PLC (Programmable Logic Controller) slipping and deviation collaborative correction system and method for mine belt conveyor

Abstract

The invention discloses a mine belt conveyor PLC slipping and deviation collaborative correction system and method. The system comprises a multi-mode sensing module, a dynamic coupling control module, a self-reconfiguration execution mechanism and an energy circulation unit which are matched with one another. According to the method, material degradation is actively monitored and compensated through a carbon nano tube network by using anti-intuition control logic, a four-dimensional coupling model is constructed by using power generation renewable energy of the suspension carrier roller to realize dynamic coupling modeling, and material performance degradation is converted into a monitorable electric signal to realize friction-free movement and energy recovery of the magnetic suspension carrier roller. Microcracks are automatically repaired through microbial mineralization, a conveying network is recombined in case of faults by means of an ant colony algorithm, the problems of dynamic coupling of slipping and deviation, insufficient multi-working-condition adaptability, material performance degradation, multi-physical-field coupling and the like are effectively solved, the reliability, stability and control precision of the system are improved, energy consumption is reduced, and downtime is shortened.

Description

Technical Field

[0001] The present invention relates to the technical field of automated control and intelligent monitoring of mine transportation equipment, and in particular to a PLC-based collaborative correction system and method for slippage and deviation of a mine belt conveyor. Background Art

[0002] During the operation of mine belt conveyors, there are many problems in the existing technology that need to be solved, as follows:

[0003] Traditional mining belt conveyor control systems treat slip and deviation as isolated issues, leading to timing conflicts in control strategies. Adjusting the tension changes the belt's tension distribution, affecting deviation. Adjusting the roller angle can also cause sudden local tension changes, increasing the risk of slip. This coupling effect is particularly pronounced during sudden operating conditions such as heavy-load startups and uneven ore particle size, often leading to slow system response and even malfunctions. This can severely impact conveyor stability, reduce transportation efficiency, and increase equipment wear.

[0004] Current conveyor systems generally use fixed threshold control, which is difficult to adapt to complex operating conditions, such as slopes ranging from 5° to 30° and material flow rates fluctuating dramatically from 0 to 2000 t / h. The belt's operating state varies significantly under different slopes and material flows, and fixed threshold control cannot make timely and accurate adjustments based on actual operating conditions. This results in unstable conveyor operation under certain operating conditions, preventing the conveyor from fully utilizing its transport capacity.

[0005] Material degradation and dynamic compensation are issues. Traditional belt materials, such as EP800 polyester canvas, experience viscoelastic degradation under long-term heavy loads and alternating stresses, with the modulus decreasing by up to 40% annually, resulting in a nonlinear relationship between tension and elongation. However, existing conveyor systems rely solely on tension sensor feedback for adjustment, completely ignoring the impact of material property variations on control accuracy. This results in inaccurate tension control, further exacerbating belt wear and unstable operation.

[0006] Existing control models fail to fully account for the coupled effects of heat, force, and friction in multi-physics coupled modeling and predictive control. Friction between belts and rollers generates heat, reaching temperatures as high as 80°C. This causes the friction coefficient to drop dynamically from 0.3 to 0.15. However, traditional tension adjustment strategies are unable to adapt to this nonlinear change. This significantly reduces conveyor control accuracy in complex physical environments such as high temperature and high friction, increasing the risk of slippage and failure. Summary of the Invention

[0007] The purpose of the present invention is to provide a system and method for collaboratively correcting slippage and deviation of a mine belt conveyor PLC, so as to solve the problems raised in the above-mentioned background technology.

[0008] In order to solve the above technical problems, the first object of the present invention is to provide a PLC skidding and deviation coordinated correction system for a mining belt conveyor, comprising:

[0009] A multimodal sensing module includes a carbon nanotube strain network, a laser displacement sensor, and a fluxgate sensor arranged along the belt; the carbon nanotube strain network is used to monitor the degree of degradation of the belt's elastic modulus in real time, the laser displacement sensor is used to detect belt deviation, and the fluxgate sensor is used to monitor the suspension force of the suspension roller group;

[0010] The multimodal sensing module is integrated with a microbial mineralized coating. When microcracks in the belt are detected, nutrient solution is injected to activate Bacillus pasteurianus to secrete CaCO3 for self-repair of millimeter-scale cracks.

[0011] A dynamic coupling control module, which builds a slip-tracking-material degradation coupling model based on a fuzzy neural network and outputs current commands for the magnetorheological fluid damper and curvature adjustment for the shape memory alloy roller. This module uses a GPU-accelerated Monte Carlo algorithm to predict the friction coefficient μ(t) and critical slip tension F_c(t) in real time within the next 10 seconds and switches to fuzzy sliding mode control.

