Tensioning system and stretching detection method

Abstract

The invention discloses a tensioning system and a stretching detection method in the field of tensioning equipment, the tensioning system comprises a driving module, the output end of the driving module is rotatably provided with a tensioning roller, and a pressure sensor is arranged between the tensioning roller and the output end of the driving module; the analog quantity input module is used for measuring the linear distance between the driving module and the two ends of the belt; the elongation module is used for measuring the elongation of the driving module; the controller is electrically connected with the driving module, the analog quantity input module and the elongation module; the driving module designed in the application extrudes the tensioning roller and the belt, the two ends of the belt are installed on the driven roller and the driving roller in actual production, related data are recorded through the analog input module and the elongation module, the elongation of the belt is monitored, and adaptive tensioning operation on the belt is completed.

Description

Technical Field

[0001] This application relates to the technical field of tensioning equipment, and particularly relates to a tensioning system and a stretching detection method. Background Art

[0002] There are a large number of belt conveyor equipments at the silk reeling production site. The tension of the belt is realized through a tensioning roller. As the service time becomes longer, the belt will stretch naturally, and maintenance personnel need to continuously check and adjust it; at the same time, as time goes by, the stretching length of the belt will become larger and larger, and it is almost impossible for humans to control the limit value of the elongation of the belt during use. How to achieve the adaptive tensioning of the belt is what we need to solve. Summary of the Invention

[0003] The purpose of this application is to provide a tensioning system and a stretching detection method to adaptively adjust the belt and ensure the safety of the belt during use.

[0004] To achieve the above purpose, the following technical solutions are adopted in this application: In the first aspect, this application discloses a tensioning system for tensioning a belt, which includes A driving module, a tensioning roller is rotatably installed at the output end of the driving module, and a pressure sensor is provided between the tensioning roller and the output end of the driving module; An analog input module for measuring the straight-line distance between the driving module and the bearing shafts at both ends of the belt; An elongation module for measuring the output length of the driving module; A controller, which is electrically connected to the driving module, the analog input module, and the elongation module.

[0005] A further solution of this application is that the driving module includes a first electric cylinder and a second electric cylinder. The output ends of the first electric cylinder and the second electric cylinder are respectively rotatably connected to both ends of the tensioning roller. A first sensor is provided between the first electric cylinder and the tensioning roller, and a second sensor is provided between the second electric cylinder and the tensioning roller.

[0006] A further solution is that the analog input module includes a first distance measuring instrument and a second distance measuring instrument. The first distance measuring instrument, the second distance measuring instrument, the first electric cylinder, and the second electric cylinder are arranged adjacent to each other in a one-to-one correspondence.

[0007] A further solution is that the tensioning system further includes an alarm module, and the alarm module is signal-connected to the controller.

[0008] In the second aspect, this application discloses a stretching detection method, which includes Setting the set pressure and the preset stretching limit value of the belt; The control drive module drives the tensioning roller to squeeze the belt to perform a tensioning movement until the value of the pressure sensor reaches the set pressure, and the tensioning roller stops telescoping. Obtain the initial length of the drive module recorded by the analog input module; the analog input module records the initial distances between the drive module and both ends of the belt, and calculates the initial belt length through the host computer. Control the drive module to drive the tensioning roller to continuously move and squeeze the belt. The elongation module records the real-time length of the drive module, and the analog input module records the real-time distances between the drive module and both ends of the belt. Calculate the length of the belt after stretching through the host computer. Calculate the stretching length of the belt. The host computer judges whether the stretching length of the belt exceeds the preset stretching limit value. If the stretching length of the belt is greater than the preset stretching limit value, the drive module stops operating. Otherwise, the belt is used normally.

[0009] In a further solution of the present application, the calculation of the initial belt length includes Formula: ; Where L is the initial length; X1 is the initial distance between the drive module and one end of the belt; X2 is the initial distance between the drive module and the other end of the belt; M is the initial belt length.

[0010] In a further solution of the present application, the calculation of the length of the belt after stretching includes Formula: ; Where l is the real-time length; x 1 is the real-time distance between the drive module and one end of the belt; x 2 is the real-time distance between the drive module and the other end of the belt; m is the length of the belt after stretching.

[0011] In a further solution of the present application, the calculation of the stretching length of the belt includes a formula; ; Where ΔM is the stretching length of the belt; M is the initial belt length; is the length of the belt after stretching.

