A mine long-distance bidirectional belt conveyor anti-deviation system and method

Abstract

This invention provides a system and method for preventing belt misalignment in a long-distance bidirectional conveyor belt used in mining. The system comprises a support base rotatably connected to the machine frame via a rotating shaft; idler roller supports connected to the support base via liftable support assemblies; and a linear telescopic correction mechanism connected to the support base. The misalignment monitoring unit includes a laser displacement sensor, tilt sensor, tension sensor, friction sensor, and speed monitoring mechanism. The positioning unit includes an RFID tag and multiple other devices. The method involves real-time monitoring using the monitoring and positioning units. When misalignment occurs, the linear telescopic correction mechanism is controlled to extend and retract. Simultaneously, three liftable individual supports in the corresponding monitoring section are controlled to perform a combined lifting and lowering motion. This utilizes the rotation of the support base and the swinging motion of the idler roller supports to jointly correct the misaligned belt. This system and method achieve efficient and precise belt misalignment correction.

Description

Technical Field

[0001] This invention belongs to the field of intelligent control technology, specifically relating to a system and method for preventing deviation of a long-distance bidirectional conveyor belt in mining. Background Technology

[0002] Mining conveyors are widely used in coal mines and other mining industries for material transport. With increasing mining depth, conveyors are used more frequently under complex geological conditions. However, due to the unique characteristics of the mining environment, including dust, humidity, temperature variations, and high-load operation, the stability of the conveyor is often affected, leading to belt misalignment. Belt misalignment not only damages the conveyor belt but can also affect production efficiency and even pose serious safety hazards.

[0003] Traditional technologies often rely on manual inspections or mechanical limit devices to prevent belt deviation. However, these traditional anti-deviation technologies have the following drawbacks: First, manual inspections are inefficient, lack real-time performance, and are difficult to cover long-distance conveyor belts. Second, mechanical limit devices can only trigger a stop when the deviation is severe, thus failing to achieve dynamic adjustment of the deviation. Furthermore, traditional anti-deviation technologies often use a single sensor for monitoring, which not only has low monitoring accuracy but also cannot pinpoint the specific offset position and angle, making it difficult to perform accurate correction and adjustment operations. Summary of the Invention

[0004] To address the problems existing in the prior art, this invention provides a system and method for preventing belt misalignment in long-distance bidirectional conveyor belts used in mining. This system has a simple structure and a high degree of intelligence, enabling it to accurately and efficiently determine whether the entire belt or certain parts are misaligned in real time. Furthermore, it can perform efficient and precise correction adjustments when misalignment occurs. This method also boasts a high degree of intelligence, capable of efficiently and accurately detecting belt misalignment and dynamically adjusting correction actions based on the belt's deviation.

[0005] To achieve the above objectives, the present invention provides a mine long-distance bidirectional conveyor belt conveyor anti-deviation system, including a belt conveyor, a linear telescopic correction mechanism, a deviation monitoring unit, a positioning unit, and a controller;

[0006] The belt conveyor includes a frame, a support base, liftable support assemblies, idler roller supports, and a belt. The frame is divided into multiple monitoring sections at equal intervals along the conveying direction, corresponding to the belt-carrying section. A rotating shaft is connected to the center of the lower end of the support base. Multiple support bases are evenly arranged in the multiple monitoring sections and rotatably connected to the top of the frame via the rotating shaft. Multiple liftable support assemblies are correspondingly installed on the upper ends of the multiple support bases. Multiple idler roller supports are correspondingly supported on the upper ends of the multiple liftable support assemblies. The belt is supported on the upper end of the idler roller supports.

[0007] Multiple sets of linear telescopic correction mechanisms are distributed in multiple monitoring sections. The fixed base of the linear telescopic correction mechanism is fixedly connected to the machine frame, and the end of its telescopic part is hinged to one end of the corresponding support base in the length direction.

[0008] The belt misalignment monitoring unit includes a laser displacement sensor, an tilt sensor, a tension sensor, a friction sensor, and a speed monitoring mechanism. Multiple laser displacement sensors are evenly distributed across multiple monitoring sections and mounted above the machine frame. Multiple tilt sensors are sequentially installed at the bottom of multiple idler supports. The tension sensor is mounted on the machine frame and contacts the belt. The friction sensor is mounted on the machine frame and contacts the surface of the belt. The speed monitoring mechanism includes a speed measuring roller and a speed sensor. The speed measuring roller is located between two idler supports in the middle section of the machine frame and is connected to the machine frame; its upper circular surface makes rolling contact with the belt. The speed sensor is mounted on the speed measuring roller.

[0009] The positioning unit includes RFID tags and readers. Several RFID tags are evenly embedded inside the belt along its length, and when multiple RFID tags are carried by the belt, they correspond to multiple monitoring sections. Multiple readers are distributed at the center of multiple monitoring sections and are mounted on the top of the machine frame.

[0010] The controller is connected to the deviation monitoring unit, the positioning unit, the belt conveyor, the liftable support group, and the linear telescopic entanglement mechanism.

