Intelligent deviation rectifying system of belt conveyor

Abstract

The invention discloses an intelligent deviation rectifying system of a belt conveyor, belongs to the technical field of image processing, and belongs to the technical field of solid material conveying. According to the method, the initial deviation adjusting parameters are preset, the initial deviation adjusting is executed at the first time when the deviation signal is received, then the actual deviation displacement is analyzed, the secondary deviation adjusting is judged to be executed accordingly, the deviation action of the conveying belt can be rapidly controlled through two-stage deviation adjusting, and the deviation correcting amount of adjusting the conveying belt to the correct position can be accurately controlled through secondary deviation adjusting.

Description

Technical Field

[0001] The present invention relates to the technical field of image processing, belonging to the technical field of solid material conveying, and in particular to an intelligent deviation correction system for a belt conveyor. Background Art

[0002] During the alumina production process, large quantities of raw materials are transported and transferred by belt conveyors (such as rubber belt conveyors). However, bulk materials (primarily bauxite) can easily deviate from the belt due to uneven particle size, varying drop points, and material sticking to the rollers. This can lead to material spillage and equipment failures. Therefore, rubber belt conveyors are typically equipped with a deviation correction device. Traditional deviation correction devices rely on manual adjustment, which can easily cause material spillage and equipment failures if not detected in time. Therefore, automatic deviation correction devices are designed to address this issue.

[0003] For example, the Chinese utility model patent "An automatic deviation-correcting belt conveyor, announcement number CN212892377U" states that when the conveyor belt deviates to one side beyond a reasonable range, it will block the infrared rays emitted by the infrared transmitter on that side, causing the infrared receiver on that side to fail to receive the infrared signal. Once the PLC controller receives an abnormal signal, it automatically controls the electric telescopic rod on that side to slowly extend, and uses the deviation-correcting wheel to push the conveyor belt to the other side for deviation correction. When the infrared receiver on that side receives the infrared signal again, the PLC controller controls the electric telescopic rod to retract and reset, completing the automatic deviation correction of the conveyor belt.

[0004] As mentioned above, the automatic deviation correction device is generally realized by infrared photoelectric switch detection in conjunction with the slow extension and retraction of the push rod, but it is difficult to monitor the degree of deviation and it is also difficult to control the amount of correction. Summary of the Invention

[0005] The object of the present invention is to provide an intelligent deviation correction system for a belt conveyor in order to solve the above-mentioned problems, which can accurately control the deviation correction amount to adjust the conveyor belt to the correct position.

[0006] In order to achieve the above object, the technical solution adopted by the present invention is:

[0007] An intelligent deviation correction system for a belt conveyor includes a main controller, a memory, and a deviation correction program. The deviation correction program is stored in the memory and configured to be executed by a processor to perform the following steps:

[0008] The deviation collection step includes the following: receiving a conveyor belt deviation signal obtained by real-time detection by an infrared photoelectric module, and receiving a conveyor belt image obtained by real-time detection by a camera module;

[0009] The deviation control steps include the following: determining whether the conveyor belt is deviating according to the deviation signal; issuing a preliminary deviation instruction configured with initial deviation parameters to control the deviation correction actuator to complete the initial deviation adjustment; obtaining the actual deviation displacement of the conveyor belt according to the conveyor belt image analysis; comparing the actual deviation displacement with the initial deviation adjustment displacement d1, and analyzing to obtain the deviation adjustment value d0 required to correct the conveyor belt to the running position; determining whether the deviation adjustment value is within the error range. If so, no secondary deviation adjustment is required. Otherwise, issuing a secondary deviation adjustment instruction configured with the deviation adjustment value d0 to control the deviation correction actuator to complete the secondary deviation adjustment.