[0012] In a third aspect, the present application discloses a computer-readable storage medium, on which a computer program / instructions are stored. When the computer program / instructions are executed by a processor, the steps of the above stretching detection method are implemented.

[0013] The beneficial effects of the present application are: The drive module designed in this application realizes the extrusion of the tension roller and the belt. In actual production, both ends of the belt are installed on the driven and driving rollers. The analog input module and the elongation module record relevant data to monitor the elongation of the belt and complete the adaptive tensioning operation of the belt.

[0014] In addition, a detection method is also provided. The host computer calculates the difference between the initial length and the stretched length of the belt, compares the difference with the ultimate stretching value of the belt, and the host computer judges whether it can continue to be used and gives an early warning to ensure the safety of the belt during use. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is the front view after the tensioning system is installed in the embodiment of this application; Figure 2 It is the side view after the tensioning system is installed in the embodiment of this application Figure 3 It is the control logic schematic diagram of the tensioning system in the embodiment of this application; Figure 4 It is the flow chart in the stretching detection method in the embodiment of this application.

[0016] Wherein: 1. Tension roller; 2. Mounting bracket; 3. First sensor; 4. Second sensor; 5. First electric cylinder; 6. Second electric cylinder; 7. First rangefinder; 8. Second rangefinder; 71. First reflector; 81. Second reflector; 11. Driven roller; 12. Driving roller. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0017] Next, the technical solutions in the embodiments of this application will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of this application. Obviously, the described embodiments are only a part of the embodiments of this application, rather than all the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and in no way limits this application and its application or use. Embodiment 1

[0018] In this embodiment, a belt tensioning system is disclosed, which includes a drive module, an analog input module, an elongation module, and a PLC controller; a tension roller 1 is rotatably installed at the telescopic end (output end) of the drive module, and a pressure sensor is provided between the tension roller 1 and the output end of the drive module; the analog input module is used to measure the straight-line distance from the drive module to the bearing shafts at both ends of the belt; the elongation module is used to measure the output length of the drive module; the controller is electrically connected to the drive module, the analog input module, and the elongation module; an alarm module is also provided, which is electrically connected to the controller. Usually, the analog input module and the elongation module can be combined.

[0019] As Figure 1 AndFigure 2 As shown, in this embodiment, in order to facilitate the installation of the tensioning roller 1, the first electric cylinder 5 and the second electric cylinder 6 are arranged at intervals. The first electric cylinder 5 and the second electric cylinder 6 are fixed on the mounting bracket 2 and then fixed to the equipment or the basic bracket by bolts. The first sensor 3 and the second sensor 4 are respectively arranged between the electric cylinder and the corresponding mounting position of the tensioning roller 1; the output end of the PLC controller is electrically connected to the electric push cylinder through a module, and its function is to convert the output electrical signal into a longitudinal displacement. The first electric cylinder 5 and the second electric cylinder 6 are respectively connected to both ends of the tensioning roller 1 through bearings. The electric cylinder is electrically connected to the input port of the PLC controller through an elongation module, and its function is to transmit the extension length data of the electric cylinder to the PLC controller; the pressure signal detected by the sensor is electrically connected to the input port of the PLC controller through an analog input module, and its function is to transmit the pressure data borne on the tensioning roller to the PLC controller; finally, the first distance measuring instrument 7 and the first distance measuring instrument 7 are correspondingly arranged. The two are arranged adjacent to the first electric cylinder 5 and the second electric cylinder 6 in a one-to-one correspondence, and the distance measuring instrument is fixed at the root of the corresponding electric cylinder.

[0020] Observe the appendix Figure 2 As shown, a first reflector 71 is fixed directly below the driven roller 11; similarly, a second reflector 81 is fixed below the driving roller 12. The first reflector 71 corresponds to the first distance measuring instrument 7, and the second reflector 81 corresponds to the second distance measuring instrument 8. Each distance measuring instrument is electrically connected to the input port of the PLC controller through an analog input module, and transmits the horizontal distance data between the tensioning roller 1 and the rollers on both sides of the belt conveyor to the PLC controller; the extrusion degree between the tensioning roller 1 and the belt is controlled by the telescopic movement of the two electric cylinders, and the tensioning work of the belt is realized adaptively. Embodiment 2