[0011] In this invention, by connecting the support base to the machine frame via a rotating shaft, and simultaneously using a linear telescopic correction mechanism to drive the support base to rotate relative to the machine frame, a reverse force can be provided to the misaligned belt by rotating the idler bracket via the support base. This allows for quick and easy correction of the misaligned belt. Connecting the idler bracket to the support base via a liftable bracket assembly allows for adjusting the tilt angle of the idler bracket using the lifting motion of the assembly. This tilt angle adjustment further corrects the misaligned belt. Thus, the belt misalignment can be corrected through a combination of the rotation of the idler bracket relative to the machine frame and the tilt angle adjustment, ensuring the belt remains on its normal operating track and achieving reliable and efficient correction. The use of multiple laser displacement sensors facilitates the acquisition of displacement data at the belt edge positions in each monitoring section. By combining RFID tags and readers in the positioning unit, the local location information and offset angle of the belt in each monitoring section can be accurately determined. This facilitates the precise acquisition of offset direction and angle data at local locations, providing accurate adjustment basis for the correction process through precise location information. This allows for more accurate implementation of correction actions. Furthermore, the low power consumption and high stability of RFID tags enable precise identification and positioning of the belt. In this way, by simultaneously obtaining displacement and offset angle data, it is easy to determine whether a belt misalignment has occurred from different perspectives, ensuring the accuracy of the judgment. Because multiple readers are distributed at the center of multiple monitoring sections, and multiple RFID tags are embedded in the belt, multiple readers can synchronously collect information from multiple RFID tags at the center of multiple monitoring sections. This enables accurate local positioning of the belt in multiple monitoring sections, allowing for the detection of even minor belt misalignments. Therefore, it can accurately identify belt deviation when even a small deviation occurs, and intervene with correction actions immediately, effectively ensuring the timeliness and accuracy of correction and avoiding the difficulties of correction when larger deviations occur. The layout of multiple laser displacement sensors and multiple RFID tags in the positioning unit, combined with multiple readers, allows for comprehensive and real-time monitoring of belt deviation, facilitating timely detection of deviation problems throughout the entire conveying distance and ensuring the timeliness and reliability of local deviation correction. The installation of multiple tilt sensors facilitates the acquisition of tilt angle data for each idler support, thereby obtaining the change in tilt angle data during the correction process. The installation of tension sensors facilitates the acquisition of belt tension data. By setting up a friction sensor, it is easy to obtain the friction data of the belt.In this way, the tension and friction data facilitate the analysis of the belt's stress state, helping to identify the causes of belt misalignment and providing reliable technical support for corrective adjustments. The controller settings enable intelligent and precise detection of belt misalignment, automated corrective adjustments, and the transmission of monitoring data and corrective actions to a host computer. This allows the host computer to analyze the causes of belt misalignment and record historical corrective actions, providing reliable data support for subsequent controller adjustments.

[0012] The system has a simple structure and a high degree of intelligence. It can accurately and efficiently determine whether the belt is misaligned in the whole or in a local area in real time. At the same time, it can perform efficient and accurate correction and adjustment when misalignment occurs, which helps to ensure the efficient operation of the conveying operation.

[0013] Furthermore, to ensure monitoring accuracy, the spacing between multiple RFID tags is 0.5m, and the spacing between multiple readers is 2m.

[0014] Furthermore, to facilitate adjustment of the tilt angle of the idler bracket and to facilitate correction operations, the idler bracket is a V-shaped idler bracket; the liftable bracket assembly consists of three liftable individual brackets spaced apart along the length of the support base. Each liftable individual bracket includes an upper support frame, a lifting hydraulic cylinder, and a lower seat frame. The lower seat frame is fixedly connected to the upper end of the support base; the lower end of the upper support frame is connected to the lower seat frame via the lifting hydraulic cylinder, and the upper end of the upper support frame is hinged to the lower end of the idler bracket.

[0015] Furthermore, in order to facilitate timely and effective alerts to relevant management personnel in case of abnormal situations through sound and light reminders, so as to enable timely emergency response measures, an alarm is also included. The alarm is installed on the machine frame and connected to the controller, and is used to issue an alarm action according to the control of the controller.

[0016] As a preferred embodiment, it also includes a host computer, which is connected to the controller.

[0017] As a preferred embodiment, the controller is a PLC controller, and the host computer is an industrial computer.

[0018] This invention also provides a method for preventing deviation of a long-distance bidirectional conveyor belt in mining, employing a system for preventing deviation of a long-distance bidirectional conveyor belt in mining, comprising the following steps:

[0019] Step 1: During the operation of the belt conveyor, real-time monitoring is performed using the belt misalignment monitoring unit and the positioning unit. The displacement signal of each monitoring section edge of the belt is obtained by the laser displacement sensor at a set sampling frequency. The tilt angle signal of each idler support is obtained by the tilt sensor at a set sampling frequency. The tension signal of the belt is obtained by the tension sensor at a set sampling frequency. The friction force signal of the belt surface is obtained by the friction force sensor at a set sampling frequency. The running speed signal of the belt is obtained by the speed monitoring mechanism at a set sampling frequency. At the same time, multiple readers read the radio frequency signals emitted by multiple RFID tags at the center position of multiple monitoring sections at a set sampling frequency and send all the above monitoring signals to the controller.

[0020] Step 2: The controller obtains displacement data, tilt angle data, tension data, friction force data, running speed data, and coordinate data based on displacement signal, tilt angle signal, tension signal, friction force signal, running speed data, and radio frequency signal, respectively;

[0021] Step 3: Monitor the belt misalignment online and make timely corrections when misalignment occurs;

[0022] S31: Data filtering processing; Kalman filtering is used to denoise all monitoring data to obtain the denoised monitoring data, as shown in formula (1);

[0023] (1);

[0024] In the formula, for The posterior estimate of the state at time t. for The posterior estimate of the state at time t. Let H be the Kalman gain, and H be the observation matrix; for The actual observed value at time;

[0025] S32: Calculation of included angle deviation and displacement; First, obtain the included angle of coordinates of two adjacent RFID tags according to formula (2). Then, the deviation angle is calculated according to formula (3). Simultaneously, based on displacement data, ;

[0026] (2);

[0027] (3);

[0028] In the formula, For the first The coordinates of an RFID tag in the x-direction. For the first The coordinates of an RFID tag in the x-direction. For the first The coordinates of an RFID tag in the y-direction. For the first The coordinates of an RFID tag in the y-direction. This is the reference angle along the conveying direction;

[0029] S33: Judgment of deviation status; if the displacement... Or deviation angle If the belt speed is within the set speed range and no misalignment occurs within the set monitoring time period, the controller adjusts the sampling frequency of the misalignment monitoring unit and the sampling frequency of the positioning unit to sampling frequency two, where sampling frequency one is greater than sampling frequency two. When a misalignment occurs in any monitoring section, the controller restores the sampling frequency of the misalignment monitoring unit and the sampling frequency of the positioning unit to sampling frequency one.