[0010] As mentioned above, the initial deviation adjustment parameters are preset, and preliminary deviation adjustment is performed as soon as the deviation signal is received. Then, the actual offset displacement is analyzed and the secondary deviation adjustment is performed accordingly. The two-stage deviation adjustment is adopted. The preliminary deviation adjustment can quickly control the deviation of the conveyor belt, and the secondary deviation adjustment can accurately control the deviation correction amount to adjust the conveyor belt to the correct position.

[0011] Based on the above-mentioned scheme, in an improved scheme, in order to solve the problem that the initial deviation adjustment displacement value is too large, resulting in excessive correction, and the initial deviation adjustment displacement value is too small, resulting in the inability to control the deviation movement, the initial deviation adjustment displacement value is optimized, and the deviation control step of the correction system also includes the following content: according to the initial deviation adjustment displacement d1 and the deviation value d0, the deviation adjustment displacement d2 is analyzed and updated to the initial deviation parameter, and the initial deviation parameter is used to perform the initial deviation adjustment of the next deviation of the wheel conveying operation.

[0012] Based on the above scheme, in an improved scheme, in order to solve the problem of material drift and scattering caused by large changes in the initial deviation speed, the initial deviation speed is optimized, and the deviation control step of the correction system also includes the following: according to the conveyor belt image, the drift distance information of the material moving toward the outer edge of the conveyor belt within the initial deviation time t1 is analyzed and obtained; according to the drift distance information and the initial deviation speed v1, the deviation speed v2 is analyzed and updated to the initial deviation parameter, and the initial deviation parameter is used to perform the initial deviation of the next deviation of the conveying operation of this wheel.

[0013] Based on the above-mentioned scheme, in an improved scheme, in order to solve the problem of different material types adapting to the corresponding initial adjustment parameters, the adjustment control step of the correction system also includes the following: presetting each material type and its corresponding initial adjustment parameters; obtaining the material type based on the conveyor belt image recognition, and then selecting the corresponding initial adjustment parameters to perform the initial adjustment of the next deviation of the conveying operation of this wheel; wherein the material types include powder, small blocks and large blocks.

[0014] Based on the above scheme, in an improved scheme, the correction system includes a peripheral device that cooperates with it. The infrared photoelectric module is arranged on both sides of the conveyor belt, which includes a transmitter and a receiver. The transmitter and the receiver are arranged in a facing direction, and the deviation signal is uploaded when the receiver loses the signal.

[0015] Based on the above solution, in an improved solution, the correction system includes a peripheral device that cooperates with it. The camera module is arranged above the conveyor belt and is used to capture the conveyor belt image in real time and upload it.

[0016] Based on the above scheme, in an improved scheme, the correction system includes a peripheral device that cooperates with it, and further includes a correction actuator, which is arranged under the conveyor belt and is used to receive the control signal of the main controller and perform movement and / or rotation accordingly to correct the conveyor belt to make it run straight.

[0017] Due to the adoption of the above technical solution, the present invention has the following beneficial effects:

[0018] The present invention presets initial deviation adjustment parameters, performs preliminary deviation adjustment at the first time of receiving the deviation signal, and then analyzes the actual offset displacement to determine whether to perform secondary deviation adjustment based on the analysis. The two-stage deviation adjustment is adopted. The preliminary deviation adjustment can quickly control the deviation of the conveyor belt, and the secondary deviation adjustment can accurately control the deviation correction amount to adjust the conveyor belt to the straight position. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a schematic layout diagram of Example 1 of the belt conveyor intelligent deviation correction system of the present invention.

[0020] Figure 2 This is a detection principle diagram of an infrared detector of Example 1 of the belt conveyor intelligent deviation correction system of the present invention.

[0021] Figure 3 This is a camera processing logic diagram of Example 1 of the belt conveyor intelligent deviation correction system of the present invention.

[0022] In the attached figure, 1. conveyor, 2. adhesive belt, 3. infrared camera, 4. upper correction roller, 5. lower correction roller, 6. correction motor, 7. counterweight roller, 8. discharge chute. DETAILED DESCRIPTION

[0023] The specific implementation of the invention is further described below with reference to the accompanying drawings.

