Belt conveyor deviation rectifying method, device and system

Abstract

The invention discloses a belt conveyor deviation rectification method, device and system, and relates to the technical field of belt conveyor deviation rectification, the deviation rectification method comprises the following steps: S1, dynamic signal acquisition and analysis; s2, environmental noise suppression processing; s3, material feature extraction and classification; s4, modeling and analyzing spatio-temporal characteristics; s5, deviation correction control is carried out; the deviation rectifying device comprises a deviation rectifying module, and the deviation rectifying module comprises a driving unit and a deviation rectifying rod; one end of the deviation rectifying rod is connected with an adjusting lead screw of a belt conveyor guide plate, and the other end of the deviation rectifying rod is connected with the output end of the driving unit. The driving unit can drive the deviation rectifying rod to rotate forwards or reversely so as to drive the adjusting lead screw to rotate forwards or reversely, the position of the material guide plate is changed, and adjustment of the material falling point is achieved. By means of the scheme, deviation of the conveyor belt is effectively controlled, abrasion of the belt is obviously reduced, non-planned shutdown of a unit caused by frequent replacement of the belt is avoided, material supply is guaranteed, and non-planned shutdown check is avoided.

Description

Technical Field

[0001] The invention relates to the technical field of belt conveyor deviation correction, and in particular to a belt conveyor deviation correction method, device and system. Background Art

[0002] The production, transportation and processing of coal in power plants, steel mills and coal are inseparable from the transportation of coal. Belt conveyors have become increasingly common in many industries due to their large transportation volume, strong carrying capacity and long transportation distance.

[0003] The Euro warehouse for storing coal is 65 meters high. Coal can only reach the coal bunker from the dock through multi-stage belt conveyors. During the transportation process, the horizontal speed of the coal falling process will be different due to factors such as the change in the conveying speed of the upper belt, causing the center of gravity of the material piled on the belt to shift to the right or left. If the center of gravity shifts in one direction for a long time, it will cause the belt to deviate in the opposite direction. The existing method of detecting belt deviation is manual on-site patrol or installing a camera at the end of the belt line to monitor the deviation of the belt in the central control room. If the belt is found to be deviated, maintenance personnel need to go to the starting end of the belt line to manually adjust the position of the belt. Manual patrols are limited by the number of patrols and may not be able to detect belt deviation in time; relying on maintenance personnel to visually judge the deviation through the camera reduces the workload of maintenance personnel, but after the belt is found to be deviated, it takes some time to walk from the central control room to the belt conveyor line, and it is not possible to correct the deviation in time. In addition, it is difficult to make quick and accurate judgments through manual detection, which also increases the workload of relevant personnel. Summary of the invention

[0004] In view of the deficiencies in the prior art, the present invention provides a belt conveyor deviation correction method, device and system to solve the problems raised in the above background technology.

[0005] The above technical problem is solved by the following technical solution: The present invention proposes a belt conveyor deviation correction method, comprising the following steps:

[0006] S1: Dynamic signal acquisition and analysis, transmitting modulated signals through electromagnetic wave detection devices, acquiring the original signals of the target area in real time, and analyzing the original signals to generate a multi-dimensional data set containing the position, speed, and phase information of the target object;

[0007] S2: environmental noise suppression processing, performing dynamic background separation on the multidimensional data set, distinguishing static structures from dynamic targets, and implementing adaptive filtering in the frequency domain or the joint time-frequency domain to suppress multipath interference and electromagnetic noise;

[0008] S3: Material feature extraction and classification, reconstructing the three-dimensional spatial distribution of materials based on dynamic target data, analyzing the motion velocity field of materials, correcting the velocity error caused by external vibration, and inverting the physical properties of materials based on electromagnetic scattering characteristics to achieve material classification;

[0009] S4: Spatiotemporal feature modeling and analysis, combining the three-dimensional spatial distribution with the corrected motion velocity field, extracting the spatiotemporal features of material motion, and dynamically focusing on the motion state of key areas through the feature enhancement module;

[0010] S5: Correction control, which calculates the real-time flow and center of gravity offset of the material based on the time and space characteristics, and uses a multi-source data fusion algorithm to optimize the calculation results and output correction instructions to the actuator.