[0030] S34: Corrective adjustment action:

[0031] S34-1: Construct the pose inverse solution model; construct the displacement inverse solution model of the linear telescopic correction mechanism according to formula (4); at the same time, construct the inverse solution model of the liftable support group according to formula (5); and simplify formula (5) based on the height relationship of the three liftable single supports in the liftable support group to obtain formula (6).

[0032] (4); In the formula, The working arm length of the linear telescopic correction mechanism; The required rotation angle for correction; The radius of rotation between the support base and the main frame (2);

[0033] (5);

[0034] In the formula, and These refer to the lifting heights of the two lifting hydraulic cylinders at both ends of the length direction in the liftable support assembly; The tilt angle required for correction; The length of the roller support (6);

[0035] (6);

[0036] In the formula, , The lifting height of a lifting hydraulic cylinder in the central area of ​​the liftable support assembly;

[0037] S34-2: Obtain the target pose according to formula (7) The error correction function is constructed according to formula (8). ;

[0038] (7);

[0039] (8);

[0040] In the formula, A value of 1 indicates high sensitivity to lateral displacement. A value of 10 makes it more sensitive to changes in angle.

[0041] S34-3: Solve using gradient descent or Newton's method , , and , making Minimum, or according to formula (9), perform PID feedback control on the linear telescopic correction mechanism, and according to formula (10), perform PID feedback control on the lifting height of each lifting hydraulic cylinder in the liftable support group to perform correction adjustment actions until... And the deviation angle Then, the changes in the extension displacement of the linear telescopic correction mechanism and the changes in the tilt angle of the idler roller bracket during the correction and adjustment process are sent to the host computer. If the correction and adjustment operation is not completed after 10 seconds, the controller controls the alarm to perform an audible and visual alarm and controls the belt conveyor to stop.

[0042] (9);

[0043] In the formula, ;

[0044] (10);

[0045] In the formula, .

[0046] As a preferred embodiment, in step S33 of step three, the host computer analyzes the force on the belt based on the tension data and friction data. Based on the force, the offset direction, offset angle data, and displacement data of each monitoring section, the change in the extension displacement of the linear telescopic correction mechanism and the change in the tilt angle data of the idler support during the correction and adjustment operation, the computer analyzes the deviation status, the cause of deviation, and the adjustment action. The analysis results are then sent to the controller to provide reliable data support for the controller's subsequent correction and adjustment operations.

[0047] This invention provides a method for preventing belt misalignment in long-distance bidirectional conveyor belts used in mining. Multiple readers are positioned at the center of multiple monitoring sections, and these readers read the radio frequency signals of multiple RFID tags located at the center of each monitoring section. This allows for precise acquisition of positioning information at the center of each monitoring section, enabling accurate local positioning of the belt within those sections. This facilitates the timely and accurate detection of even minor belt misalignments. Therefore, it can accurately identify belt misalignment even with slight deviations and intervene with corrective actions immediately, ensuring timely and accurate correction and avoiding the difficulties of corrective action when larger deviations occur. Furthermore, the coordinated operation of laser displacement sensors, tilt sensors, and positioning units allows for comprehensive monitoring of the belt's operating status from multiple angles and dimensions, enabling timely detection of even minor misalignments. This ensures timely detection and avoids the missed detection problems common in traditional monitoring methods. Using small angle and displacement values ​​(≥2° or ≥5mm) as the criteria for belt misalignment not only ensures the accuracy of misalignment detection but also facilitates timely real-time correction in the early stages of misalignment. This allows for rapid detection of belt deviation and prompt adjustment via the linear telescopic correction mechanism, ensuring timely correction and guaranteeing the continuity and stability of transportation. When no misalignment occurs within the set monitoring period and the operating speed is stable, the sampling frequency of each monitoring sensor and reader is reduced to save energy and reduce data transmission. When misalignment occurs, the sampling frequency is increased to promptly capture even minor misalignment trends, providing comprehensive and timely information on the belt's operating status. Once misalignment occurs, the controller directly controls the linear telescopic correction mechanism and the adjustable support assembly to perform correction adjustments, enabling timely correction and significantly shortening the processing time for misalignment issues. This reduces equipment damage and production interruptions caused by misalignment, improving the efficiency and safety of mine production. In addition, based on the monitoring data, filtering, coordinate calculation, and deviation analysis are performed to obtain the deviation angle and displacement. Then, the deviation state is judged. When deviation occurs, the extension length is calculated based on the constructed pose inverse solution model. The lifting height of the three lifting hydraulic cylinders in the liftable support assembly , and Then, by using a PID control algorithm to output the correction action, the linear telescopic correction mechanism and the lifting hydraulic cylinder are precisely controlled. The combined force of the linear telescopic correction mechanism and the liftable single support can be used to form a compound correction force, thereby completing the correction and adjustment process more efficiently.

[0048] This highly intelligent method employs multi-sensor + RFID full-coverage monitoring technology to efficiently and accurately detect belt misalignment. Even minor, localized misalignments can be detected precisely and efficiently, significantly reducing the missed detection rate. Furthermore, it dynamically adjusts the correction actions based on the belt's deviation, ensuring the belt quickly and stably returns to its normal operating position. This method also boasts good scalability and adaptability, allowing for flexible adjustments and optimization based on the specific needs and operating conditions of different mines. Attached Figure Description

[0049] Figure 1 This is an assembly diagram of the belt conveyor and the linear telescopic correction mechanism in this invention;

[0050] Figure 2 This is a schematic diagram showing the distribution of the deviation monitoring unit and the positioning unit on the belt conveyor in this invention;

[0051] Figure 3 This is a block diagram of the control section in this invention.