[0024] Example 1

[0025] like Figure 1 and Figure 2 、 Figure 3As shown, the present invention combines infrared detection, video capture and imaging, intelligent computing, and motor drive to achieve intelligent belt deviation correction through non-contact intelligent judgment and the rotation of support rollers driven by a correction motor. An infrared detector, image acquisition system, and motor-driven correction roller device are installed at the front and rear ends of the belt conveyor, at the discharge point (discharge chute 8), and at the counterweight roller 7, where the belt (conveyor belt) 2 is prone to deviation. After the intelligent computing module calculates the belt deviation displacement, it issues an operating command to the correction motor to adjust the displacement of the upper and lower correction rollers, achieving intelligent belt deviation correction.

[0026] The conveyor 1, its correcting roller device (correcting actuator), infrared camera (camera) 3, and infrared detector are all existing equipment. For example, the correcting actuator is illustrated by the combination of an upper correcting roller 4, a lower correcting roller 5, and a correcting motor 6. The correcting actuator is positioned below the conveyor belt and receives control signals from the main controller. Based on these signals, it moves and / or rotates (some correcting actuators use translational movement, some use rotational movement, and some use a combination of translational and rotational movement) to correct the conveyor belt's alignment. The infrared detector (infrared photoelectric module) is positioned on both sides of the conveyor belt and includes a transmitter and receiver, arranged in opposing beams. If the receiver loses signal, it transmits a deviation signal. The infrared camera (camera module) is positioned above the conveyor belt to capture and upload real-time images of the conveyor belt. The main controller is a PLC and an intelligent AI processor, CRAE1000. This application improves the correcting control method described therein, as detailed below.

[0027] The correction control process of the correction system includes the following steps:

[0028] Step 1, a deviation collection step, includes the following: receiving a conveyor belt deviation signal obtained by real-time detection by an infrared photoelectric module, and receiving a conveyor belt image obtained by real-time detection by a camera module;

[0029] Step 2: Deviation control step, including the following:

[0030] Step 21: Determine whether the conveyor belt is deviating according to the deviation signal;

[0031] Step 22: issuing a preliminary deviation adjustment instruction configured with initial deviation adjustment parameters to control the deviation correction actuator to complete the initial deviation adjustment;

[0032] Step 23: Analyze the conveyor belt image to obtain the actual deviation displacement of the conveyor belt;

[0033] Step 24: Compare the actual deviation displacement with the initial deviation adjustment displacement d1, and analyze to obtain the deviation adjustment value d0 required to correct the conveyor belt to the running position;

[0034] Step 25: Determine whether the deviation value is within the error range. If so, no secondary deviation adjustment is required. Otherwise, issue a secondary deviation adjustment command configured with the deviation value d0 to control the deviation correction actuator to complete the secondary deviation adjustment.

[0035] The initial deviation adjustment parameters include the initial deviation adjustment time t1, the initial deviation adjustment speed v1, and the initial deviation adjustment displacement d1. These are inputted via an input device into the deviation correction program (which executes the deviation correction control method) in the main controller and memory. The deviation adjustment speed v1 is designed to adjust the distance to achieve the deviation adjustment displacement d1 within the deviation adjustment time t1. The deviation adjustment speed generally includes acceleration, constant speed, and deceleration.

[0036] As mentioned above, as the basic solution of the deviation correction system, the initial deviation adjustment parameters are preset, and preliminary deviation adjustment is performed as soon as the deviation signal is received. Then the actual offset displacement is analyzed and the secondary deviation adjustment is performed based on this. A two-stage deviation adjustment is adopted. The preliminary deviation adjustment can quickly control the deviation of the conveyor belt, and the secondary deviation adjustment can accurately control the deviation correction amount to adjust the conveyor belt to the correct position.

