energy into electrical energy to drive the electric push rod to perform deviation correction operations. Then a closed-loop deviation correction device is formed, the deviation of the belt causes the conductive roller to rotate, and the electrical energy generated by the rotation drives the electric push rod to correct the deviation, thereby maintaining the stable operation of the belt.

[0037] Step S400, monitoring the belt deviation at the plurality of points by means of the conductive rollers in the plurality of deviation correcting devices, generating offset points and corresponding belt deviation vectors, and corresponding target deviation correcting devices.

[0038] Preferably, the belt deviation is monitored at multiple corresponding points through the conduction rollers in each correcting device. That is, when the belt deviates during transmission, the conduction rollers at the offset points capture the offset information of the belt in real time, including the direction and degree of the offset, to generate the offset point and the belt deviation vector. Specifically, the offset point refers to the specific position where the belt deviates, and the belt deviation vector describes the direction and degree of the belt deviation. After determining the offset point and the belt deviation vector, the target correcting device that needs to be activated is finally determined to correct the belt deviation. The target correcting device is usually a device located near the offset point or that can most effectively correct the belt deviation, thereby improving the operating efficiency and safety of the belt conveyor and reducing problems such as equipment damage and material spillage caused by belt deviation.

[0039] Furthermore, step S400 also includes step S410, establishing multiple groups of preset deviation vector samples; step S420, operating the conduction roller with the multiple groups of preset deviation vector samples, and obtaining multiple groups of rotation sensor samples by testing the rotation sensor inside the conduction roller; step S430, wherein any group of rotation sensor samples includes a rotation speed and a rotation direction; step S440, establishing a deviation identification model based on the mapping relationship between the multiple groups of preset deviation vector samples and the multiple groups of rotation sensor samples; step S450, monitoring the belt deviation according to the rotation sensor inside the conduction roller through the deviation identification model, and generating the offset point and the belt deviation vector.

[0040] Preferably, when the conveyor belt is in normal operation, the conductive roller maintains a certain distance or slight contact with the edge of the belt to ensure that the conveyor belt runs along its predetermined track. When the conveyor belt deviates, one or both sides of the belt will excessively contact the conductive roller. When the belt deviates, the friction between the belt and the conductive roller increases, pushing the conductive roller to rotate along the movement direction of the belt. At this time, the rotation speed and rotation direction of the conductive roller can reflect the degree and direction of the deviation of the belt.

[0041] Preferably, based on the historical data of the target belt conveyor, multiple sets of preset deviation vector samples are established, representing the possible deviation conditions (deviation direction and deviation degree) of the belt under different conditions. Then, based on the multiple sets of preset deviation vector samples, by simulating the belt displacement and running the conduction roller in the deviation correction device in real time, and recording the key information such as the search speed and rotation direction of the conduction roller in real time, multiple sets of rotation sensor samples are formed. Each set of rotation sensor samples should include two key parameters, rotation speed and rotation direction. These parameters can reflect the rotation condition of the conduction roller when the belt is deviated. Then, based on the machine learning model (such as decision tree, random forest, neural network, etc.), the belt displacement condition is simulated and the conduction roller in the deviation correction device is operated in real time. The recognition model is constructed by using a plurality of preset deviation vector samples as training input and a plurality of rotation sensor samples as training output. The recognition model is supervised and trained to learn the correlation between the belt deviation and the rotation of the conduction roller. The deviation recognition model is trained and established. During the actual operation, the rotation sensor inside the conduction roller will capture the deviation information of the belt in real time and input it into the deviation recognition model. The trained deviation recognition model is applied to the actual belt deviation monitoring. The deviation recognition model outputs the current deviation point and belt deviation vector according to the input belt deviation information, so as to realize real-time monitoring and accurate recognition of the operation status of the belt conveyor.

[0042] Step S500, performing a deviation balance analysis on the electric push rod of the target deviation correction device based on the belt deviation vector, and generating a balance correction control vector.

[0043] Preferably, the belt deviation vector refers to the direction and degree of deviation of the belt from the normal position during operation, including the direction of belt deviation (such as left or right) and the degree of deviation (such as the distance or angle of deviation). The electric push rod is a key component in the correction device, responsible for adjusting the position of the belt according to the control signal. The electric push rod is usually composed of a motor, a reducer, a push rod and other components. The push rod can be driven by the motor to achieve the telescopic movement of the push rod, thereby adjusting the position of the belt. The deviation balance analysis refers to analyzing how the electric push rod needs to move to achieve belt deviation correction based on the belt deviation vector. Specifically, with the running load of the belt as a constraint condition, according to the direction and degree of belt deviation, the direction and distance that the electric push rod needs to be telescoped are determined. According to the running speed and deviation of the belt, the response speed of the electric push rod is adjusted to ensure the timeliness and accuracy of the correction, and then a balance guidance control vector is generated, including the action instructions that the electric push rod needs to execute, such as the telescopic direction, telescopic distance, response speed, etc. By inputting these instructions into the control system of the correction device, the electric push rod can be controlled, thereby achieving belt deviation correction.

