Conveyor speed control method and device and conveyor

Abstract

The embodiment of the invention provides a conveyor speed control method and device and a conveyor, and the method comprises the steps that S1, load data of a conveying area are collected, and the load data comprise cargo distribution pressure Lp, driving motor current Lc and conveyor belt deformation curvature Ld; s2, calculating a comprehensive load coefficient L of the conveying area; and S3, carrying out speed control on the conveying area based on the comprehensive load coefficient L. According to the method, load detection precision is improved through multi-source data fusion, dynamic weight adjustment adapts to different working conditions, resource allocation is optimized through partition differentiation control, faults are prevented through an exception handling mechanism, efficient, energy-saving and stable conveyor speed control is achieved, and production efficiency is improved.

Description

Technical Field

[0001] This application relates to the field of conveyor speed control, and particularly to a conveyor speed control method, a control device, and a conveyor. Background Art

[0002] The conveyor is the core conveyor in modern industrial production and logistics systems, and its speed control directly affects system efficiency, energy consumption, and conveyor life. Existing technologies mostly rely on a single sensor for load assessment, resulting in a high misjudgment rate, and adopt a fixed-parameter control strategy, which is difficult to adapt to complex working conditions such as impact loads and conveyor aging. Existing technologies often cause idling energy consumption in non-critical sections due to global unified speed regulation, insufficient response in critical bottleneck areas, and lack of real-time monitoring of the mechanical health state, resulting in frequent sudden failure shutdowns. This application aims to solve the above problems through multi-source data fusion and dynamic partition control. Summary of the Invention

[0003] This application provides a conveyor speed control method, a control device, and a conveyor. This method improves the load detection accuracy through multi-source data fusion, adjusts dynamic weights to adapt to different working conditions, optimizes resource allocation through partition differential control, and has an exception handling mechanism to prevent failures, realizing efficient, energy-saving, and stable conveyor speed control and improving production efficiency.

[0004] In a first aspect, a conveyor speed control method is provided, and the method includes:

[0005] S1: Collect load data of the conveying area, where the load data includes: cargo distribution pressure L p , drive motor current L c , and conveyor belt deformation curvature L d ;

[0006] S2: Calculate the comprehensive load coefficient L of the conveying area;

[0007] S3: Perform speed control on the conveying area based on the comprehensive load coefficient L.

[0008] It should be understood that this method collects the cargo distribution pressure L p , drive motor current L c , and conveyor belt deformation curvature L d , fuses multi-dimensional data to calculate the comprehensive load coefficient L, breaking through the limitations of traditional single-sensor detection. It should be noted that L p reflects the real cargo load, L c monitors the mechanical efficiency, L dWarn of structural deformation. The three complement each other to significantly improve the accuracy of load assessment and avoid false speed regulation caused by one-sided data. In addition, this method also adapts to different working conditions through dynamic weight adjustment, optimizes resource allocation through zone differential control, and has an exception handling mechanism to prevent failures, achieving efficient, energy-saving, and stable conveyor speed control and improving production efficiency.

[0009] Combined with the first aspect, in some implementation manners of the first aspect, the calculation method of the comprehensive load factor L is as follows:

[0010] L = αL p + βL c + γL d ,

[0011] where α, β, and γ are weight coefficients, satisfying α + β + γ = 1, and the distribution strategy of the weight coefficients is:

[0012] Under normal working conditions: α > β > γ;

[0013] Under high-load working conditions: β > α > γ;

[0014] Under the working condition of mechanical aging: γ > α > β.

[0015] It should be understood that through the weight distribution strategy adaptive to the working condition, the load assessment model is dynamically optimized, making the comprehensive load factor L more in line with the actual requirements, reducing the probability of false acceleration during light load in express sorting, and improving the overload warning sensitivity during heavy load in mines.

[0016] It should also be understood that under normal working conditions, the load fluctuation is stable, and the conveyor speed control gives priority to efficiency; under high-load working conditions, the conveyor pressure is large, and the conveyor speed control is mainly based on stability; while under the working condition of mechanical aging, the conveyor speed control should give priority to protecting the mechanical structure of the conveyor.

[0017] Combined with the first aspect, in some implementation manners of the first aspect, the step S3 includes:

[0018] S301: Divide the conveying area into a first area and a second area based on the comprehensive load factor of each position;

[0019] S302: Adopt dynamic PID control for the first area and PID control with fixed parameters for the second area.