[0037] This application utilizes an intelligent belt conveyor deviation correction system to achieve unmanned intelligent deviation correction for belt conveyors. Using bauxite conveying as an example, this system has achieved excellent results in field practice, completely eliminating the need for manual inspection and correction, and achieving inherently safe, unmanned operation. The system intelligently determines the amount of belt deviation through non-contact analysis, avoiding common failures associated with contact-based vertical roller switches. The correction unit utilizes easy-to-install support rollers and motors, effectively preventing problems such as material burial and jamming. The system also offers a low failure rate, ease of maintenance, and a high level of intelligence.

[0038] Example 2

[0039] Based on Example 1, this Example 2 is improved to solve the problem that an excessively large initial deviation adjustment displacement value may cause excessive deviation correction, and an excessively small initial deviation adjustment displacement value may cause an uncontrolled deviation movement.

[0040] The deviation adjustment control steps of the deviation correction system of this embodiment 2 also include the following:

[0041] Step 301: Based on the initial deviation adjustment displacement d1 and the deviation value d0, the deviation adjustment displacement d2 is analyzed and updated to the initial deviation adjustment parameter. The initial deviation adjustment parameter (in this case, the deviation adjustment displacement is d2) is used to perform the initial deviation adjustment for the next deviation of the wheel conveying operation. Steps 21-25 are performed first, and then step 301 is performed.

[0042] In this way, the initial deviation adjustment displacement value can be optimized, and better initial deviation adjustment parameters can be obtained under the current material conveying conditions, so that the conveyor belt can run straight as much as possible during the first deviation adjustment.

[0043] Example 3

[0044] Based on Example 1 or Example 2, this Example 3 is improved to solve the problem of material drift and scattering caused by large changes in the initial deviation adjustment speed.

[0045] The deviation adjustment control steps of the deviation correction system of this embodiment 2 also include the following:

[0046] Step 401: Analyze and obtain information on the drift distance of the material moving toward the outer edge of the conveyor belt within the initial deviation adjustment time t1 based on the conveyor belt image;

[0047] Step 402: Analyze the drift distance information and the initial deviation speed v1 to obtain the deviation speed v2 and update it to the initial deviation parameter. Use the initial deviation parameter (the deviation speed is v2 at this time) to perform the initial deviation adjustment of the next deviation of the wheel conveying operation.

[0048] The order of each step can be adjusted according to actual conditions. For example, step 21 to step 25 can be performed first, then step 301, and then step 401 to step 402.

[0049] In this way, the initial deviation adjustment speed value can be optimized to ensure that the material will not drift and spread due to excessive deviation correction movement.

[0050] Example 4

[0051] Based on Example 1 or Example 2 and Example 3, this Example 4 is improved to adapt to the corresponding initial adjustment parameter problem for different material types.

[0052] The deviation adjustment control steps of the deviation correction system of this embodiment 2 also include the following:

[0053] Step 501: Preset each material type and its corresponding initial deviation adjustment parameters;

[0054] Step 502: Obtain the material type based on the conveyor belt image recognition, and then select the corresponding initial deviation adjustment parameters to perform the initial deviation adjustment for the next deviation of the conveying operation of the wheel.

[0055] Material types include powders, small lumps, and large chunks. Material size information can be obtained from conveyor belt images and then categorized into categories, small chunks, and large chunks based on classification thresholds. This can be achieved using existing technologies and will not be further explained here. For example, if excessive acceleration causes small chunks to drift and scatter, the acceleration is subtracted from a preset adjustment value to generate new velocity information (or speed and time information). This velocity is gradually reduced until the small chunks are no longer scattered, or the correction efficiency and effectiveness do not meet the requirements.

[0056] The order of each step can be adjusted according to actual conditions. For example, first execute step 501 to step 502, then execute step 21 to step 25, then execute step 301, and then execute step 401 to step 402.