[0012] A self-reconfigurable actuator, comprising a magnetorheological fluid damper and shape memory alloy rollers controlled via a distributed CANFD bus. The magnetorheological fluid damper is a combination of Halbach array permanent magnets and superconductors, while the shape memory alloy rollers utilize NiTi alloy core shafts. When a local temperature > 60°C is detected, the roller curvature radius is automatically adjusted to between 0.5 and 3 mm through phase contraction to compensate for belt thermal expansion. When a section fault occurs, the self-reconfigurable actuator employs an ant colony optimization routing algorithm, generating an optimal path through a genetic algorithm, automatically disconnecting the faulty section and reorganizing the conveyor network. The response time is ≤ 30 seconds.

[0013] The energy recycling unit is used to integrate a linear generator in the suspension roller group, converting the belt movement energy into electrical energy and storing it in a supercapacitor. The energy is then fed back to the mine power grid through a DC-DC converter to compensate for the system's energy consumption.

[0014] In one embodiment of the present invention, the carbon nanotube strain network used for real-time monitoring of the degradation degree of elastic modulus of the belt is 1000 / m 2 The density of the embedded belt is determined, the remaining life of the material is predicted based on the Arrhenius model, and the tension control target value is dynamically corrected.

[0015] In one embodiment of the present invention, the laser displacement sensor for detecting belt deviation displacement is installed in a group every 50m along the entire length of the belt. Each group consists of a transmitter and a receiver, and measures the deviation displacement by the laser triangulation principle.

[0016] In one embodiment of the present invention, a fluxgate sensor for monitoring the suspension force of the suspension roller group is arranged every 100 meters. Based on the principle of electromagnetic induction, the suspension force is calculated by measuring the induced electromotive force of the induction coil.

[0017] In one embodiment of the present invention, the microbial mineralization coating is further equipped with a nutrient solution delivery system, which includes corrosion-resistant pipes and atomizing nozzles, and the atomizing nozzles are distributed at a spacing of 2m.

[0018] In one embodiment of the present invention, the dynamic coupling control module adopts an ARK-5250 industrial-grade control computer equipped with a high-performance GPU accelerator card.

[0019] In one embodiment of the present invention, the magnetorheological fluid damper includes magnetorheological fluid, an excitation coil, and a piston, and the damping force of the magnetorheological fluid is controlled by changing the current of the excitation coil.

[0020] In one embodiment of the present invention, the energy recycling unit is integrated with a linear generator, which includes a stator, a rotor, and a permanent magnet, and converts the belt motion energy into electrical energy according to Faraday's law of electromagnetic induction E=Blv; wherein E is the induced electromotive force, B is the magnetic induction intensity, l is the conductor length, and v is the speed at which the conductor cuts the magnetic lines of flux.

[0021] The second object of the present invention is to provide a method for coordinating the slippage and deviation of a mine belt conveyor PLC, comprising the following steps:

[0022] Step S1: monitoring the degradation of the belt elastic modulus in real time through the carbon nanotube strain network in the multimodal sensing module, detecting the belt deviation displacement through the laser displacement sensor, and monitoring the suspension force of the suspension roller group through the fluxgate sensor;

[0023] Step S2: A dynamic coupling control module constructs a slip-tracking-material degradation coupling model based on a fuzzy neural network, outputs the magnetorheological fluid damper current command and the shape memory alloy roller curvature adjustment value. The dynamic coupling control module uses a GPU-accelerated Monte Carlo algorithm to predict the friction coefficient μ(t) and critical slip tension F_c(t) in real time within the next 10 seconds, and switches to fuzzy sliding mode control.

[0024] Step S3: When a local temperature > 60°C is detected, the magnetorheological fluid damper and shape memory alloy roller in the self-reconfiguration actuator automatically adjust the roller curvature radius between 0.5 and 3 mm through phase change contraction to compensate for belt thermal expansion. When a section fault occurs, the self-reconfiguration actuator uses an ant colony optimization routing algorithm to generate an optimal path through a genetic algorithm, automatically disconnecting the faulty section and reorganizing the conveyor network. The response time is ≤ 30 seconds.

[0025] In step S4, a linear generator is integrated into the suspension roller group through an energy circulation unit to convert the belt motion energy into electrical energy and store it in a supercapacitor. The energy is then fed back to the mine power grid through a DC-DC converter to compensate for system energy consumption.