[0011] In a preferred implementation of the belt conveyor correction method described in the present invention: the correction instruction output in step S5 is generated using a PID control algorithm, and the PID control algorithm is based on the deviation e(t) between a preset target value r(t) and the real-time center of gravity offset y(t) of the material calculated in step S5, that is, e(t)=r(t)-y(t), and then generates a control quantity through a linear combination of proportion, integration, and differentiation.

[0012] In a preferred implementation of the belt conveyor deviation correction method of the present invention: the transfer function of the PID control algorithm is:

[0013]

[0014] In the formula, K p is the magnification factor of the proportional link;

[0015] T i is the integration time constant, K i is the integration coefficient, K i =K p / T i ;

[0016] T d is the differential time constant, K d is the differential coefficient, K d =K p *T d .

[0017] In a preferred embodiment of the belt conveyor deviation correction method of the present invention: the proportionality coefficient K p Used to accelerate system response; integral time constant T i Used to eliminate steady-state errors; differential time constant T d Used to predict deviation change trends.

[0018] Preferably, the present invention proposes a belt conveyor correction device, which is used to adjust the position of the belt conveyor guide plate to adjust the material drop position, including a correction module, wherein the correction module includes a driving unit and a correction rod; one end of the correction rod is connected to the adjusting screw rod of the belt conveyor guide plate, and the other end of the correction rod is connected to the output end of the driving unit; the driving unit can drive the correction rod to rotate forward or reverse, thereby driving the adjusting screw rod to rotate forward or reverse, changing the position of the guide plate, and realizing the adjustment of the material drop point.

[0019] In a preferred embodiment of the belt conveyor correction device of the present invention: the driving unit includes a motor, a reducer connected to the output end of the motor, and a transmission assembly connecting the reducer and the correction rod; the reducer is used to reduce the motor speed and increase the output torque; the transmission assembly is used to transmit the output power of the motor to the correction rod.

[0020] In a preferred embodiment of the belt conveyor correction device of the present invention: it also includes a monitoring module, which includes a detector for monitoring the falling track of materials, and a suspension frame for hanging and installing the detector on one side of the belt conveyor; one end of the suspension frame is detachably connected to the truss, and the other end of the suspension frame is detachably connected to the detector.

[0021] In a preferred embodiment of the belt conveyor correction device of the present invention: the suspension frame includes a cantilever, a locking bracket arranged at one end of the cantilever for connecting the truss, and a movable bracket arranged at the other end of the cantilever for installing the detector, and the locking bracket and the movable bracket are both connected to the cantilever by bolts.

[0022] In a preferred embodiment of the belt conveyor deviation correcting device of the present invention: the cantilever includes a first arm and a second arm, the first arm and the second arm are connected by bolts, and the first arm or the second arm has through holes arranged along the length direction.

[0023] Preferably, the present invention proposes a belt conveyor correction system, comprising at least one belt conveyor correction device; and a server; a programmable controller, wherein the programmable controller is used to receive material center of gravity offset data sent by the server, perform PID calculations, and output correction instructions to the belt conveyor correction device to control the operation of the motor.

[0024] The beneficial effects of the present invention are as follows: through this solution, the conveyor belt deviation is effectively controlled, the belt wear is significantly reduced, and the unplanned shutdown of the unit due to frequent belt replacement is avoided, the material supply is guaranteed, and the unplanned shutdown assessment is avoided. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings of the embodiments of the present invention are briefly introduced below. Obviously, the drawings described below only relate to some embodiments of the present invention, but are not intended to limit the present invention. Among them:

[0026] Figure 1 The overall structural diagram of the correction module in the present invention is shown;

[0027] Figure 2 A schematic diagram of the side view structure of the correction module in the present invention is shown;

[0028] Figure 3 A rear view structural schematic diagram of the correction module in the present invention is shown;

[0029] Figure 4 The overall structural diagram of the monitoring module in the present invention is shown;