[0044] Furthermore, step S500 also includes step S510, collecting multiple groups of belt correction samples for the feed belt with the running load as a constraint, any group of belt correction samples including a deviation vector sample and a corresponding balance correction control vector sample; step S520, training a correction control model with the multiple groups of belt correction samples; and step S530, performing a deviation balance analysis on the belt deviation vector through the correction control model to generate the balance correction control vector.

[0045] Preferably, taking the running load as a constraint, multiple groups of belt deviation correction samples are collected for the feed belt to ensure that they are carried out under different running load conditions to fully reflect the deviation correction characteristics of the belt under different loads. Each group of samples should include deviation vector samples and corresponding balance correction control vector samples, wherein the deviation vector samples describe the deviation direction and degree of the belt at a certain moment, and the balance correction control vector samples describe the action instructions that the electric push rod needs to execute in order to correct the deviation. A control model is constructed based on a machine learning model (such as a neural network, a support vector machine, etc.), with multiple groups of belt deviation vectors as training inputs and multiple groups of balance correction control vector samples as training outputs. The control model is supervised and trained, and the correlation between the belt deviation and the deviation correction action is learned from the sample data. To the correction control model, the correction control model can accept the new belt deviation vector as input and output the corresponding balance and correction control vector. The output balance and correction control vector will guide the electric push rod of the correction device on how to move to correct the deviation of the belt; when the belt deviates, the correction control model will perform a deviation balance analysis on the belt deviation vector. Based on the results of the deviation balance analysis, the correction control model will generate a balance and correction control vector, which includes the control instructions required to adjust the belt position, such as the extension and retraction direction, distance and speed of the electric push rod. By inputting this control vector into the control system of the correction device, real-time correction control of the belt can be achieved, thereby improving the operating efficiency and stability of the belt conveyor and reducing problems such as equipment damage and material spillage caused by belt deviation.

[0046] Step S600, a power generation module is established with the conductive roller and the micro generator of the target deviation correction device to drive the corresponding electric push rod to correct the deviation according to the balance correction control vector.

[0047] Preferably, a power generation module is established with the conduction roller and micro-generator of the target deviation correction device, and the mechanical energy generated by the rotation of the conduction roller is transmitted to the micro-generator. The micro-generator uses this mechanical energy to generate electricity, thereby providing the required electrical energy for the electric push rod, and then driving the corresponding electric push rod to adjust the position of the belt through telescopic movement. Specifically, during the belt deviation correction process, the electric push rod drives the electric push rod to perform telescopic movement according to the instructions in the balance guide control vector (instructing the electric push rod in what way and at what speed to perform telescopic movement). By accurately controlling the telescopic distance and speed of the electric push rod, real-time monitoring of the belt position and precise deviation correction adjustment are achieved, which not only improves the operating efficiency and stability of the belt conveyor, but also reduces energy consumption and maintenance costs.

[0048] Furthermore, step S600 also includes step S610, wherein the target deviation correction device also includes an inverter rectifier controller; in step S620, the conduction roller of the target deviation correction device rotates to drive the micro-generator to generate electrical energy, and the inverter rectifier controller sends a control signal according to the balance correction control vector; in step S630, the control signal is used to control the corresponding electric push rod to correct the deviation.

[0049] Preferably, the target deviation correction device further includes an inverter rectifier controller. The micro generator is combined with the conduction roller to generate electricity using the mechanical energy generated by the rotation of the conduction roller. However, the electric energy generated by the micro generator may be alternating current (AC) or unstable direct current (DC). The inverter rectifier controller is used to convert this unstable electric energy into stable and usable direct current (DC) or to invert and convert it into alternating current (AC) as needed for use by the electric push rod. The inverter rectifier controller is not only responsible for the conversion of electric energy, but also sends a corresponding control signal according to the balance and correction control vector (calculated by the deviation correction control model). These control signals contain the action instructions that the electric push rod needs to execute, such as the extension direction, extension distance, response speed, etc. The control signals are used to control the corresponding electric push rod to correct the deviation. After the control system of the electric push rod receives the control signal from the inverter rectifier controller, it will parse these signals and act according to the instructions in the signal. That is, the electric push rod retracts and retracts according to the instructions in the control signal, adjusts the position of the belt and accurately controls the extension distance and speed of the electric push rod, thereby correcting the belt deviation and restoring the belt to normal operating state, thereby improving the operating efficiency and stability of the belt conveyor.