[0052] In the diagram: 1. Belt conveyor, 2. Machine frame, 3. Rotating shaft, 4. Belt, 5. Idler roller, 6. Idler roller bracket, 7. Support base frame, 8. Linear telescopic correction mechanism, 9. Laser displacement sensor, 10. Tilt sensor, 11. Tension sensor, 12. Friction sensor, 13. RFID tag, 14. Reader, 15. Controller, 16. Upper support frame, 17. Lifting hydraulic cylinder, 18. Lower base frame, 19. Liftable single support frame. Detailed Implementation

[0053] The invention will now be further described with reference to the accompanying drawings.

[0054] like Figures 1 to 3 As shown, the present invention provides a mine long-distance bidirectional conveyor belt conveyor anti-deviation system, including a belt conveyor 1, a linear telescopic correction mechanism 8, a deviation monitoring unit, a positioning unit and a controller 15;

[0055] The belt conveyor 1 includes a frame 2, a support base 7, liftable support groups, idler roller supports 6, and a belt 4. The frame 2 is divided into multiple monitoring sections at equal intervals along the conveying direction in the section corresponding to the belt 4. Preferably, each monitoring area has a unique identification number. A rotating shaft 3 is fixedly connected to the lower center of the support base 7. Multiple support bases 7 are evenly arranged in multiple monitoring sections along the conveying direction and are rotatably connected to the top of the frame 2 via the rotating shaft 3. Multiple liftable support groups are correspondingly installed on the upper ends of multiple support bases 7. Multiple idler roller supports 6 are correspondingly supported on the upper ends of multiple liftable support groups. The belt 4 is supported on the upper end of the idler roller supports 6 and rolls in contact with the idler rollers 5 on the idler roller supports 6.

[0056] Multiple sets of linear telescopic correction mechanisms 8 are distributed in multiple monitoring sections, and each linear telescopic correction mechanism 8 is distributed at a set angle with the conveying direction. At the same time, the fixed seat of the linear telescopic correction mechanism 8 is fixedly connected to the machine frame 2, and the end of its telescopic part is hinged to one end of the support base 7 in the length direction, which is used to drive the rotation of the support base 7 relative to the machine frame 2.

[0057] As a preferred option, the linear telescopic correction mechanism 8 is driven by a stepper motor. Stepper motors have the advantage of fast response speed, with a response time of ≤50ms, and can quickly respond to the control commands of the controller 15. At the same time, the linear telescopic correction mechanism 8 can adjust the correction angle of the support frame 7 within a range of ±15°, which can flexibly adjust the running direction of the belt 4 within a large range, effectively solving various deviation problems and ensuring that the belt 4 always stays on the normal operating trajectory.

[0058] As a preferred embodiment, the controller 15 employs a PID control algorithm to control the stepper motor in the linear telescopic correction mechanism 8. In the PID control algorithm, the proportional coefficient (Kp), integral time (Ti), and derivative time (Td) are dynamically adjusted according to the load condition of the belt 4, enabling precise driving of the linear telescopic correction mechanism 8 to perform accurate correction adjustments. When the load on the belt 4 changes, the controller 15 can sense this in real time and automatically optimize the PID parameters, ensuring that the linear telescopic correction mechanism 8 maintains good control performance under different load conditions. This avoids insufficient or excessive correction due to load changes, ensuring the accuracy and stability of the correction.

[0059] The belt misalignment monitoring unit includes a laser displacement sensor 9, an tilt sensor 10, a tension sensor 11, a friction sensor 12, and a speed monitoring mechanism. Multiple laser displacement sensors 9 are evenly distributed along the conveying direction in multiple monitoring sections and are mounted above the machine frame 2. They are used to collect displacement signals from one edge of the belt 4 in real time. Preferably, the laser displacement sensors 9 are high-precision laser displacement sensors. More preferably, during the installation of the laser displacement sensors 9, it is ensured that their sensing surface is aligned with the edge of the belt 4, and the baseline error is carefully calibrated during installation, controlling the error to ≤1mm to ensure the accuracy of the displacement data. Multiple tilt sensors 10 are sequentially installed at the bottom of multiple idler supports 6 to collect the tilt angle signal of the idler supports 6 in real time, in order to accurately obtain the belt 4's position. The tilt angle data provides reliable technical support. More preferably, after installation, the tilt sensor 10 needs zero-point calibration, and the zero-point drift should be checked and calibrated regularly during use to ensure accurate acquisition of the tilt angle data of the idler support 6. The tension sensor 11 is installed on the machine frame 2 and contacts the belt 4 to collect the tension signal of the belt 4 in real time. The friction sensor 12 is installed on the machine frame 2 and contacts the surface of the belt 4 to collect the surface friction signal of the belt 4 in real time. Preferably, both the tension sensor 11 and the friction sensor 12 are located in the critical stress area of ​​the belt 4 to accurately collect tension and friction data. During installation, any adverse interference to the normal conveying process of the belt 4 should be avoided. The speed monitoring mechanism includes a speed measuring roller and a speed sensor. The speed measuring roller is located between the two idler supports 6 in the middle section of the machine frame 2 and is connected to the machine frame 2. Its upper circular surface makes rolling contact with the belt 4. The speed sensor is installed on the speed measuring roller to collect the movement speed signal of the belt 4.

[0060] The positioning unit includes radio frequency tags (RFID) 13 and readers 14. Several RFID tags 13 are evenly embedded inside the belt 4 along its length. When multiple RFID tags 13 move to the belt bearing section, they correspond to multiple monitoring sections. During installation, the seams of the belt 4 should be avoided to prevent affecting the reading of radio frequency signals and the load-bearing strength of the belt 4. Multiple readers 14 are distributed at the center of multiple monitoring sections and supported above the machine frame 2. Preferably, the installation height of the readers 14 can be the same as the installation height of the RFID tags 13 to ensure stable and reliable signal transmission. As a preferred embodiment, each reader 14 and each RFID tag 13 has a unique identification number. Preferably, the readers 14 are connected to the controller 15 via industrial Ethernet, and protective measures are taken for the communication cables during the connection process to avoid electromagnetic interference and mechanical damage in the mining environment.

[0061] As an alternative, the RFID tag 13 can also be specially packaged to adapt to the harsh working environment of the mine, while also helping to optimize the signal strength and anti-interference capability of the reader 14.