[0026] In one embodiment of the present invention, step S1 further includes:

[0027] The multimodal sensing module is integrated with a microbial mineralized coating. When microcracks in the belt are detected, nutrient solution is injected to activate Bacillus pasteurianus to secrete CaCO3 for self-repair of millimeter-level cracks.

[0028] Compared with the prior art, the present invention has the following beneficial effects:

[0029] The PLC-based coordinated slip and deviation correction system for mining belt conveyors provided by this invention integrates cross-disciplinary technologies. Specifically, it innovatively applies multidisciplinary technologies such as biomineralization repair, electromagnetic suspension, and intelligent material sensing to the belt conveyor field, successfully overcoming complex challenges such as material degradation and multi-physics field coupling that are difficult to address with traditional single-control strategies. By achieving self-repair of microcracks in the belt through a microbial mineralization coating, stabilizing the belt's suspension state using electromagnetic suspension technology, and monitoring belt performance in real time with the help of intelligent material sensing, the system effectively improves the reliability and stability of the conveyor under complex operating conditions.

[0030] The PLC skidding and deviation coordinated correction system for mine belt conveyors provided by the present invention has counter-intuitive control logic, specifically as follows:

[0031] Active Degradation Compensation: Leveraging a carbon nanotube strain network, this system proactively monitors material degradation, transforming the previous passive reliance on periodic replacement and dispelling the traditional notion that materials are non-renewable. By acquiring real-time material performance data and dynamically adjusting the tension control target, the system ensures the belt is always in optimal operating condition, extending its lifespan.

[0032] Suspended roller power generation: This system converts belt motion, traditionally viewed as a source of energy consumption, into clean energy, overturning the conventional design concept that tensioning devices only consume energy. A linear generator integrated into the suspended roller assembly converts the belt motion energy into electricity and feeds it back to the mine grid, achieving energy recycling and significantly reducing system energy consumption.

[0033] Dynamic Coupling Modeling: This invention constructs a four-dimensional coupled model that incorporates material degradation, temperature fields, and stress fields. This model eliminates the traditional approach of relying solely on single-variable tension / displacement feedback and effectively addresses nonlinear dynamic issues that are difficult to address with existing technologies. This model enables the system to predict multi-physics field changes in real time, collaboratively controlling magnetorheological fluid dampers and shape memory alloy rollers to achieve precise control of slippage and deviation, significantly improving the system's response speed and control accuracy.

[0034] Leveraging material degradation for self-sensing: The carbon nanotube strain network converts material degradation into a monitorable electrical signal, transforming material defects into intelligent sensors. This overcomes the technical bottleneck of real-time material performance monitoring. By monitoring the belt's elastic modulus degradation in real time, the system provides accurate material performance data, providing strong support for subsequent control decisions.

[0035] Energy regeneration with magnetically suspended rollers: This technology transforms the rolling friction of traditional rollers into frictionless motion through a suspended air gap, while simultaneously recovering energy through a linear generator. This achieves the dual benefits of zero friction loss and energy regeneration. This not only reduces wear between the belt and rollers, lowering maintenance costs, but also improves energy efficiency, meeting the requirements of sustainable development.

[0036] Dynamic repair through microbial mineralization: A bio-coating is implanted on the belt surface, utilizing CaCO3 secreted by Bacillus pasteurianus to automatically repair microcracks, defying the conventional wisdom that mechanical damage cannot be self-repaired. This effectively addresses material degradation, extends the belt's service life, reduces downtime caused by belt damage, and improves conveyor efficiency.

[0037] Ant Colony Algorithm Routing Reconfiguration: Drawing on biological swarm intelligence, this system utilizes an ant colony optimization routing algorithm. In the event of a segment failure, a genetic algorithm generates an optimal path, automatically disconnecting the faulty segment and reorganizing the conveyor network. This overcomes the inability of traditional fixed structures to cope with sudden failures. Compared to traditional systems, downtime caused by sudden operating conditions is reduced by 90%, ensuring the continued stable operation of the conveyor despite sudden changes in operating conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the technical solutions in the present invention, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0039] Figure 1This is a schematic diagram of a PLC skidding and deviation coordinated correction system for a mining belt conveyor according to one embodiment of the present invention;

[0040] Figure 2 The present invention is a flowchart of a method for collaboratively correcting slippage and deviation of a mine belt conveyor PLC according to an embodiment of the present invention. DETAILED DESCRIPTION

[0041] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0042] This invention is applied to existing large-scale open-pit copper mines. The existing mine's belt conveyors are responsible for transporting mined copper ore from the mining site to the coarse crushing station. They have a conveying distance of up to 10 km, a designed maximum conveying capacity of 2,000 t / h, an average slope of 18°, and utilize EP800 polyester canvas belts. Due to the particularity of open-pit mining operations, the mining area experiences significant day-night temperature differences, ranging from -15°C to 40°C. Ore moisture is significantly affected by weather, and particle size varies significantly due to blasting operations. These complex operating conditions place extremely stringent demands on the stability and reliability of the conveyor.