[0020] Combined with the first aspect, in some implementation manners of the first aspect, the first area satisfies at least one of the following conditions:

[0021] The comprehensive load factor L of this conveying area is higher than the average value of adjacent sections and the difference exceeds the first threshold;

[0022] The absolute value of the change rate of the comprehensive load factor L in this conveying area is more than twice the absolute value of the average change rate of the adjacent section.

[0023] It should be understood that the first area is the conveying area on the conveyor where the comprehensive load factor changes suddenly and is significantly higher than that of the adjacent section; the second area is the conveying area on the conveyor where the comprehensive load factor is relatively stable.

[0024] It should be understood that by dividing the conveying area into the first area and the second area, and combining with the comprehensive load factor, the first area adopts dynamic PID for fast response, and the second area adopts fixed PID for energy-saving operation, which can improve the speed control efficiency and reduce energy consumption.

[0025] Combined with the first aspect, in some implementation manners of the first aspect, the dynamic PID control method includes:

[0026] The proportional term P is negatively correlated with the comprehensive load factor L;

[0027] The differential term D is positively correlated with the comprehensive load factor L.

[0028] It should be understood that proportional-integral-derivative (PID) control quickly responds to errors through the proportional term (P), eliminates steady-state errors through the integral term (I), and suppresses overshoot through the differential term (D). In this application, the dynamic PID adjusts parameters according to the comprehensive load factor L: when L increases, the proportional gain is reduced (to prevent overshoot under heavy load), when L changes suddenly, the differential effect is enhanced (to resist disturbances), and the integral term I is enabled when the comprehensive load factor L is within a specific range to eliminate steady-state errors; when L exceeds this range, the integral term is frozen.

[0029] Combined with the first aspect, in some implementation manners of the first aspect, the dynamic PID control method further includes:

[0030] Assigning priority control rights to the first area, and the execution priority of the control instructions in the first area is higher than that in the second area.

[0031] It should be understood that by assigning a higher control priority to the first area, real-time response to instructions in the key area is ensured, control delay is reduced, resource occupation in the non-key area is reduced at the same time, the overall control efficiency and stability of the system are improved, and regulation lag caused by resource competition is avoided.

[0032] Combined with the first aspect, in some implementation manners of the first aspect, the speed adjustment range of the first area is determined according to the value of the comprehensive load factor L, and the single adjustment range does not exceed 20% of the current speed.

[0033] It should be understood that restricting the single - time speed adjustment range to no more than 20% can effectively prevent the goods from tipping over or the conveyor from being impacted due to the rapid speed reduction under heavy load.

[0034] Combined with the first aspect, in some implementation manners of the first aspect, the method further includes an exception - handling step, which includes:

[0035] When the first region L c continues to exceed the second threshold, the speed is forced to decrease;

[0036] When the comprehensive load factor L of the second region is less than the third threshold, the second region enters the low - power state.

[0037] It should be understood that the drive - motor current (Lc) is selected as the exception reference value because it directly reflects the mechanical load and energy consumption. A sudden increase in current may indicate overload or slippage. Exceeding the second threshold indicates that the motor is operating over - loaded, and continuous exceeding the limit will trigger a gradual speed reduction to avoid burning out the motor. Through the current - protection and light - load sleep mechanisms, the service life of the conveyor can be extended and the operation safety can be guaranteed.

[0038] In a second aspect, a control device is provided. The control device includes a processor and a memory. The processor is coupled to the memory. The memory is used to store computer programs or instructions, and the processor is used to execute the computer programs or instructions in the memory so that any implementation manner in the first aspect is executed.

[0039] In a third aspect, a conveyor is provided. The conveyor includes the control device as described in the second aspect of the claims. Description of the Drawings

[0040] Figure 1 It is a flowchart of an implementation of a conveyor speed - control method provided by an embodiment of the present application.

[0041] Figure 2 It is a flowchart of an implementation of a conveying - area control method provided by an embodiment of the present application. Detailed Embodiments

[0042] The terms used in the following embodiments are only for the purpose of describing specific embodiments and are not intended to limit the present application. As used in the specification and appended claims of the present application, the singular forms "a", "an", "", "the above", "the", and "this" are also intended to include expressions such as "one or more", unless the context clearly indicates otherwise. It should also be understood that in the following embodiments of the present application, "at least one" and "one or more" mean one, two, or more than two. The term "and / or" is used to describe the association relationship of associated objects and indicates that three relationships can exist; for example, A and / or B can represent: A exists alone, A and B exist simultaneously, and B exists alone, where A and B can be singular or plural. The character " / " generally represents an "or" relationship between the associated objects before and after.