[0062] The controller 15 is connected to the deviation monitoring unit, the positioning unit, the belt conveyor 1, the liftable support group and the linear telescopic correction mechanism 8 respectively.

[0063] To ensure monitoring accuracy, the spacing between multiple RFID tags is 0.5m, and the spacing between multiple readers is 2m. This spacing ensures accurate identification of the belt position while also taking into account overall cost and ease of installation.

[0064] To facilitate adjustment of the roller bracket's tilt angle and to facilitate correction operations, the roller bracket 6 is a V-shaped roller bracket. The liftable support assembly consists of three liftable individual brackets 19 spaced apart along the length of the support base 7. Each liftable individual bracket 19 includes an upper support frame 16, a lifting hydraulic cylinder 17, and a lower seat frame 18. The lower seat frame 18 is fixedly connected to the upper end of the support base 7. The lower end of the upper support frame 16 is connected to the lower seat frame 18 via the lifting hydraulic cylinder 17, and the upper end of the upper support frame 16 is hinged to the lower end of the roller bracket 6. The lifting hydraulic cylinder 17 is connected to a high-pressure...

[0065] In order to facilitate timely and effective alerts to relevant management personnel in case of abnormal situations through sound and light reminders, so as to enable timely emergency response measures, an alarm is also included. The alarm is installed on the machine frame 2 and connected to the controller 15, and is used to perform alarm actions according to the control of the controller 15.

[0066] Preferably, a host computer is also included, which is connected to the controller 15. More preferably, a communication module is also included, connected to the controller 15, for establishing a communication link between the controller 15 and the host computer. More preferably, the host computer is connected to the mine's central control system via the OPC UA protocol. This leverages the openness and compatibility of the OPC UA protocol to achieve remote monitoring and fault diagnosis functions. This allows mine personnel to monitor the operating status of the belt conveyor 1 in real time through the road control system. If a fault occurs in the belt conveyor 1, timely remote diagnosis and corresponding maintenance measures can be taken, thereby effectively improving the safety and continuity of mine production.

[0067] Preferably, the controller is a PLC controller, and the host computer is an industrial computer. More preferably, the controller 15 is connected to the host computer via an industrial Ethernet network. The high speed and stability of the industrial Ethernet network ensure that monitoring data can be transmitted to the host computer in a timely and accurate manner, providing strong technical support for precise and efficient deviation correction operations.

[0068] In this invention, by connecting the support base to the machine frame via a rotating shaft, and simultaneously using a linear telescopic correction mechanism to drive the support base to rotate relative to the machine frame, a reverse force can be provided to the misaligned belt by rotating the idler bracket via the support base. This allows for quick and easy correction of the misaligned belt. Connecting the idler bracket to the support base via a liftable bracket assembly allows for adjusting the tilt angle of the idler bracket using the lifting motion of the assembly. This tilt angle adjustment further corrects the misaligned belt. Thus, the belt misalignment can be corrected through a combination of the rotation of the idler bracket relative to the machine frame and the tilt angle adjustment, ensuring the belt remains on its normal operating track and achieving reliable and efficient correction. The use of multiple laser displacement sensors facilitates the acquisition of displacement data at the belt edge positions in each monitoring section. By combining RFID tags and readers in the positioning unit, the local location information and offset angle of the belt in each monitoring section can be accurately determined. This facilitates the precise acquisition of offset direction and angle data at local locations, providing accurate adjustment basis for the correction process through precise location information. This allows for more accurate implementation of correction actions. Furthermore, the low power consumption and high stability of RFID tags enable precise identification and positioning of the belt. In this way, by simultaneously obtaining displacement and offset angle data, it is easy to determine whether a belt misalignment has occurred from different perspectives, ensuring the accuracy of the judgment. Because multiple readers are distributed at the center of multiple monitoring sections, and multiple RFID tags are embedded in the belt, multiple readers can synchronously collect information from multiple RFID tags at the center of multiple monitoring sections. This enables accurate local positioning of the belt in multiple monitoring sections, allowing for the detection of even minor belt misalignments. Therefore, it can accurately identify belt deviation when even a small deviation occurs, and intervene with correction actions immediately, effectively ensuring the timeliness and accuracy of correction and avoiding the difficulties of correction when larger deviations occur. The layout of multiple laser displacement sensors and multiple RFID tags in the positioning unit, combined with multiple readers, allows for comprehensive and real-time monitoring of belt deviation, facilitating timely detection of deviation problems throughout the entire conveying distance and ensuring the timeliness and reliability of local deviation correction. The installation of multiple tilt sensors facilitates the acquisition of tilt angle data for each idler support, thereby obtaining the change in tilt angle data during the correction process. The installation of tension sensors facilitates the acquisition of belt tension data. By setting up a friction sensor, it is easy to obtain the friction data of the belt.In this way, the tension and friction data facilitate the analysis of the belt's stress state, helping to identify the causes of belt misalignment and providing reliable technical support for corrective adjustments. The controller settings enable intelligent and precise detection of belt misalignment, automated corrective adjustments, and the transmission of monitoring data and corrective actions to a host computer. This allows the host computer to analyze the causes of belt misalignment and record historical corrective actions, providing reliable data support for subsequent controller adjustments.

[0069] The system has a simple structure and a high degree of intelligence. It can accurately and efficiently determine whether the belt is misaligned in the whole or in a local area in real time. At the same time, it can perform efficient and accurate correction and adjustment when misalignment occurs, which helps to ensure the efficient operation of the conveying operation.