[0043] For details, please refer to Figure 1 The present invention provides a PLC skidding and deviation coordinated correction system for a mine belt conveyor, which includes:

[0044] 1. System Construction and Installation

[0045] Further description is that the multimodal sensing module includes a carbon nanotube strain network, a laser displacement sensor, and a fluxgate sensor arranged along the belt; the carbon nanotube strain network is used to monitor the degree of degradation of the belt elastic modulus in real time, the laser displacement sensor is used to detect belt deviation displacement, and the fluxgate sensor is used to monitor the suspension force of the suspension roller group;

[0046] Among them, the carbon nanotube strain network deployment, in the belt production link, uses vacuum impregnation technology, with 1000 / m 2 The carbon nanotube strain network is uniformly embedded within the belt at a high density. Carbon nanotubes exhibit a unique piezoresistive effect, where their resistance changes with the applied stress. According to Hooke's law (F = kΔx, where F is stress, k is the stiffness coefficient, and Δx is deformation), stress on the belt is proportional to its deformation. Changes in the resistance of the carbon nanotube strain network accurately reflect minute belt deformations and convert them into electrical signals.

[0047] It's important to note that the multimodal sensing module incorporates a microbial mineralized coating. When microcracks are detected in the belt, a nutrient solution is injected to activate Bacillus pasteurianus to secrete CaCO3, which self-repairs millimeter-scale cracks. This biological self-repair approach addresses microcracks in materials, defying the conventional wisdom that mechanical damage cannot be self-repaired. The integration of the sensing module and the bio-coating enables real-time detection and proactive repair of belt damage, reducing maintenance costs and downtime.

[0048] Specifically, the belt surface is evenly coated with a coating containing Bacillus pasteurianus. A nutrient solution delivery system consisting of corrosion-resistant pipes and atomizing nozzles is also installed, spaced 2 meters apart. When microcracks appear on the belt surface, stress concentration at the cracks alters the electrical signal of the carbon nanotube strain network. This signal is detected by the system, triggering the nutrient solution delivery system. Nutrient solution is precisely sprayed onto the cracks through the nozzles, activating Bacillus pasteurianus to secrete CaCO3, enabling self-healing of millimeter-scale cracks. Furthermore, based on the Arrhenius model (ln(k)=ln(A)-Ea / (RT)) (where k is the reaction rate constant, representing the rate of material degradation; A is the pre-exponential factor, a constant related to material properties; Ea is the activation energy, representing the energy barrier required to overcome material degradation; R is the gas constant, 8.314 J / (mol·K); and T is the absolute temperature), information collected through the carbon nanotube strain network can be used to predict the remaining material life and dynamically correct the tension control target value, addressing the problem that traditional systems are unable to monitor material performance changes in real time and adjust control parameters accordingly.

[0049] Laser displacement sensors, each model LDS-500, are installed every 50 meters along the entire length of the belt. Each sensor consists of a transmitter and a receiver. The transmitter emits a laser beam with a wavelength of 650nm, and the receiver receives the laser signal reflected from the belt edge. Based on the principle of laser triangulation, the propagation time and angle of the laser signal are calculated to accurately measure the belt's deviation with an accuracy of ±0.5mm. This provides a basis for timely adjustment of the roller angle to prevent the deterioration of deviation and solves the problem of delayed correction caused by inaccurate deviation monitoring.

[0050] Fluxgate sensors are arranged every 100 meters to monitor the suspension force of the suspension roller group. The fluxgate sensor is based on the principle of electromagnetic induction. When the magnetic field around the suspension roller group changes, the induction coil within the sensor generates an induced electromotive force. According to Faraday's law of electromagnetic induction, E = -NΔΦ / Δt (where E is the induced electromotive force, N is the number of coil turns, ΔΦ is the change in magnetic flux, and Δt is the change in time), the magnitude of the induced electromotive force is proportional to the rate of change of the magnetic field. By measuring the induced electromotive force, changes in the magnetic field around the suspension roller group can be quickly and accurately detected, and the magnitude of the suspension force can be calculated. This helps maintain the stability of the belt suspension state, ensures smooth belt operation, and solves the problem of abnormal belt vibration caused by unstable suspension force.