[0043] Reference to "one embodiment" or "some embodiments" etc. described in this specification means that a specific feature, structure, or characteristic described in connection with that embodiment is included in one or more embodiments of the present application. Thus, statements such as "in one embodiment", "in some embodiments", "in other some embodiments", "in still other embodiments", etc. that appear in different places in this specification do not necessarily refer to the same embodiment, but mean "one or more but not all embodiments", unless otherwise specifically emphasized in other ways. The terms "comprising", "including", "having", and their variants all mean "including but not limited to", unless otherwise specifically emphasized in other ways.

[0044] As the core conveyor in industrial logistics, the speed control of the conveyor is related to the energy efficiency and reliability of the system. Due to relying on a single sensor in the prior art, the misjudgment rate is high. The fixed parameter strategy is difficult to cope with impact loads and conveyor aging. Global speed regulation leads to idling in non-critical areas and response lag in critical areas, and the lack of mechanical health monitoring causes sudden failures.

[0045] The embodiments of the present application provide a conveyor speed control method, a control device, and a conveyor. This method can achieve efficient, energy-saving, and stable conveyor speed control and improve production efficiency.

[0046] Next, the technical solutions of the embodiments of the present application will be described in conjunction with the drawings.

[0047] Figure 1 It is a flowchart of the implementation of a conveyor speed control method provided by the embodiments of the present application. In some examples, the method includes:

[0048] S1: Collect load data in the conveying area, and the load data includes: cargo distribution pressure L p 、drive motor current L c and conveyor belt deformation curvature Ld ;

[0049] S2: Calculate the comprehensive load factor L of the conveying area;

[0050] S3: Perform speed control on the conveying area based on the comprehensive load factor L.

[0051] In a possible implementation, the cargo distribution pressure L p is detected in real time by a piezoelectric film sensor array, and the drive motor current L c is collected by a Hall current sensor. The deformation curvature L of the conveyor belt d is scanned by a laser rangefinder to obtain the transverse profile of the belt and calculate the curvature. All data are synchronously transmitted to the controller via the CAN bus.

[0052] In some examples, the calculation method of the comprehensive load factor L is:

[0053] L = αL p + βL c + γL d ,

[0054] where, are weight coefficients, satisfying, and the distribution strategy of the weight coefficients is:

[0055] Under normal working conditions: α > β > γ;

[0056] Under high load working conditions: β > α > γ;

[0057] Under mechanical aging working conditions: γ > α > β.

[0058] In a possible implementation, if the drive motor current L c increases by more than 15% / s continuously for 5 seconds, switch to the high load working condition weight; if the deformation curvature L d exceeds the threshold for 30 seconds continuously, switch to the mechanical aging working condition weight; otherwise, default to the normal working condition weight.

[0059] Figure 2 This is the implementation flowchart of a conveying area control method provided by an embodiment of this application.

[0060] In some examples, the step S3 includes:

[0061] S301: Divide the conveying area into a first area and a second area based on the comprehensive load factor at each position;

[0062] S302: Perform dynamic PID control on the first area and perform PID control with fixed parameters on the second area.

[0063] In some examples, the first area satisfies at least one of the following conditions:

[0064] The comprehensive load factor L of this conveying area is higher than the average value of the adjacent section and the difference exceeds the first threshold;

[0065] The absolute value of the change rate of the comprehensive load factor L of this conveying area is more than twice the average absolute value of the change rates of the adjacent sections.

[0066] In some examples, the dynamic PID control method includes:

[0067] The proportional term P is negatively correlated with the comprehensive load factor L;

[0068] The derivative term D is positively correlated with the comprehensive load factor L.

[0069] In a possible implementation, the proportional term P = 2.0×(1 - 0.4L), and the derivative term The integral term I is enabled when the comprehensive load factor L is within the range of 0.4 to 0.6 to eliminate the steady-state error; when L exceeds this range or the absolute value of the change rate exceeds 10% / s, the integral term is frozen.

