Belt deviation correction method, device and system

Abstract

The application discloses a belt conveyor deviation rectifying method, device and system, relates to the technical field of belt conveyor deviation rectifying, and comprises the following steps: S1, dynamic signal acquisition and analysis; S2, environmental noise suppression processing; S3, material feature extraction and classification; S4, space-time feature modeling and analysis; and S5, deviation rectifying control. The deviation rectifying device comprises a deviation rectifying module, 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 an output end of the driving unit. The driving unit can drive the deviation rectifying rod to rotate forward or reversely, thereby driving the adjusting lead screw to rotate forward or reversely, changing the position of the guide plate and realizing the adjustment of a material falling point. Through the scheme, the belt deviation of the conveyor is effectively controlled, belt wear is obviously reduced, non-planned shutdown of the unit caused by frequent replacement of the belt is avoided, material supply is ensured, and non-planned shutdown examination is avoided.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of belt conveyor deviation correction, in particular to a belt conveyor deviation correction method, device and system. BACKGROUND

[0002] In the production, transportation and processing of power plants, steel plants and coal, the coal needs to be transported. The belt conveyor is widely used in many industries due to its large transportation capacity, strong carrying capacity and long transportation distance.

[0003] The Euro bin for storing coal is 65 meters high. The coal is transported by multi-stage belt conveyor from the wharf to the coal bin. During the transportation process, the horizontal speed difference of the coal falling process may be caused by the change of the speed of the upper belt conveyor, which may cause the center of gravity of the material accumulated on the belt to deviate to the right or left. If the center of gravity deviates to one direction for a long time, the belt may deviate to the opposite direction. The existing method for detecting the deviation of the belt is to manually patrol the site or install a camera at the end of the belt line. The deviation of the belt is monitored in the central control room. When the deviation of the belt is found, the maintenance personnel need to manually adjust the position of the belt at the starting end of the belt line. Manual patrol is limited by the number of patrols and may not be able to timely detect the deviation of the belt. The maintenance personnel can reduce the workload by visually judging the deviation of the belt through the camera. However, it takes a certain time to walk from the central control room to the belt line after the deviation of the belt is found, which cannot achieve timely correction. Moreover, it is difficult to make a quick and accurate judgment through manual detection, which also increases the work intensity of the related personnel. SUMMARY

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

[0005] The above technical problems are solved by the following technical solutions: the present application provides a belt conveyor deviation correction method, comprising the following steps,

[0006] S1: dynamic signal acquisition and analysis, emitting a modulated signal through an electromagnetic wave detection device, acquiring real-time original signals of a target area, analyzing the original signals, and generating a multi-dimensional data set containing target position, speed and phase information;

[0007] S2: environmental noise suppression processing, dynamically separating the background of the multi-dimensional data set, distinguishing static structures and dynamic targets, implementing adaptive filtering in the frequency domain or time-frequency joint domain, and suppressing multipath interference and electromagnetic noise;

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

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

[0010] S5: Correction control, calculating the real-time flow and center of gravity offset of the material based on the spatiotemporal features, and optimizing the calculation results using a multi-source data fusion algorithm to output correction instructions to the actuator.

[0011] In a preferred embodiment of the belt conveyor correction method described in the present application: the correction instruction output in step S5 is generated using a PID control algorithm, which is based on the deviation e(t) between the preset target value r(t) and the material's real-time center of gravity offset y(t) calculated in step S5, i.e. e(t) = r(t) - y(t), and then generates a control amount through a linear combination of proportion, integration, and differentiation.

[0012] In a preferred embodiment of the belt conveyor correction method described in the present application: the transfer function of the PID control algorithm is:

[0013]

[0014] where K p is the amplification coefficient of the proportional element;

[0015] T i is the integral time constant, K i is the integral 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 correction method described in the present application: the proportional coefficient K p is used to accelerate the system response; the integral time constant T i is used to eliminate steady-state error; and the differential time constant T d is used to predict the trend of deviation.

[0018] Preferably, the present application provides a belt conveyor deviation rectifying device for adjusting the position of a guide plate of a belt conveyor to adjust the material dropping position, comprising a deviation rectifying module, the deviation rectifying module comprising a driving unit and a deviation rectifying rod; one end of the deviation rectifying rod is connected with an adjusting screw rod of the guide plate of the belt conveyor, and the other end of the deviation rectifying rod is connected with an output end of the driving unit; the driving unit can drive the deviation rectifying rod to rotate forward or reversely, thereby driving the adjusting screw rod to rotate forward or reversely, changing the position of the guide plate and realizing the adjustment of the material dropping point.