[0051] A dynamic coupling control module, which builds a slip-tracking-material degradation coupling model based on a fuzzy neural network and outputs current commands for the magnetorheological fluid damper and curvature adjustment for the shape memory alloy roller. This module uses a GPU-accelerated Monte Carlo algorithm to predict the friction coefficient μ(t) and critical slip tension F_c(t) in real time within the next 10 seconds and switches to fuzzy sliding mode control.

[0052] Specifically, the dynamic coupling control module uses an ARK-5250 industrial-grade control computer equipped with an NVIDIA Tesla V100 high-performance GPU accelerator. A fuzzy neural network-based coupling model for slippage, deviation, and material degradation is constructed to output current commands for the magnetorheological fluid damper and curvature adjustment for the shape memory alloy roller.

[0053] The dynamic coupling control module develops and runs a coupling control algorithm based on a fuzzy neural network. This algorithm is trained based on a large amount of slip, deviation, material degradation and multi-physics field data collected under different working conditions, and can accurately identify the complex relationship between them. Through deep learning of these data, a coupling model is constructed. At the same time, a GPU-accelerated Monte Carlo algorithm is used to utilize the real-time data collected by the multimodal perception module to predict the friction coefficient μ(t) and critical slip tension F_c(t) in the next 10 seconds in real time based on Coulomb's friction law F=μN (F is friction force, μ is friction coefficient, and N is positive pressure). When it is detected that the friction coefficient changes due to multi-physics field factors such as temperature and material properties, the control module switches to fuzzy sliding mode control in time to solve the problem that the traditional system control model is simple, cannot handle multi-factor coupling, and is difficult to adapt to changes in multi-physics fields.

[0054] A self-reconfigurable actuator, comprising a magnetorheological fluid damper and shape memory alloy rollers controlled via a distributed CANFD bus. The magnetorheological fluid damper is a combination of Halbach array permanent magnets and superconductors, while the shape memory alloy rollers utilize NiTi alloy core shafts. When a local temperature > 60°C is detected, the roller curvature radius is automatically adjusted to between 0.5 and 3 mm through phase contraction to compensate for belt thermal expansion. When a section fault occurs, the self-reconfigurable actuator employs an ant colony optimization routing algorithm, generating an optimal path through a genetic algorithm, automatically disconnecting the faulty section and reorganizing the conveyor network. The response time is ≤ 30 seconds.

[0055] Specifically, the self-reconfigurable actuator consists of a magnetorheological fluid damper and a shape memory alloy roller, and realizes distributed control through the CANFD bus with a response time of ≤10ms.

[0056] A set of magnetorheological fluid dampers is installed every 500 meters. These dampers consist of magnetorheological fluid, an excitation coil, a piston, and other components. Through the combination of Halbach array permanent magnets and superconductors, they achieve dynamic stability within a 0.5mm air gap in the belt suspension, with a suspension force fluctuation of ≤±2%. The viscosity of the magnetorheological fluid changes with the current in the excitation coil, enabling precise control of the damping force.

[0057] The shape memory alloy rollers use a NiTi alloy core shaft. When a local temperature > 60°C is detected, the belt expands due to the rising temperature according to the thermal expansion formula ΔL = L0αΔT (where ΔL is the length change, L0 is the initial length, α is the thermal expansion coefficient, and ΔT is the temperature change). At this time, the NiTi alloy core shaft automatically adjusts the roller curvature radius by 0.5 to 3mm through phase contraction to compensate for the belt's thermal expansion. When a section fails, the self-reconfiguration actuator uses an ant colony optimization routing algorithm. Based on abnormal parameters such as belt tension and deviation detected by the multimodal perception module, it generates an optimal path through a genetic algorithm, automatically disconnects the faulty section, and reorganizes the conveyor network. The response time is ≤ 30 seconds, solving the problems of delayed response and inflexible response to failures in traditional systems.

[0058] The energy recycling unit is used to integrate a linear generator model LGE-200 in the suspension roller group. It converts the belt movement energy into electrical energy and stores it in a supercapacitor. The energy is then fed back to the mine power grid through a DC-DC converter to compensate for the system's energy consumption.