[0070] In a possible implementation, the first threshold is dynamically set to 20% of the average load factor of the adjacent section, and combined with historical data smoothing filtering to avoid misjudgment due to short-term fluctuations.

[0071] In some examples, the dynamic PID control method further includes:

[0072] Assigning priority control rights to the first area, and the execution priority of the control instructions of the first area is higher than that of the second area.

[0073] In a possible implementation, a preemptive scheduling strategy is adopted. The control instructions of the first area are triggered by a hardware interrupt, and the priority is set to the highest level of the RTOS (Real-Time Operating System). The instructions of the second area are executed in a low-priority task queue to ensure preemptive response to the instructions in the critical area.

[0074] In some examples, the speed adjustment range of the first area is determined according to the value of the comprehensive load factor L, and the single adjustment range does not exceed 20% of the current speed.

[0075] In some examples, the method further includes an exception handling step including:

[0076] When L in the first area c continuously exceeds the second threshold, the speed is forced to decrease;

[0077] When the comprehensive load factor L of the second area is less than the third threshold, the second area enters the low-power state.

[0078] In a possible implementation, the second threshold is set to 90% of the rated current of the drive motor (for example, if the rated current of the motor is 10 A, the threshold is 9 A), and exceeding the limit indicates a risk of mechanical overload; the third threshold is set to the comprehensive load factor L = 0.2, and a value lower than this is determined to be a light load.

[0079] The embodiment of the present application provides a control device, which includes a processor and a memory. The processor is coupled to the memory. The memory is used to store computer programs or instructions, and the processor is used to execute the computer programs or instructions in the memory, so that any of the foregoing examples and implementation manners are executed.

[0080] The embodiment of the present application further provides a conveyor, which includes the control device as described above.

[0081] The above is only the preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above embodiments. Any equivalent modifications or changes made by those of ordinary skill in the art according to the disclosed content of the present invention should be included in the protection scope recorded in the claims.

Claims

1. A conveyor speed control method, characterized in that: The method comprises: S1: Collecting load data of the transport area, the load data includes: cargo distribution pressure L p , drive motor current L c and the conveyor belt deformation curvature L d ; S2: Calculate the comprehensive load factor L of the conveying area; S3: Based on the comprehensive load factor L, the speed of the conveying area is controlled.

2. The method according to claim 1, characterized in that The calculation method of the comprehensive load factor L is: L=αL p +βL c +γL d , Among them, α, β, γ are weight coefficients, satisfying α+β+γ=1, and the allocation strategy of the weight coefficients is: Under normal working conditions: α>β>γ; Under high load conditions: β>α>γ; Under mechanical aging conditions: γ>α>β.

3. The method according to claim 1, characterized in that The step S3 comprises: S301: Dividing the transport area into a first area and a second area based on the comprehensive load factor of each position; S302: dynamic PID control is applied to the first region, and fixed parameter PID control is applied to the second region.

4. The method according to claim 3, characterized in that: The first area satisfies at least one of the following conditions: The comprehensive load factor L of the transport area is higher than the average of the adjacent sections and the difference exceeds the first threshold; The absolute value of the change rate of the comprehensive load factor L in this transportation area is twice the average absolute value of the change rate of the adjacent sections.

5. The method according to claim 3, characterized in that: The dynamic PID control method comprises: The proportional term P is negatively correlated with the comprehensive load factor L; The differential term D is positively correlated with the comprehensive load factor L.

6. The method according to claim 3, characterized in that The dynamic PID control method also includes: Priority control is allocated to the first region, and the execution priority of the control instruction of the first region is higher than that of the second region.

7. The method according to claim 3, characterized in that The speed adjustment range of the first area is determined according to the value of the comprehensive load factor L, and a single adjustment range does not exceed 20% of the current speed.

8. The method according to claim 1, characterized in that The method further includes an exception handling step comprising: When the driving current in the first region continuously exceeds the second threshold, the speed is forced to decrease; When the comprehensive load factor L of the second area is less than a third threshold, the second area enters a low power consumption state.

9. A control device, characterized in that: The method comprises a processor and a memory, wherein the processor is coupled to the memory, the memory is used to store computer programs or instructions, and the processor is used to execute the computer programs or instructions in the memory, so that the method according to any one of claims 1 to 8 is executed.

10. A conveyor, characterized in that: The conveyor comprises a control device as claimed in claim 9.

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