[0021] As Figure 3 shown, a stretching detection method based on the above Embodiment 1 is disclosed in this embodiment; it includes the following steps; setting the set pressure and the stretching limit preset value of the belt; Controlling the driving module to drive the tensioning roller to extrude the belt to perform a tensioning movement until the value of the pressure sensor reaches the set pressure, and the tensioning roller stops telescoping, Obtaining the initial length of the driving module recorded by the analog input module; the analog input module records the initial distances between the driving module and both ends of the belt, and calculates the initial belt length through the upper computer; Controlling the driving module to drive the tensioning roller to continuously move and extrude the belt. The elongation module records the real-time length of the driving module, and the analog input module records the real-time distances between the driving module and both ends of the belt, and calculates the length of the belt after stretching through the upper computer; Calculating the stretching length of the belt, and the upper computer judges whether the stretching length of the belt exceeds the stretching limit preset value. If the stretching length of the belt is greater than the stretching limit preset value, the driving module stops operating. Otherwise, the belt is used normally.

[0022] As shown in the appendix Figure 3 and Figure 4 , in some embodiments, the stretching detection method is specifically implemented through the following operations.

[0023] The core control logic of the system is implemented by a PLC controller. The PLC controller can select products of series such as Siemens, Mitsubishi, BECKOFF, etc. In this application example, the Siemens series PLC is adopted; The system is configured with an analog input module, which is powered by 24VDC and provides voltage and current signal input methods.

[0024] The PLC controller is connected to the human-machine operation interface HMI through the Profinet network. After the belt tensioning system is installed and the belt is in an untensioned state, the maintenance personnel first select "zero calibration operation" on the human-machine operation interface, and the system collects the pressure value received by the electric cylinder in the current installation environment and uses it as the pressure zero point; After the "zero calibration operation" is completed, the maintenance personnel can set the belt tension coefficient (hereinafter referred to as "set pressure") on the human-machine operation interface of the upper computer according to the parameters provided by the belt supplier, and the system starts automatic tensioning. At this time, the first electric cylinder 5 and the second electric cylinder 6 synchronously extend upward to tension the belt. At the same time, the pressure values detected by the two sensors and the set pressure are analyzed and calculated in the PLC controller through the PID control method. Here, the algorithm of the conventional technology is omitted, and the output signal is transmitted to the drive module, that is, to control each electric push cylinder to fine-tune upward or downward to ensure that the belt tension is appropriate (the first electric cylinder 5 and the second electric cylinder 6 are adjusted independently according to their respective signals) to meet the production requirements.

[0025] After the sensor reaches the "set pressure", the system will automatically record the extended length of the electric cylinder push rod at this time (take the average value of the extended lengths of the two side electric cylinders) and store it as the "initial length" in the PLC controller; Calculate the initial belt length through formula (1); (1) Where L is the initial length; X1 is the initial distance between the drive module and one end of the belt (the axis of the driven roller 11); X2 is the initial distance between the drive module and the other end of the belt (the axis of the driving roller 12); M is the initial belt length. The "initial belt length" is stored in the PLC controller and displayed on the human-machine interface.

[0026] During the operation of the tensioning system, the belt will produce an extension phenomenon, and the upper computer will automatically adjust the telescopic length of each electric cylinder in real time according to the "set pressure" to ensure that the belt tension meets the use requirements; During the operation of the tensioning system, the upper computer will collect the current extended length of the electric cylinder push rod in real time, which is used as the "real-time length" (taking the average of the extended lengths of the two electric cylinders), and calculate the length of the belt after stretching through formula (2); ; (2) Wherein, l is the real-time length; x 1 is the real-time distance between the driving module and one end of the belt (the axis of the driven roller 11); x 2 is the real-time distance between the driving module and the other end of the belt (the axis of the driving roller 12); m is the length of the belt after stretching.

[0027] The calculated stretching length of the belt is stored in the PLC controller as the "current belt length" and displayed on the human-machine interface to realize the real-time monitoring of the belt stretching situation.

[0028] The stretching length of the belt is calculated by formula (3) (3) Wherein, ΔM is the stretching length of the belt; M is the initial length of the belt; is the length of the belt after stretching.