[0070] This invention also provides a method for preventing deviation of a long-distance bidirectional conveyor belt in mining, employing a system for preventing deviation of a long-distance bidirectional conveyor belt in mining, comprising the following steps:

[0071] Step 1: During the operation of the belt conveyor 1, real-time monitoring is performed using the belt misalignment monitoring unit and the positioning unit. The displacement signal of each monitoring section edge of the belt 4 is obtained by the laser displacement sensor 9 at a set sampling frequency. The tilt angle signal of each idler bracket 6 is obtained by the tilt sensor 10 at a set sampling frequency. The tension signal of the belt 4 is obtained by the tension sensor 11 at a set sampling frequency. The friction force signal of the belt 4 surface is obtained by the friction force sensor 12 at a set sampling frequency. The running speed signal of the belt 4 is obtained by the speed monitoring mechanism at a set sampling frequency. At the same time, multiple readers 14 read the radio frequency signals emitted by multiple RFID tags 13 at the center position of multiple monitoring sections at a set sampling frequency, and send all the above monitoring signals to the controller 15.

[0072] Step 2: The controller 15 obtains displacement data, tilt angle data, tension data, friction force data, running speed data, and coordinate data based on displacement signal, tilt angle signal, tension signal, friction force signal, running speed data, and radio frequency signal, respectively;

[0073] Step 3: Monitor belt 4 for deviation online and make timely corrections when deviation occurs;

[0074] S31: Data filtering processing; Kalman filtering is used to denoise all monitoring data to obtain the denoised monitoring data, as shown in formula (1);

[0075] (1);

[0076] In the formula, for The posterior estimate of the state at time t. for The posterior estimate of the state at time t. H is the Kalman gain, and H is the observation matrix; for The actual observed value at time;

[0077] S32: Calculation of included angle deviation and displacement; First, obtain the included angle of coordinates of two adjacent RFID tags 13 according to formula (2). Then, the deviation angle is calculated according to formula (3). Simultaneously, based on displacement data, ;

[0078] (2);

[0079] (3);

[0080] In the formula, For the first The coordinates of the RFID tag 13 in the x-direction. For the first The coordinates of the RFID tag 13 in the x-direction. For the first The coordinates of the RFID tag 13 in the y-direction For the first The coordinates of the RFID tag 13 in the y-direction This is the reference angle along the conveying direction;

[0081] S33: Judgment of deviation status; if the displacement... Or deviation angle If the belt runs smoothly, it is determined to be misaligned; otherwise, it is determined not to have misaligned. When misalignment occurs, the current tension data, friction data, offset direction, offset angle data and displacement data of each monitoring section are sent to the host computer, and the belt correction adjustment action is performed. If the belt running speed is stable within the set speed range and no misalignment occurs within the set monitoring time period, the controller (15) adjusts the sampling frequency of the misalignment monitoring unit and the sampling frequency of the positioning unit to sampling frequency two. Sampling frequency one is greater than sampling frequency two. When misalignment occurs in any monitoring section, the controller (15) restores the sampling frequency of the misalignment monitoring unit and the sampling frequency of the positioning unit to sampling frequency one.

[0082] S34: Corrective adjustment action:

[0083] S34-1: Construct the pose inverse solution model; the correction is divided into two types of actions, in which the rotation angle of the roller bracket 6 in the horizontal direction is determined by the extension arm length (extension length) of the linear telescopic correction mechanism 9. The tilt angle of the idler roller bracket 6 is controlled by the lifting height of the three lifting hydraulic cylinders in the liftable bracket assembly. , and To take control;

[0084] The displacement inverse solution model of the linear telescopic correction mechanism 8 is constructed according to formula (4); at the same time, the inverse solution model of the liftable support group is constructed according to formula (5); and formula (5) is simplified based on the height relationship of the three liftable single support 19 in the liftable support group to obtain formula (6).

[0085] (4);

[0086] In the formula, The working arm length of the linear telescopic correction mechanism 8; The required rotation angle for correction; To support the rotation radius between the base frame 7 and the fuselage frame 2;

[0087] (5);

[0088] In the formula, and These represent the lifting heights of the two lifting hydraulic cylinders 17 at both ends of the length direction in the liftable support assembly; The tilt angle required for correction; The length of the idler roller bracket 6;

[0089] (6);

[0090] In the formula, , The lifting height of a lifting hydraulic cylinder 17 in the central area of ​​the liftable support assembly;

[0091] S34-2: Obtain the target pose according to formula (7) The error correction function is constructed according to formula (8). ;

[0092] (7);

[0093] (8);

[0094] In the formula, A value of 1 indicates high sensitivity to lateral displacement. A value of 10 makes it more sensitive to changes in angle.

[0095] S34-3: Solve using gradient descent or Newton's method , , and , making Minimum, or according to formula (9), perform PID feedback control on the linear telescopic correction mechanism 8, and according to formula (10), perform PID feedback control on the lifting height of each lifting hydraulic cylinder 17 in the liftable support group to perform correction adjustment actions until... And the deviation angle During the correction and adjustment process, the attitude surface of the roller bracket 6 is ensured to meet the requirements through real-time feedback. The changes in the extension and retraction displacement of the linear telescopic correction mechanism 8 and the changes in the tilt angle of the roller bracket 6 during the correction and adjustment process are sent to the host computer. If the correction and adjustment operation is not completed after 10 seconds, the controller 15 controls the alarm to perform an audible and visual alarm and controls the belt conveyor 1 to stop.

[0096] (9);

[0097] In the formula, ;

[0098] (10);

[0099] In the formula, .

[0100] As a preferred embodiment, in step S33 of step three, the host computer analyzes the force situation of belt 4 based on tension data and friction data. Based on the force situation, the offset direction, offset angle data, and displacement data of each monitoring section, the change in the extension displacement of the linear telescopic correction mechanism 8 and the change in the tilt angle data of the idler roller bracket 6 during the correction and adjustment operation, the computer analyzes the deviation status, the cause of deviation, and the adjustment action. The analysis results are then sent to the controller 15 to provide reliable data support for the controller 15's subsequent correction and adjustment operations.