[0030] Figure 5 The schematic diagram of the front view structure of the monitoring module in the present invention is shown;

[0031] Figure 6 A schematic diagram of the side structure of the monitoring module in the present invention is shown;

[0032] In the figure: 1. Correction module; 11. Drive unit; 11a. Motor; 11b. Reducer; 11c. Transmission assembly; 12. Correction rod; 13. Coupling; 14. Machine base; 2. Monitoring module; 21. Detector; 22. Suspension bracket; 22a. Cantilever; 22a-1. First arm; 22a-2. Second arm; 22a-3. Through hole; 22b. Locking bracket; 22c. Movable bracket; 22c-1. Upper connecting plate; 22c-2. Lower connecting plate; 22c-3. Movable shaft; 3. Position sensor; A. Guide plate; B. Adjustment screw; C. Truss. DETAILED DESCRIPTION

[0033] In order to enable those skilled in the art to better understand the present invention, the present invention is further described in detail below in conjunction with specific implementation methods and drawings.

[0034] The terms used in the present invention are those general terms currently widely used in the art in consideration of the functions of the present invention, but these terms may vary according to the intention of a person of ordinary skill in the art, precedents, or new technologies in the art. In addition, specific terms may be selected by the applicant, and in this case, their detailed meanings will be described in the detailed description of the present invention. Therefore, the terms used in the specification should not be understood as simple names, but rather as a general description based on the meaning of the terms and the present invention.

[0035] This embodiment provides a belt conveyor deviation correction method, comprising the following steps:

[0036] S1: Dynamic signal acquisition and analysis: The modulated signal is emitted by the electromagnetic wave detection device to obtain the original signal of the target area in real time, and the original signal is analyzed to generate a multi-dimensional data set containing the target object's position, speed, and phase information.

[0037] Specifically, the electromagnetic wave detection device is preferably a laser radar, and step S1: the specific steps of dynamic signal collection and analysis include:

[0038] S1.1: Use a 77 GHz millimeter wave radar array to transmit a FMCW signal with a sweep bandwidth of 4 GHz and a sweep frequency of ≥ 20 Hz to collect raw radar signals in real time.

[0039] S1.2: Based on the original radar signal, a multi-dimensional data matrix is ​​generated by analysis, including the range-Doppler spectrum (RDM), the azimuth-elevation angle spectrum (AES), and the I / Q signal phase stream.

[0040] S2: Environmental noise suppression processing, dynamic background separation of multidimensional data sets, distinguishing static structures from dynamic targets, implementing adaptive filtering in the frequency domain or time-frequency joint domain, and suppressing multipath interference and electromagnetic noise.

[0041] Specifically, step S2: the specific steps of environmental noise suppression processing include:

[0042] S2.1: Separation of static background and dynamic targets, i.e., separation of belts, brackets (static background) and materials (dynamic targets), is performed by sliding window Kalman filtering (SW-KF).

[0043] S2.2: Perform Wiener filtering on the separated dynamic target data in the range-velocity domain to suppress multipath interference and electromagnetic noise, and output the dynamic target data after noise reduction.

[0044] S3: Material feature extraction and classification, reconstructing the three-dimensional spatial distribution of materials based on dynamic target data, analyzing the motion velocity field of materials, correcting the velocity error caused by external vibration, and inverting the physical properties of materials based on electromagnetic scattering characteristics to achieve material classification.

[0045] Specifically, step S3: the specific steps of material feature extraction and classification include:

[0046] S3.1: Based on the dynamic target data after noise reduction in step S2.2, the MIMO radar virtual aperture technology is used to reconstruct the three-dimensional point cloud of the material surface.

[0047] S3.2: Perform Doppler velocity field analysis on the 3D point cloud to extract the micro-motion characteristics of the material surface and eliminate the velocity error caused by belt vibration.

[0048] S3.3: Invert the dielectric constant of the material based on the radar cross section (RCS) characteristics and identify the type of material (coal, ore, etc.).

[0049] S4: Spatiotemporal feature modeling and analysis, combining the three-dimensional spatial distribution with the corrected motion velocity field, extracting the spatiotemporal characteristics of material motion, and dynamically focusing on the motion state of key areas through the feature enhancement module.