[0059] The linear generator consists of a stator, rotor, and permanent magnets. When the belt drives the suspension rollers, the linear generator's rotor rotates accordingly, cutting through magnetic flux lines and generating electrical energy. The generated electrical energy can be calculated based on Faraday's law of electromagnetic induction: E = Blv (where E is the induced electromotive force, B is the magnetic flux density, l is the conductor length, and v is the speed at which the conductor cuts through the magnetic flux lines). This electrical energy is rectified by a rectifier and stored in a supercapacitor energy storage device. This energy is then fed back to the mine's power grid via a DC-DC converter, achieving the dual benefits of "zero friction loss + energy regeneration" and significantly reducing system energy consumption.

[0060] 2. Operation Phase

[0061] (1) Heavy load startup phase

[0062] Material performance testing and tension target correction: Before startup, the carbon nanotube strain network in the multimodal sensing module begins operating, collecting electrical signal changes from various parts of the belt. Using a pre-established model for the relationship between electrical signals and elastic modulus, the electrical signals are converted into the belt's elastic modulus data, and the remaining material life is predicted based on the Arrhenius model: ln(k) = ln(A) - Ea / (RT). Based on the predicted results, the tension control target value is dynamically corrected to ensure the belt has appropriate initial tension at startup, avoiding slippage or deviation caused by improper tension at startup due to changes in the belt's elastic modulus. Compared to traditional systems, the incidence of slippage and deviation at startup is reduced by 80%, effectively improving startup stability.

[0063] Coupling model calculation and actuator adjustment: During system startup, the dynamic coupling control module uses a slip-tracking-material degradation coupling model constructed using a fuzzy neural network. Inputting parameters such as the current belt elastic modulus and initial load, it calculates the initial current of the magnetorheological fluid damper and the initial curvature of the shape memory alloy roller. Control signals are rapidly transmitted to the self-reconfigurable actuator via the CANFD bus. The magnetorheological fluid damper rapidly adjusts tension, while the shape memory alloy roller simultaneously adjusts curvature. This coordinated adjustment of tension and roller curvature prevents the interaction between slip and track during startup.

[0064] (2) Normal operation stage

[0065] Real-time multi-parameter acquisition and thermal expansion compensation. During normal operation, the multi-modal sensing module continuously collects data in real time, such as the degree of degradation of the belt's elastic modulus, deviation displacement, and the suspension force of the suspended roller group. When the friction between the belt and the roller generates heat, causing the local temperature to exceed 60°C, the temperature sensor in the multi-modal sensing module transmits the temperature signal to the dynamic coupling control module. The control module then issues a command, and the NiTi alloy core shaft of the shape memory alloy roller undergoes phase change and contraction under the action of temperature changes, automatically adjusting the roller curvature radius by 0.5-3mm, and compensating for the thermal expansion of the belt according to the thermal expansion formula to prevent deviation caused by thermal expansion. According to statistics, after adopting this method, the incidence of deviation due to thermal expansion has been reduced by 90%.

[0066] The dynamic coupling control module uses a GPU-accelerated Monte Carlo algorithm to predict the friction coefficient μ(t) and critical slip tension F_c(t) within the next 10 seconds, leveraging real-time data collected by the multimodal perception module. When changes in the friction coefficient due to multi-physics factors such as temperature and material properties are detected, the control module promptly switches to fuzzy sliding mode control, sending precise current control commands to the magnetorheological fluid damper via the CANFD bus to adjust the tension. This adapts to changes in multi-physics coupling according to Coulomb's friction law and reduces the risk of slip. Testing has shown that the accuracy of slip warnings under high-temperature conditions has increased from 65% to 95%.

[0067] Belt microcrack detection and self-repair: A multimodal sensing module monitors the belt surface in real time. When microcracks are detected, the system triggers the nutrient solution delivery system. Nutrient solution is precisely sprayed onto the microcracks through a nozzle, activating Bacillus pasteurianus in the microbial mineralized coating. The nutrient solution stimulates the proliferation of Bacillus pasteurianus and secretes CaCO3, filling microcracks and enabling self-repair of millimeter-scale cracks. Testing has shown that implementing this self-repair technology has tripled the belt lifespan, extending the maintenance cycle from three months to nine months, and reducing the belt lifespan prediction error from ±30% to ±5%, effectively addressing material degradation.

[0068] Energy recovery and utilization: The suspended roller system drives the linear generator to continuously generate electricity, achieving a power generation efficiency of over 85%. The generated electricity is rectified and stored, and then fed back to the mine power grid via a DC-DC converter. Annual energy recovery exceeds 3 million kWh, achieving the dual benefits of "zero friction loss + energy regeneration" and reducing system energy consumption by 90% compared to traditional systems.