[0019] In a preferred embodiment of the belt conveyor deviation rectifying device, the driving unit comprises a motor, a speed reducer connected with the output end of the motor, and a transmission assembly connecting the speed reducer and the deviation rectifying rod; the speed reducer is used to reduce the rotating speed of the motor and increase the output torque; and the transmission assembly is used to transmit the output power of the motor to the deviation rectifying rod.

[0020] In a preferred embodiment of the belt conveyor deviation rectifying device, the device further comprises a monitoring module, the monitoring module comprising a detector for monitoring the falling track of the material and a suspension bracket for suspending and mounting the detector on one side of the belt conveyor; one end of the suspension bracket is detachably connected with a truss, and the other end of the suspension bracket is detachably connected with the detector.

[0021] In a preferred embodiment of the belt conveyor deviation rectifying device, the suspension bracket comprises a cantilever, a locking support arranged at one end of the cantilever for connecting the truss, and a movable support arranged at the other end of the cantilever for mounting the detector; the locking support and the movable support are connected with the cantilever through bolts.

[0022] In a preferred embodiment of the belt conveyor deviation rectifying device, the cantilever comprises a first arm rod and a second arm rod, the first arm rod and the second arm rod are connected through bolts, and the first arm rod or the second arm rod has through holes arranged along the length direction.

[0023] Preferably, the present application provides a belt conveyor deviation rectifying system, comprising at least one belt conveyor deviation rectifying device, a server, and a programmable controller; the programmable controller is used to receive the material gravity center deviation data sent by the server, perform PID operation, and output a deviation rectifying instruction to the belt conveyor deviation rectifying device to control the operation of the motor.

[0024] The present application has the advantages that the belt deviation of the conveyor is effectively controlled, the belt wear is significantly reduced, the non-planned shutdown of the unit caused by frequent replacement of the belt is avoided, the material supply is ensured, and the non-planned shutdown examination is avoided. BRIEF DESCRIPTION OF DRAWINGS

[0025] In order to make the technical solutions of the embodiments of the present application clearer, the drawings of the embodiments of the present application will be briefly introduced below. Obviously, the drawings described in the following description are only related to some embodiments of the present application and not limit the present application. Among them:

[0026] Fig. 1 The overall structure schematic diagram of the deviation correction module in the present application is shown;

[0027] Fig. 2 The side view structure schematic diagram of the deviation correction module in the present application is shown;

[0028] Fig. 3 The rear view structure schematic diagram of the deviation correction module in the present application is shown;

[0029] Fig. 4 The overall structure schematic diagram of the monitoring module in the present application is shown;

[0030] Fig. 5 The front view structure schematic diagram of the monitoring module in the present application is shown;

[0031] Fig. 6 The side view structure schematic diagram of the monitoring module in the present application is shown;

[0032] In the figure: 1, deviation correction module; 11, driving unit; 11a, motor; 11b, speed reducer; 11c, transmission assembly; 12, deviation correction rod; 13, shaft coupling; 14, machine base; 2, monitoring module; 21, detector; 22, suspension bracket; 22a, cantilever; 22a-1, first arm rod; 22a-2, second arm rod; 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, adjusting screw; C, truss. DETAILED DESCRIPTION

[0033] In order for those skilled in the art to have a better understanding of the present application, the present application will be further described in detail below in conjunction with specific embodiments and drawings.

[0034] The terms used in the present application are those general terms currently widely used in the art in consideration of the functions about the present application, but these terms can be changed according to the intention of those skilled in the art, precedents, or new technologies in the art. In addition, specific terms can be selected by the applicant, and in this case, the detailed meaning thereof will be described in the detailed description of the present application. Therefore, the terms used in the specification should not be understood as simple names, but based on the meaning of the terms and the overall description of the present application.

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

[0036] S1: Dynamic signal acquisition and analysis, emit modulated signals through electromagnetic wave detection devices, acquire real-time original signals of the target area, and analyze the original signals to generate a multi-dimensional data set containing target position, speed, and phase information.

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

[0038] S1.1: Use a 77GHz millimeter wave radar array to emit an FMCW signal with a sweep bandwidth of 4GHz, and the scanning frequency is ≥20Hz, to collect real-time original radar signals.