[0050] Specifically, step S4: the specific steps of spatiotemporal feature modeling and analysis include:

[0051] S4.1: Input the 3D point cloud reconstructed in step S3.1 and the velocity field data corrected in step S3.2 into the spatiotemporal model, and use the 3D convolution kernel to extract the material motion trajectory characteristics.

[0052] S4.2: Introduce an attention mechanism (CBAM module) into the spatiotemporal model to dynamically focus on the motion features of high-traffic areas.

[0053] S5: Correction control, which calculates the real-time flow and center of gravity offset of the material based on the time and space characteristics, and uses a multi-source data fusion algorithm to optimize the calculation results and output correction instructions to the actuator.

[0054] Specifically, step S5: the specific steps of the deviation correction control include:

[0055] S5.1: Based on the motion characteristics of the dynamic target in the high-flow area focused in step S4.2, the volume flow rate and center of gravity offset of the dynamic target are calculated by the spatiotemporal convolution of the point cloud density field integral and the belt speed.

[0056] S5.2: Use the Federated Kalman Filter (FKF) to fuse the multi-dimensional radar data, perform error compensation on the calculation result in step S5.1, generate the final center of gravity offset data, and output it to the control system. The control system outputs the correction instruction to the actuator to perform the correction action.

[0057] Furthermore, the correction instruction output in step S5 is generated using a PID control algorithm. The PID control algorithm is based on the deviation e(t) between the preset target value r(t) and the real-time center of gravity offset y(t) of the material calculated in step S5, that is, e(t)=r(t)-y(t), and then generates a control quantity through a linear combination of proportion, integration, and differentiation.

[0058] Furthermore, the transfer function of the PID control algorithm is:

[0059]

[0060] In the formula, K p is the amplification factor of the proportional link; specifically, the proportional coefficient K pIt is used to accelerate system response and improve system adjustment accuracy. The larger the proportional coefficient, the faster the adjustment speed. However, too large a proportional coefficient will cause system instability, and too small a proportional coefficient will cause the system adjustment time to be too long. Considering all factors, K p The value range is 0.5~1.2, and K is preferred p =0.8.

[0061] T i is the integration time constant, K i is the integration coefficient, K i =K p / T i ; Specifically, the integral time constant T i It is used to eliminate steady-state errors. The larger the integral time constant, the faster the steady-state error is eliminated. However, if the integral time constant is too large, integral saturation will occur. If it is too small, it will be difficult to eliminate the steady-state error, affecting the accuracy of system regulation. Considering all factors, T i The value range is 3s to 8s, preferably T i =5.

[0062] T d is the differential time constant, K d is the differential coefficient, K d =K p *T d ; Specifically, the differential time constant T d It is used to predict the deviation change trend and reduce overshoot and adjustment time. However, if the differential time constant is too large, the anti-interference ability of the system will be reduced. d The value range is 0.1s~0.5s, preferably T d =0.2.

[0063] Reference Figures 1 to 6 This embodiment provides a belt conveyor deviation correction device, which is used to adjust the position of the belt conveyor guide plate A to adjust the material drop position, including a deviation correction module 1 and a monitoring module 2.

[0064] like Figure 1 to Figure 3 As shown, the correcting module 1 includes a driving unit 11 and a correcting rod 12; one end of the correcting rod 12 is connected to the adjusting screw B of the belt conveyor guide plate A, and the other end of the correcting rod 12 is connected to the output end of the driving unit 11; the driving unit 11 can drive the correcting rod 12 to rotate forward or reverse, and then drive the adjusting screw B to rotate forward or reverse, change the position of the guide plate A, and realize the adjustment of the material landing point.

[0065] Specifically, the correcting rod 12 is connected to the opposite end of the adjusting screw B of the belt conveyor guide plate A through a coupling 13. The use of the coupling 13 for connection can compensate for the axial, radial or angular displacement that occurs when the correcting rod 12 is connected to the adjusting screw B, and ensure that the torque and rotational motion on the correcting rod 12 can be transmitted to the adjusting rod.