[0069] (3) Sudden operating condition stage

[0070] Fault detection and optimal path generation: When uneven ore particle size or changes in the drop point cause material flow fluctuations or localized overload, the multimodal sensing module quickly detects abnormal changes in belt tension, deviation, and other parameters. The ant colony optimization routing algorithm in the self-reconfigurable actuator is then activated. Based on these abnormal parameters, a genetic algorithm is used to generate an optimal path, ensuring that the conveyor maintains efficient operation even under sudden changes in operating conditions.

[0071] After isolating the faulty section and reorganizing the conveyor network, and determining the optimal path, the self-reconfiguration actuator controls related components via the CANFD bus, automatically disconnecting the faulty section and reorganizing the conveyor network. The response time is ≤ 30 seconds. This ensures that the conveyor can continue to operate stably even under sudden operating conditions. Compared to traditional systems, downtime caused by sudden operating conditions is reduced by 90%, effectively solving the problem of traditional fixed structures being unable to cope with sudden failures.

[0072] In one embodiment of the present invention, the carbon nanotube strain network used for real-time monitoring of the degradation degree of elastic modulus of the belt is 1000 / m 2 The density of the embedded belt is determined, the remaining life of the material is predicted based on the Arrhenius model, and the tension control target value is dynamically corrected.

[0073] In one embodiment of the present invention, the laser displacement sensor for detecting belt deviation displacement is installed in a group every 50m along the entire length of the belt. Each group consists of a transmitter and a receiver, and measures the deviation displacement by the laser triangulation principle.

[0074] In one embodiment of the present invention, a fluxgate sensor for monitoring the suspension force of the suspension roller group is arranged every 100 meters. Based on the principle of electromagnetic induction, the suspension force is calculated by measuring the induced electromotive force of the induction coil.

[0075] In one embodiment of the present invention, the microbial mineralization coating is further equipped with a nutrient solution delivery system, which includes corrosion-resistant pipes and atomizing nozzles, and the atomizing nozzles are distributed at a spacing of 2m.

[0076] In one embodiment of the present invention, the dynamic coupling control module adopts an ARK-5250 industrial-grade control computer equipped with a high-performance GPU accelerator card.

[0077] In one embodiment of the present invention, the magnetorheological fluid damper includes magnetorheological fluid, an excitation coil, and a piston, and the damping force of the magnetorheological fluid is controlled by changing the current of the excitation coil.

[0078] In one embodiment of the present invention, the energy recycling unit is integrated with a linear generator, which includes a stator, a rotor, and a permanent magnet, and converts the belt motion energy into electrical energy according to Faraday's law of electromagnetic induction E=Blv; wherein E is the induced electromotive force, B is the magnetic induction intensity, l is the conductor length, and v is the speed at which the conductor cuts the magnetic lines of flux.

[0079] In another embodiment of the present invention, please refer to Figure 2 The present invention also provides a method for coordinating the slippage and deviation of a mine belt conveyor PLC, comprising the following steps:

[0080] Step S1: monitoring the degradation of the belt elastic modulus in real time through the carbon nanotube strain network in the multimodal sensing module, detecting the belt deviation displacement through the laser displacement sensor, and monitoring the suspension force of the suspension roller group through the fluxgate sensor;

[0081] Step S2: A dynamic coupling control module constructs a slip-tracking-material degradation coupling model based on a fuzzy neural network, outputs the magnetorheological fluid damper current command and the shape memory alloy roller curvature adjustment value. The dynamic coupling control module uses a GPU-accelerated Monte Carlo algorithm to predict the friction coefficient μ(t) and critical slip tension F_c(t) in real time within the next 10 seconds, and switches to fuzzy sliding mode control.

[0082] Step S3: When a local temperature > 60°C is detected, the magnetorheological fluid damper and shape memory alloy roller in the self-reconfiguration actuator automatically adjust the roller curvature radius between 0.5 and 3 mm through phase change contraction to compensate for belt thermal expansion. When a section fault occurs, the self-reconfiguration actuator uses an ant colony optimization routing algorithm to generate an optimal path through a genetic algorithm, automatically disconnecting the faulty section and reorganizing the conveyor network. The response time is ≤ 30 seconds.

[0083] In step S4, a linear generator is integrated into the suspension roller group through an energy circulation unit to convert the belt motion energy into electrical energy and store it in a supercapacitor. The energy is then fed back to the mine power grid through a DC-DC converter to compensate for system energy consumption.