[0029] Finally, enter the preset stretching limit value in the upper computer. When the "belt stretching length" exceeds the preset stretching limit value, the upper computer locks the elongation function of the electric push cylinder to prevent the belt from being further stretched and broken. At the same time, the alarm module automatically sends out audible and visual alarm information to prompt the personnel to conduct on-site inspection and replacement; if the "belt stretching length" does not exceed the preset stretching limit value, the tensioning system can work normally. Embodiment 3

[0030] This embodiment discloses a computer-readable storage medium, on which a computer program / instructions are stored. When the computer program / instructions are executed by a processor, the steps of the stretching detection method in Embodiment 2 are implemented.

[0031] In the description of the present application, it should be understood that the orientation or positional relationship indicated by the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation to the present application. In addition, the terms "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first", "second", etc. may explicitly or implicitly include one or more of such features. In the description of the present application, unless otherwise specified, the meaning of "a plurality" is two or more.

[0032] In the description of the present application, it should be noted that unless otherwise clearly specified and defined, the terms "mounted", "connected", "coupled" shall be construed broadly. For example, it may be a fixed connection, a detachable connection, or an integral connection; it may be a mechanical connection or an electrical connection; it may be directly connected or indirectly connected through an intermediate medium, and it may be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present application can be understood through specific circumstances.

Claims

1. A tensioning system for tensioning a belt, characterized in that, including a driving module, a tensioning roller is rotatably installed at the output end of the driving module, and a pressure sensor is arranged between the tensioning roller and the output end of the driving module; an analog input module for measuring the straight-line distance between the driving module and the bearing shafts at both ends of the belt; an elongation module for measuring the output length of the driving module; a controller electrically connected to the driving module, the analog input module and the elongation module.

2. The tensioning system according to claim 1, characterized in that The driving module includes a first electric cylinder and a second electric cylinder. The output ends of the first electric cylinder and the second electric cylinder are respectively rotatably connected to both ends of the tensioning roller. A first sensor is arranged between the first electric cylinder and the tensioning roller, and a second sensor is arranged between the second electric cylinder and the tensioning roller.

3. A tensioning system according to claim 2, wherein, The analog input module includes a first distance measuring instrument and a second distance measuring instrument. The first distance measuring instrument, the second distance measuring instrument, the first electric cylinder and the second electric cylinder are arranged adjacent to each other in one-to-one correspondence.

4. A tensioning system according to claim 3, characterized in that, The tensioning system further includes an alarm module, and the alarm module is signal-connected to the controller.

5. A stretching detection method based on the tensioning system according to any one of claims 1 to 4, characterized in that, including setting the set pressure of the belt and the preset value of the stretching limit; controlling the driving module to drive the tensioning roller to extrude the belt to perform a tensioning movement until the value of the pressure sensor reaches the set pressure, and the tensioning roller stops telescoping; acquiring the initial length of the driving module recorded by the analog input module; the analog input module records the initial distances between the driving module and both ends of the belt, and the initial belt length is calculated by the upper computer; controlling the driving module to drive the tensioning roller to continuously move to extrude the belt, the elongation module records the real-time length of the driving module, the analog input module records the real-time distances between the driving module and both ends of the belt, and the length of the belt after stretching is calculated by the upper computer; calculating the stretching length of the belt, and the upper computer judges whether the stretching length of the belt exceeds the preset value of the stretching limit. If the stretching length of the belt is greater than the preset value of the stretching limit, the driving module stops operating. Otherwise, the belt is used normally.

6. The stretch detection method according to claim 5, characterized in that The calculation of the initial belt length includes Formula: ; where L is the initial length; X1 is the initial distance between the driving module and one end of the belt; X2 is the initial distance between the driving module and the other end of the belt; M is the initial belt length.

7. A stretching detection method according to claim 6, wherein The calculation of the length of the belt after stretching includes Formula: ; Among them, among them, l is the real-time length; x 1 is the real-time distance between the driving module and one end of the belt; x 2 is the real-time distance between the driving module and the other end of the belt; m is the length of the belt after stretching.

8. A stretching detection method according to claim 7, characterized in that, The calculation of the stretching length of the belt includes a formula; ； Where, ΔM is the belt stretching length; M is the initial belt length; is the length after belt stretching.

9. A computer-readable storage medium having computer programs / instructions stored thereon, characterized in that, When the computer program / instructions are executed by a processor, the steps of the stretching detection method described in claim 6 are implemented.

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