[0050] The above specific implementation manner does not constitute a limitation to the protection scope of the present application. It should be understood by those skilled in the art that various modifications, combinations and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present application should be included in the protection scope of the present application. In some cases, the actions or steps recorded in the present application can be performed in an order different from that in the embodiment and can still achieve the desired results. In addition, the process depicted in the accompanying drawings does not necessarily require the specific order or continuous order shown to achieve the desired results. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

Claims

1. The automatic balancing adjustment method of the belt conveyor deviation correction device is characterized in that: include: Obtaining basic information of a feed belt of a target belt conveyor, wherein the basic information of the feed belt includes belt length, belt width, belt structure and running load; Optimizing the correction nodes of the correction device by combining the belt length, the belt width, the belt structure and the running load to generate an optimal correction point distribution; A plurality of correcting devices are arranged at a plurality of points according to the optimal correcting point distribution, wherein any correcting device comprises a conductive roller, a micro generator and an electric push rod; Monitoring belt deviation at the plurality of points by means of conductive rollers in the plurality of deviation correcting devices, generating offset points and corresponding belt deviation vectors, and corresponding target deviation correcting devices; Using the belt deviation vector, a deviation balance analysis is performed on the electric push rod of the target deviation correction device to generate a balance correction control vector; A power generation module is established with the conductive roller and micro-generator of the target deviation correction device to drive the corresponding electric push rod to correct the deviation according to the balance correction control vector.

2. The automatic balancing adjustment method of the belt conveyor deviation correction device according to claim 1, characterized in that: The correction nodes of the correction device are optimized by combining the belt length, the belt width, the belt structure and the running load to generate the optimal correction point distribution, including: Configure the initial correction points; The belt length, the belt width, the belt structure and the running load are used as structural modeling data, and historical belt running records are collected to establish a conveyor belt simulation model; Loading the initial deviation correction point into the feed belt simulation model to simulate the belt operation, and establishing new points according to the simulation results; The optimal correction point distribution is generated by using the newly added points and the initialized correction points.

3. The automatic balancing adjustment method of the belt conveyor deviation correction device according to claim 2, characterized in that: Configure the initial deviation correction points, including: If the conveying mode of the conveyor belt is one-way transportation, the initial deviation correction point is the end of the belt; If the conveying mode of the conveyor belt is bidirectional transportation, the initial deviation correction points are the starting end and the end end of the belt.

4. The automatic balancing adjustment method of the belt conveyor deviation correction device according to claim 3, characterized in that: The initial deviation correction point is loaded into the feed belt simulation model to simulate the belt operation, and a new point is established according to the simulation result, including: In the feed belt simulation model, an immediate response correction mechanism is set for the initial correction point, and then multiple belt operation simulations are performed; According to the simulation results, multiple fitting points with deviation frequencies higher than the preset frequencies are collected; Calculating the distances from the multiple fitting points to the initialization correction point, and extracting the first fitting point with the farthest distance; After adding the first fitting point to the instant response correction mechanism, the simulation result is updated through the conveyor belt simulation model, and so on, until the updated simulation result shows that the deviation frequency of all points is less than the preset frequency.

5. The automatic balancing adjustment method of the belt conveyor deviation correction device according to claim 1, characterized in that: The conductive rollers include a first conductive roller and a second conductive roller, which are symmetrically distributed on both sides of the belt at the plurality of points; The electric push rod comprises a first push rod and a second push rod, which are symmetrically distributed on both sides of the belt at the plurality of points; The conductive roller serves as a power source and is connected with the micro generator to form a power generation module, which provides electrical energy for driving the electric push rod.

6. The automatic balancing adjustment method of the belt conveyor deviation correction device according to claim 5, characterized in that: The belt deviation is monitored at the plurality of points by the conductive rollers in the plurality of deviation correcting devices to generate the offset points and the corresponding belt deviation vectors, including: Establish multiple sets of preset deviation vector samples; The conduction roller is operated with the plurality of sets of preset deviation vector samples, and a plurality of sets of rotation sensor samples are obtained by testing the rotation sensor inside the conduction roller; Wherein, any set of rotation sensing samples includes rotation speed and rotation direction; Establishing a deviation recognition model based on the mapping relationship between the plurality of groups of preset deviation vector samples and the plurality of groups of rotation sensor samples; The belt deviation is monitored by the deviation identification model according to the rotation sensor inside the conductive roller to generate the offset point and the belt deviation vector.

7. The automatic balancing adjustment method of the belt conveyor deviation correction device according to claim 1, characterized in that: The belt deviation vector is used to perform a deviation balance analysis on the electric push rod of the target deviation correction device to generate a balance correction control vector, including: Taking the running load as a constraint, multiple groups of belt deviation correction samples are collected for the feed belt, and any group of belt deviation correction samples includes a deviation vector sample and a corresponding balance and guidance control vector sample; Using the multiple groups of belt deviation correction samples to train a deviation correction control model; The deviation correction control model is used to perform a deviation balance analysis on the belt deviation vector to generate the balance correction control vector.

8. The automatic balancing adjustment method of the belt conveyor deviation correction device according to claim 1, characterized in that: A power generation module is established with the conductive roller and the micro-generator of the target deviation correction device to drive the corresponding electric push rod to correct the deviation according to the balance correction control vector, including: The target deviation correction device also includes an inverter rectifier controller; The conduction roller of the target deviation correction device rotates to drive the micro generator to generate electric energy, and the inverter rectifier controller sends a control signal according to the balance correction control vector; The control signal is used to control the corresponding electric push rod to correct the deviation.

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