[0066] Furthermore, the driving unit 11 includes a motor 11a, a reducer 11b connected to the output end of the motor 11a, and a transmission assembly 11c connecting the reducer 11b and the correcting rod 12; the motor 11a and the reducer 11b are both arranged on the machine base 14, the transmission assembly 11c is a belt drive or a chain drive, the reducer 11b is used to reduce the speed of the motor 11a and increase the output torque; the transmission assembly 11c is used to transmit the output power of the motor 11a to the correcting rod 12.

[0067] like Figures 4 to 6 As shown, as an optional embodiment, the monitoring module 22 includes a detector 21 for monitoring the falling track of materials, and a suspension frame 22 for suspending the detector 21 on one side of the belt conveyor; the detector 21 uses a laser radar, which can adapt to a working environment with a temperature range of -40°C to +60°C, a humidity of up to 80%, and a high dust content in the air. It uses laser scanning technology to collect cross-sectional data of materials on the belt conveyor and generate a continuous three-dimensional point cloud map; one end of the suspension frame 22 is detachably connected to the truss C, and the other end of the suspension frame 22 is detachably connected to the detector 21.

[0068] Specifically, the suspension frame 22 includes a cantilever 22a, a locking bracket 22b arranged at one end of the cantilever 22a for connecting to the truss C, and a movable bracket 22c arranged at the other end of the cantilever 22a for installing the detector 21. The locking bracket 22b and the movable bracket 22c are both connected to the cantilever 22a by bolts.

[0069] Furthermore, the cantilever 22a includes a first arm 22a-1 and a second arm 22a-2, and the first arm 22a-1 and the second arm 22a-2 are connected by bolts. The first arm 22a-1 or the second arm 22a-2 has through holes 22a-3 arranged along the length direction, and the bolts can pass through any two communicating through holes 22a-3 on the first arm 22a-1 and the second arm 22a-2.

[0070] Furthermore, the movable bracket 22c includes an upper connecting plate 22c-1, a lower connecting plate 22c-2, and a movable shaft 22c-3 arranged between the upper connecting plate 22c-1 and the lower connecting plate 22c-2; wherein, the upper connecting plate 22c-1 is connected to the second cantilever 22a by bolts, the lower connecting plate 22c-2 is detachably connected to the detector 21, and the lower connecting plate 22c-2 is movably connected to the upper connecting plate 22c-1 by the movable shaft 22c-3 to realize the adjustment of the detection range of the detector 21.

[0071] As an optional embodiment, the correction device also includes an electrical auxiliary module, including a position sensor 3 and a limit switch, the position sensor 3 is used to detect the position of the guide plate A on the belt conveyor in real time, and the limit switch is used to limit the maximum displacement stroke of the guide plate A.

[0072] The present embodiment provides a belt conveyor correction system, comprising at least one of the above-mentioned belt conveyor correction devices; as well as a server and a programmable controller; wherein the programmable controller is used to receive material center of gravity offset data sent by the server, perform PID calculations, and output correction instructions to the belt conveyor correction device to control the operation of the motor 11a.

[0073] Finally, it should be pointed out that the methods and devices described in detail above are only embodiments, and those skilled in the art can modify these embodiments in different ways without departing from the scope of the present invention.

Claims

1. A belt conveyor deviation correction method, characterized in that: The following steps are included: S1: Dynamic signal acquisition and analysis, transmitting modulated signals through electromagnetic wave detection devices, acquiring the original signals of the target area in real time, and analyzing the original signals to generate a multi-dimensional data set containing the position, speed, and phase information of the target object; S2: environmental noise suppression processing, performing dynamic background separation on the multidimensional data set, distinguishing static structures from dynamic targets, and implementing adaptive filtering in the frequency domain or the joint time-frequency domain to suppress multipath interference and electromagnetic noise; S3: Material feature extraction and classification, reconstructing the three-dimensional spatial distribution of materials based on dynamic target data, analyzing the motion velocity field of materials, correcting the velocity error caused by external vibration, and inverting the physical properties of materials based on electromagnetic scattering characteristics to achieve material classification; S4: Spatiotemporal feature modeling and analysis, combining the three-dimensional spatial distribution with the corrected motion velocity field, extracting the spatiotemporal features of material motion, and dynamically focusing on the motion state of key areas through the feature enhancement module; S5: Correction control, which calculates the real-time flow and center of gravity offset of the material based on the time and space characteristics, and uses a multi-source data fusion algorithm to optimize the calculation results and output correction instructions to the actuator.