[0057] In this way, according to the speed change that different material types can withstand through image detection, the corresponding initial deviation adjustment parameters can be selected to further improve the deviation correction efficiency.

[0058] It should be pointed out that the examples of the above embodiments can be preferably combined with one or more of them according to actual needs, and multiple examples use a set of drawings to illustrate the combined technical features, which will not be explained one by one here.

[0059] It should be noted that the orientations or positional relationships indicated by terms such as "center", "up", "down", "left", "right", "vertical", "horizontal", "inside" and "outside" are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation.

[0060] The above description is a detailed description and illustration of the preferred embodiments of the present invention, but these descriptions are not intended to limit the scope of protection claimed by the present invention. Any equivalent changes or modifications completed under the technical teachings suggested by the present invention should fall within the scope of patent protection covered by the present invention.

Claims

1. An intelligent deviation correction system for a belt conveyor, characterized in that: The system includes a main controller, a memory, and a correction program, wherein the correction program is stored in the memory and configured to be executed by a processor to perform the following steps: The deviation collection step includes the following: receiving a conveyor belt deviation signal obtained by real-time detection by an infrared photoelectric module, and receiving a conveyor belt image obtained by real-time detection by a camera module; The deviation control steps include: determining the deviation of the conveyor belt according to the deviation signal; issuing a preliminary deviation instruction configured with initial deviation parameters to control the deviation correction actuator to complete the initial deviation adjustment; The actual deviation displacement of the conveyor belt is obtained based on the conveyor belt image analysis; the actual deviation displacement is compared with the initial adjustment displacement d1, and the adjustment deviation value d0 required to correct the conveyor belt to the running position is analyzed; it is determined whether the adjustment deviation value is within the error range. If so, no secondary adjustment is required. Otherwise, a secondary adjustment command configured with the adjustment deviation value d0 is issued to control the correction actuator to complete the secondary adjustment.

2. The intelligent deviation correction system for a belt conveyor according to claim 1 is characterized in that: The deviation control step also includes the following: according to the initial deviation displacement d1 and the deviation value d0, the deviation displacement d2 is analyzed and updated to the initial deviation parameter, and the initial deviation parameter is used to perform the initial deviation adjustment of the next deviation of the wheel conveying operation.

3. The intelligent deviation correction system for a belt conveyor according to claim 1 is characterized in that: The deviation control step also includes the following: according to the conveyor belt image, the drift distance information of the material moving toward the outer edge of the conveyor belt within the initial deviation time t1 is analyzed and obtained; according to the drift distance information and the initial deviation speed v1, the deviation speed v2 is analyzed and updated to the initial deviation parameter, and the initial deviation parameter is used to perform the initial deviation of the next deviation of the conveying operation of this wheel.

4. The intelligent deviation correction system for a belt conveyor according to claim 1 is characterized in that: The deviation control step further includes the following: presetting each material type and its corresponding initial deviation parameter; The material type is obtained based on the conveyor belt image recognition, and then the corresponding initial deviation adjustment parameters are selected to perform the initial deviation adjustment for the next deviation of the conveying operation; The material types include powder, small pieces and large pieces.

5. The intelligent deviation-correcting system for a belt conveyor according to claim 1 is characterized in that: It also includes an infrared photoelectric module, which is arranged on both sides of the conveyor belt. It includes a transmitter and a receiver. The transmitter and the receiver are arranged in opposition to each other, and a deviation signal is uploaded when the receiver loses the signal.

6. The intelligent deviation-correcting system for a belt conveyor according to claim 1, characterized in that: It also includes a camera module, which is arranged above the conveyor belt and is used to capture and upload images of the conveyor belt in real time.

7. The intelligent deviation-correcting system for a belt conveyor according to claim 1, characterized in that: It also includes a deviation correction actuator, which is arranged below the conveyor belt and is used to receive control signals from the main controller and execute movement and / or rotation accordingly to correct the conveyor belt to make it run straight.

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