[0101] This invention provides a method for preventing belt misalignment in long-distance bidirectional conveyor belts used in mining. Multiple readers are positioned at the center of multiple monitoring sections, and these readers read the radio frequency signals of multiple RFID tags located at the center of each monitoring section. This allows for precise acquisition of positioning information at the center of each monitoring section, enabling accurate local positioning of the belt within those sections. This facilitates the timely and accurate detection of even minor belt misalignments. Therefore, it can accurately identify belt misalignment even with slight deviations and intervene with corrective actions immediately, ensuring timely and accurate correction and avoiding the difficulties of corrective action when larger deviations occur. Furthermore, the coordinated operation of laser displacement sensors, tilt sensors, and positioning units allows for comprehensive monitoring of the belt's operating status from multiple angles and dimensions, enabling timely detection of even minor misalignments. This ensures timely detection and avoids the missed detection problems common in traditional monitoring methods. Using small angle and displacement values ​​(≥2° or ≥5mm) as the criteria for belt misalignment not only ensures the accuracy of misalignment detection but also facilitates timely real-time correction in the early stages of misalignment. This allows for rapid detection of belt deviation and prompt adjustment via the linear telescopic correction mechanism, ensuring timely correction and guaranteeing the continuity and stability of transportation. When no misalignment occurs within the set monitoring period and the operating speed is stable, the sampling frequency of each monitoring sensor and reader is reduced to save energy and reduce data transmission. When misalignment occurs, the sampling frequency is increased to promptly capture even minor misalignment trends, providing comprehensive and timely information on the belt's operating status. Once misalignment occurs, the controller directly controls the linear telescopic correction mechanism and the adjustable support assembly to perform correction adjustments, enabling timely correction and significantly shortening the processing time for misalignment issues. This reduces equipment damage and production interruptions caused by misalignment, improving the efficiency and safety of mine production. In addition, based on the monitoring data, filtering, coordinate calculation, and deviation analysis are performed to obtain the deviation angle and displacement. Then, the deviation state is judged. When deviation occurs, the extension length is calculated based on the constructed pose inverse solution model. The lifting height of the three lifting hydraulic cylinders in the liftable support assembly , and Then, by using a PID control algorithm to output the correction action, the linear telescopic correction mechanism and the lifting hydraulic cylinder are precisely controlled. The combined force of the linear telescopic correction mechanism and the liftable single support can be used to form a compound correction force, thereby completing the correction and adjustment process more efficiently.

[0102] This highly intelligent method employs multi-sensor + RFID full-coverage monitoring technology to efficiently and accurately detect belt misalignment. Even minor, localized misalignments can be detected precisely and efficiently, significantly reducing the missed detection rate. Furthermore, it dynamically adjusts the correction actions based on the belt's deviation, ensuring the belt quickly and stably returns to its normal operating position. This method also boasts good scalability and adaptability, allowing for flexible adjustments and optimization based on the specific needs and operating conditions of different mines.

Claims

1. A mine long distance bidirectional belt conveyor anti-deviation system, comprising a belt conveyor (1); characterized in that, It also comprises a straight line telescopic deviation rectifying mechanism (8), a deviation monitoring unit, a positioning unit and a controller (15); The belt conveyor (1) comprises a machine body frame (2), a supporting base frame (7), a liftable support group, a roller support (6) and a belt (4); the machine body frame (2) is divided into multiple monitoring sections along the conveying direction at equal intervals at the part corresponding to the belt (4) bearing section; the lower end center of the supporting base frame (7) is connected with a rotating shaft (3), multiple supporting base frames (7) are evenly arranged in the multiple monitoring sections and are rotationally connected to the top of the machine body frame (2) through the rotating shaft (3); multiple liftable support groups are correspondingly installed at the upper end of the multiple supporting base frames (7); multiple roller supports (6) are correspondingly arranged at the upper end of the multiple liftable support groups; and the belt (4) is arranged at the upper end of the roller support (6). Multiple straight line telescopic deviation rectifying mechanisms (8) are correspondingly arranged in the multiple monitoring sections, the fixed seat of the straight line telescopic deviation rectifying mechanism (8) is fixedly connected with the machine body frame (2), and the end of the telescopic part is hingedly connected with one end of the length direction of the corresponding supporting base frame (7). The deviation monitoring unit comprises a laser displacement sensor (9), an inclination sensor (10), a tension sensor (11), a friction sensor (12) and a speed monitoring mechanism; multiple laser displacement sensors (9) are evenly arranged in the multiple monitoring sections and are arranged above the machine body frame (2); multiple inclination sensors (10) are sequentially installed at the bottom of the multiple roller supports (6); the tension sensor (11) is installed on the machine body frame (2) and is in contact with the belt (4); the friction sensor (12) is installed on the machine body frame (2) and is in contact with the surface of the belt (4); the speed monitoring mechanism comprises a speed measuring roller and a speed sensor; the speed measuring roller is located between the two roller supports (6) at the middle section of the machine body frame (2) and is connected with the machine body frame (2), and the upper surface thereof is in rolling contact with the belt (4); and the speed sensor is installed on the speed measuring roller; The positioning unit comprises a radio frequency tag (13) and a reader (14); multiple radio frequency tags (13) are evenly embedded in the inside of the belt (4) along the length direction of the belt (4), and when multiple radio frequency tags (13) among them run to the belt (4) bearing section, they correspond to multiple monitoring sections respectively; multiple readers (14) are correspondingly arranged at the center positions of the multiple monitoring sections and are arranged above the machine body frame (2); The controller (15) is connected with the deviation monitoring unit, the positioning unit, the belt conveyor (1), the liftable support group and the straight line telescopic deviation rectifying mechanism (8) respectively.

2. The mine long distance bidirectional belt conveyor anti-deviation system according to claim 1, characterized in that, The spacing between the multiple radio frequency tags (13) is 0.5m; and the spacing between the multiple readers (14) is 2m.

3. The mine long distance bidirectional belt conveyor anti-deviation system according to claim 1, characterized in that, The roller support (6) is a V-shaped roller support; the liftable support group is composed of three liftable single supports (19) which are sequentially and spacedly distributed along the length direction of the support base frame (7), the liftable single support (19) comprises an upper support frame (16), a lifting hydraulic cylinder (17) and a lower seat frame (18), the lower seat frame (18) is fixedly connected to the upper end of the support base frame (7); the lower end of the upper support frame (16) is connected with the lower seat frame (18) through the lifting hydraulic cylinder (17), and the upper end of the upper support frame (16) is hingedly connected with the lower end of the roller support (6).