2. The belt conveyor deviation correction method according to claim 1, characterized in that: The correction instruction output in step S5 is generated by a PID control algorithm, which is based on the deviation e(t) between the preset target value r(t) and the real-time center of gravity offset y(t) of the material calculated in step S5, that is, e(t)=r(t)-y(t), and then generates the control quantity through a linear combination of proportion, integration and differentiation.

3. The belt conveyor deviation correction method according to claim 2, characterized in that: The transfer function of the PID control algorithm is: In the formula, K p is the magnification factor of the proportional link; T i is the integration time constant, K i is the integration coefficient, K i =K p / T i ; T d is the differential time constant, K d is the differential coefficient, K d =K p *T d .

4. The belt conveyor deviation correction method according to claim 3, characterized in that: Proportional coefficient K p Used to speed up system response; Integration time constant T i Used to eliminate steady-state errors; Differential time constant T d Used to predict deviation change trends.

5. A belt conveyor deviation correction device, characterized in that: Used to adjust the position of the belt conveyor guide plate (A) to adjust the material drop position, including: A deviation correction module (1), the deviation correction module (1) comprising a driving unit (11) and a deviation correction rod (12); one end of the deviation correction rod (12) is connected to an adjusting screw rod (B) of a belt conveyor guide plate (A), and the other end of the deviation correction rod (12) is connected to an output end of the driving unit (11); The driving unit (11) can drive the deviation correction rod (12) to rotate forward or reverse, thereby driving the adjusting screw rod (B) to rotate forward or reverse, changing the position of the material guide plate (A) to adjust the material landing point.

6. The belt conveyor deviation correcting device according to claim 5, characterized in that: The driving unit (11) comprises a motor (11a), a reducer (11b) connected to the output end of the motor (11a), and a transmission assembly (11c) connecting the reducer (11b) and the deviation correction rod (12); The reducer (11b) is used to reduce the rotation speed of the motor (11a) and increase the output torque; The transmission assembly (11c) is used to transmit the output power of the motor (11a) to the deviation correction rod (12).

7. The belt conveyor deviation correcting device according to claim 6, characterized in that: Also includes, A monitoring module (2), the monitoring module (2) comprising a detector (21) for monitoring the falling track of materials, and a hanging frame (22) for hanging and installing the detector (21) on one side of the belt conveyor; One end of the suspension frame (22) is detachably connected to the truss (C), and the other end of the suspension frame (22) is detachably connected to the detector (21).

8. The belt conveyor deviation correcting device according to claim 7, characterized in that: The suspension frame (22) comprises a cantilever (22a), a locking bracket (22b) arranged at one end of the cantilever (22a) for connecting to a truss (C), and a movable bracket (22c) arranged at the other end of the cantilever (22a) for mounting a detector (21); the locking bracket (22b) and the movable bracket (22c) are both connected to the cantilever (22a) by bolts.

9. The belt conveyor deviation correcting device according to claim 8, characterized in that: The cantilever (22a) comprises a first arm (22a-1) and a second arm (22a-2), wherein the first arm (22a-1) and the second arm (22a-2) are connected by bolts, and the first arm (22a-1) or the second arm (22a-2) has through holes (22a-3) arranged along the length direction.

10. A belt conveyor deviation correction system, characterized in that: It comprises at least one belt conveyor deviation correcting device as claimed in any one of claims 5 to 9; and server; A programmable controller is used to receive material center of gravity deviation data sent by a server, perform PID calculation, and output a deviation correction instruction to the belt conveyor deviation correction device to control the operation of the motor (11a).

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