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

[0040] S2: Environmental noise suppression processing, dynamically separate static structures and dynamic targets, implement adaptive filtering in the frequency domain or time-frequency joint domain, and suppress multipath interference and electromagnetic noise.

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

[0042] S2.1: Separate static background and dynamic targets by sliding window Kalman filtering (SW-KF), i.e., separate the belt, support (static background) and material (dynamic target).

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

[0044] S3: Material feature extraction and classification, reconstruct the three-dimensional spatial distribution of the material based on the dynamic target data, analyze the material's motion velocity field, correct the velocity error caused by external vibration, and according to the electromagnetic scattering characteristics, inverse the material physical properties to realize material classification.

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

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

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

[0048] S3.3: Inversion of material dielectric constant based on radar cross section (RCS) characteristics, identification of material types (coal, ore, etc.).

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

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

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

[0052] S4.2: Introduce attention mechanism (CBAM module) in the spatiotemporal model to dynamically focus on the movement features of high-flow areas.

[0053] S5: Correction control, based on spatiotemporal features to calculate the real-time flow and center of gravity offset of the material, and use multi-source data fusion algorithm to optimize the calculation results, and output correction instructions to the execution mechanism.

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

[0055] S5.1: Based on the dynamic target movement features of high-flow areas focused in step S4.2, calculate the volume flow rate and center of gravity offset of the dynamic target through point cloud density field integration and spatiotemporal convolution of belt speed.

[0056] S5.2: Use federated Kalman filter (FKF) to fuse multi-dimensional radar data to compensate for errors in the calculation results in step S5.1, generate the final center of gravity offset data, and output to the control system to output correction instructions to the execution mechanism to execute correction action.

[0057] Further, the correction instructions output in step S5 are generated using 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, i.e. e(t) = r(t) - y(t), and then generates the control amount through linear combination of proportion, integral and differential.

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

[0059]

[0060] In the formula, K p is the amplification coefficient of the proportional link; specifically, the proportional coefficient K pUsed to accelerate system response and improve system adjustment accuracy, a larger proportional gain results in faster adjustment. However, a proportional gain that is too large can cause system instability, while a proportional gain that is too small can lead to excessively long system settling time. Taking all factors into consideration, K... p The value range is 0.5 to 1.2, with K being the preferred value. p =0.8.

[0061] T i K is the integration time constant. i K is the integral coefficient. i =K p / T i Specifically, the integration time constant T i To eliminate steady-state error, a larger integral time constant results in faster elimination of the steady-state error. However, an excessively large integral time constant can lead to integral saturation, while an excessively small one will make it difficult to eliminate the steady-state error, affecting the system's adjustment accuracy. Considering all factors, T... i The value range is 3s to 8s, with T being the preferred value. i =5.

[0062] T d K is the differential time constant. d K is the differential coefficient. d =K p *T d Specifically, the differential time constant T d It is used to predict the trend of deviation changes and reduce overshoot and settling time. However, an excessively large differential time constant will reduce the system's anti-interference capability, T d The value range is 0.1s to 0.5s, with T being preferred. d =0.2.

[0063] Reference Figs. 1-6 This embodiment provides a belt conveyor correction device for adjusting the position of the belt conveyor guide plate A to adjust the material drop position, including a correction module 1 and a monitoring module 2.

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

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

[0066] Further, the driving unit 11 includes a motor 11a, a speed reducer 11b connected to the output end of the motor 11a, and a transmission assembly 11c connecting the speed reducer 11b and the deviation rectifying rod 12. The motor 11a and the speed reducer 11b are both arranged on the base 14, and the transmission assembly 11c is a belt transmission or a chain transmission. The speed reducer 11b is used to reduce the rotating 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 rectifying rod 12.

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

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

[0069] Further, the cantilever 22a includes a first arm 22a-1 and a second arm 22a-2. 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. The bolts can pass through any two through holes 22a-3 of the first arm 22a-1 and the second arm 22a-2.

[0070] Further, 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. 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 adjust the detection range of the detector 21.

[0071] As an optional embodiment, the deviation rectifying device further comprises an electrical auxiliary module, including a position sensor 3 for detecting the position of the material guide plate A on the belt conveyor in real time and a limit switch for limiting the maximum displacement stroke of the material guide plate A.