4. The mine long distance bidirectional belt conveyor anti-deviation system according to claim 1, characterized in that, Further comprising an alarm, which is installed on the machine frame (2) and connected with the controller (15), for performing warning action according to the control of the controller (15).

5. The mine long distance bidirectional belt conveyor anti-deviation system according to claim 1, characterized in that, Further comprising an upper computer, which is connected with the controller (15).

6. The mine long distance bidirectional belt conveyor anti-deviation system according to claim 5, characterized in that, The controller (15) is a PLC controller, and the upper computer is an industrial computer.

7. A method for preventing deviation of a long-distance reversible belt conveyor for mining, using a system for preventing deviation of a long-distance reversible belt conveyor for mining according to any one of claims 1 to 6, characterized in that, The method comprises the following steps: Step one: during the operation of the belt conveyor (1), real-time monitoring operation is performed by using the deviation monitoring unit and the positioning unit, the displacement signal of the edge of each monitoring section of the belt (4) is obtained by the laser displacement sensor (9) at a set sampling frequency, the inclination angle signal of each roller support (6) is obtained by the inclination sensor (10) at a set sampling frequency, the tension signal of the belt (4) is obtained by the tension sensor (11) at a set sampling frequency, the friction force signal on the surface of the belt (4) is obtained by the friction force sensor (12) at a set sampling frequency, the running speed signal of the belt (4) is obtained by the speed monitoring mechanism at a set sampling frequency, at the same time, the radio frequency signals emitted by the plurality of radio frequency tags (13) running to the center positions of the plurality of monitoring sections are read by the plurality of readers (14) respectively at a set sampling frequency, and the above various signals are sent to the controller (15); Step two: the controller (15) respectively obtains displacement data, inclination angle data, tension data, friction force data, running speed data and coordinate data based on the displacement signal, the inclination angle signal, the tension signal, the friction force signal, the running speed signal and the radio frequency signal; Step three: the deviation of the belt (4) is monitored online, and deviation correction adjustment is performed in time when deviation occurs; S31: data filtering processing; All monitoring data are denoised by using Kalman filtering to obtain denoised monitoring data, as shown in formula (1); （1）； wherein is the state posterior estimate at time is the state posterior estimate at time is the Kalman gain, and H is the observation matrix. is the actual observation at time S32: Calculation of the included angle deviation and displacement; first, the coordinate included angle of the two adjacent radio frequency tags (13) is obtained according to formula (2) , and then the running deviation offset angle is calculated according to formula (3) ; at the same time, the displacement data is obtained ; （2）； （3）； wherein is the coordinate of the rfid tag (13) in the x direction, is the coordinate of the rfid tag (13) in the x direction, is the coordinate of the rfid tag (13) in the y direction, is the coordinate of the rfid tag (13) in the y direction, is the reference angle in the conveying direction; S33: determination of the running-off state; if the displacement amount or the running-off angle , the running-off is determined, the current tension data, the friction data, the offset direction of each monitoring section, the offset angle data and the displacement amount data are sent to the upper computer, and the deviation adjustment action is performed; if and the running-off angle , it is determined that the running-off does not occur; if the belt running speed is stable in the set speed interval range, and the running-off condition is not issued within the set monitoring time period, the controller (15) adjusts the sampling frequency of the running-off monitoring unit and the sampling frequency of the positioning unit to the second sampling frequency, the first sampling frequency is greater than the second sampling frequency, and when the running-off condition occurs in any monitoring section, the controller (15) restores the sampling frequency of the running-off monitoring unit and the sampling frequency of the positioning unit to the first sampling frequency; S34: deviation correction adjustment action: S34-1: constructing a pose inverse solution model; constructing a displacement inverse solution model of the linear telescopic deviation correction mechanism (8) according to formula (4); at the same time, constructing an inverse solution model of the liftable support group according to formula (5), and simplifying formula (5) based on the height relationship of the three liftable single supports (19) in the liftable support group to obtain formula (6); （4）； In the formula, is the length of the action arm of the straight telescopic deviation rectifying mechanism (8); is the rotation angle required for deviation rectification; is the rotation radius between the support chassis (7) and the machine body frame (2); （5）； In the formula, and are the lifting heights of the two lifting hydraulic cylinders (17) at the two ends in the length direction of the liftable support group, respectively; is the inclination angle required for rectification; is the length of the carrier roller support (6); (6); In the formula, , is the lifting height of a lifting hydraulic cylinder (17) in the center region of the lifting support group S34-2: Obtain the target pose according to formula (7) Construct the error function of rectification according to formula (8) ; （7）； （8）； In the formula, A value of 1 is highly sensitive to lateral displacement; A value of 10 is more sensitive to angle change; S34-3: solve using gradient descent method or Newton method , , and , so that minimum, or according to formula (9) to the linear telescopic rectification mechanism (8) PID feedback control, according to formula (10) to each lifting hydraulic cylinder (17) in the lifting support group lifting height PID feedback control, to carry out rectification adjustment action, until and the deviation angle , the rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment rectification adjustment （9）； In the formulae, ; （10）； In the formulae, .

8. The mine long distance bidirectional belt conveyor anti-deviation method according to claim 7, characterized in that, In S33 of step three, the host computer analyzes the stress condition of the belt (4) according to the tension data and the friction data, and based on the stress condition, the deviation direction, the deviation angle data, the displacement amount data of each monitoring section, the change amount of the telescopic displacement of the straight line telescopic correction mechanism (8) in the correction adjustment operation, and the change amount of the inclination angle data of the roller support (6), the running deviation state, the running deviation reason and the adjustment action are analyzed, and the analysis result is sent to the controller (15) to provide reliable data support for the subsequent correction adjustment operation of the controller (15).

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