[0072] The embodiment provides a belt conveyor deviation rectifying system, which comprises at least one above-mentioned belt conveyor deviation rectifying device; and a server and a programmable controller; wherein the programmable controller is used for receiving material gravity center deviation data sent by the server, performing PID operation, and outputting a deviation rectifying instruction to the belt conveyor deviation rectifying device to control the operation of the motor 11a.

[0073] Finally, it should be noted 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 application.

Claims

1. A method for correcting deviation of a belt conveyor, characterized by: The method comprises the following steps, S1: dynamic signal acquisition and analysis, emitting a modulated signal through an electromagnetic wave detection device, acquiring the original signal of the target area in real time, analyzing the original signal, and generating a multi-dimensional data set containing the position, velocity, and phase information of the target object; S2: environmental noise suppression processing, dynamically separating the background of the multi-dimensional data set, distinguishing static structures from dynamic targets, and implementing adaptive filtering in the frequency domain or time-frequency joint domain to suppress multipath interference and electromagnetic noise; S3: material feature extraction and classification, reconstructing the three-dimensional spatial distribution of the material based on the dynamic target data, analyzing the material's velocity field, correcting the velocity error caused by external vibration, and inverting the material's physical properties according to the electromagnetic scattering characteristics to achieve material classification; S4: spatiotemporal feature modeling and analysis, combining the three-dimensional spatial distribution and the corrected velocity field to extract the spatiotemporal features of the material motion, and dynamically focusing on the motion state of the key area through the feature enhancement module; S5: deviation correction control, calculating the real-time flow and center of gravity deviation of the material based on the spatiotemporal features, optimizing the calculation results using a multi-source data fusion algorithm, and outputting deviation correction instructions to the execution mechanism; The deviation of the offset instruction output in step S5 is generated by using a PID control algorithm, and the PID control algorithm is based on a preset target value The deviation of the offset instruction output in step S5 is generated by using a PID control algorithm, and the PID control algorithm is based on a preset target value The deviation of the offset instruction output in step S5 is generated by using a PID control algorithm, and the PID control algorithm is based on a preset target value The deviation of the offset instruction output in step S5 is generated by using a PID control algorithm, and the PID control algorithm is based on a preset target value The deviation of the offset instruction output in step S5 is generated by using a PID control algorithm, and the PID control algorithm is based on a preset target value The transfer function of the PID control algorithm is: ； In the formula, is the amplification factor of the proportional element; is an integration time constant, is an integration coefficient, ; is the differential time constant, is the differential coefficient, ; proportionality factor for accelerating system response; Integration time constant For eliminating steady state error; Differential time constant For predicting the trend of the bias variation.

2. The belt deviation correction method according to claim 1, characterized in that: A belt deviation correction device using the belt deviation correction method, the belt deviation correction device is used to adjust the position of the belt guide plate (A) to adjust the material falling position, comprising, A 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 with the adjusting screw rod (B) of the belt guide plate (A), and the other end of the deviation correction rod (12) is connected with the 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 guide plate (A), and realizing the adjustment of the material falling point.

3. The belt deviation correction method according to claim 2, characterized in that: The driving unit (11) comprises a motor (11a), a speed reducer (11b) connected with the output end of the motor (11a), and a transmission assembly (11c) connecting the speed reducer (11b) and the deviation correction rod (12); The speed reducer (11b) is used to reduce the rotating 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).

4. The belt deviation correction method according to claim 3, characterized in that: Further comprising, A monitoring module (2) comprising a detector (21) for monitoring the material falling track, and a suspension bracket (22) for suspending the detector (21) on one side of the belt conveyor; One end of the suspension bracket (22) is detachably connected with the truss (C), and the other end of the suspension bracket (22) is detachably connected with the detector (21).

5. The belt deviation correction method according to claim 4, characterized in that: The suspension bracket (22) comprises a cantilever (22a), a locking bracket (22b) provided at one end of the cantilever (22a) for connecting the truss (C), and a movable bracket (22c) provided at the other end of the cantilever (22a) for mounting the detector (21), and the locking bracket (22b) and the movable bracket (22c) are connected with the cantilever (22a) by bolts.

6. The belt deviation correction method according to claim 5, wherein: The cantilever (22a) includes a first arm rod (22a-1) and a second arm rod (22a-2), the first arm rod (22a-1) and the second arm rod (22a-2) are connected by bolts, the first arm rod (22a-1) or the second arm rod (22a-2) has a through hole (22a-3) arranged along the length direction.

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