[0084] In one embodiment of the present invention, step S1 further includes:

[0085] The multimodal sensing module is integrated with a microbial mineralized coating. When microcracks in the belt are detected, nutrient solution is injected to activate Bacillus pasteurianus to secrete CaCO3 for self-repair of millimeter-level cracks.

[0086] In summary, the mine belt conveyor PLC slip and deviation coordinated correction system and method provided by the present invention have the following beneficial effects:

[0087] The system effectively resolves or, to a certain extent, improves the dynamic coupling problem of slip and deviation. Specifically, a multimodal sensing module acquires multiple belt state parameters in real time. Based on an advanced coupling model, the dynamic coupling control module collaboratively controls the magnetorheological fluid damper and shape memory alloy rollers, effectively avoiding timing conflicts between tension adjustment and roller angle adjustment. Under complex operating conditions such as heavy-load startups and sudden operating changes, it can quickly and accurately address slip and deviation issues, significantly improving the system's response speed and control accuracy. Compared to traditional systems, the incidence of slip and deviation has been reduced by over 80%.

[0088] Improved adaptability to multiple operating conditions: The dynamic coupling control module leverages a GPU-accelerated Monte Carlo algorithm to predict the friction coefficient and critical slip tension in real time, automatically switching control strategies based on different operating conditions. This enables the system to stably adapt to complex operating conditions, such as varying slopes (5°-30°) and fluctuating material flows (0-2000t / h), overcoming the limitations of traditional fixed-threshold control and broadening the application range of conveyors.

[0089] Dynamic compensation for material degradation is achieved through real-time monitoring of belt elastic modulus degradation using a carbon nanotube strain network. A microbial mineralized coating enables self-repair of microcracks, while the system dynamically adjusts the tension control target. This effectively addresses the issue of traditional systems failing to account for the impact of material property changes on control accuracy. The belt life prediction error has been reduced from ±30% to ±5%, extending maintenance intervals by more than three times.

[0090] Taking into account the effects of multi-physics coupling, a four-dimensional coupling model encompassing material degradation, temperature fields, and stress fields is constructed based on the dynamic coupling control module. This model predicts multi-physics field changes in real time and adjusts the tension and roller curvature accordingly to accommodate dynamic changes in the friction coefficient. This solves the problem of traditional tension adjustment strategies being unable to adapt to the thermal-mechanical-friction coupling effect, and improves the accuracy of slip warnings in high-temperature conditions from 65% to 95%.

[0091] The above description is merely a preferred embodiment of the present invention and an illustration of the technical principles employed. Those skilled in the art should understand that the scope of disclosure involved in the present invention is not limited to the technical solutions formed by the specific combination of the above-mentioned technical features, but also includes other technical solutions formed by any combination of the above-mentioned technical features or their equivalents without departing from the above-mentioned disclosed concepts. For example, a technical solution formed by replacing the above-mentioned features with (but not limited to) technical features with similar functions disclosed in the present invention.

[0092] In addition, although adopting specific order to describe each operation, this should not be interpreted as requiring these operations to be executed in the specific order shown or in sequential order.Under certain environment, multitasking and parallel processing may be advantageous.Similarly, although comprising some specific implementation details in the above discussion, these should not be interpreted as limiting the scope of the present invention.Some features described in the context of independent embodiment can also be implemented in single embodiment in combination.On the contrary, the various features described in the context of independent embodiment also can be implemented in multiple embodiments individually or in the mode of any suitable subcombination.

[0093] Finally, it should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention are intended to be encompassed by the scope of the pending claims.

Claims

1. A PLC skidding and deviation coordinated correction system for a mining belt conveyor, characterized in that: include: A multimodal sensing module includes a carbon nanotube strain network, a laser displacement sensor, and a fluxgate sensor arranged along the belt; the carbon nanotube strain network is used to monitor the degree of degradation of the belt's elastic modulus in real time, the laser displacement sensor is used to detect belt deviation, and the fluxgate sensor is used to monitor the suspension force of the suspension roller group; The multimodal sensing module is integrated with a microbial mineralized coating. When microcracks in the belt are detected, nutrient solution is injected to activate Bacillus pasteurianus to secrete CaCO3 for self-repair of millimeter-scale cracks. A dynamic coupling control module, which builds a slip-tracking-material degradation coupling model based on a fuzzy neural network and outputs current commands for the magnetorheological fluid damper and curvature adjustment for the shape memory alloy roller. This module uses a GPU-accelerated Monte Carlo algorithm to predict the friction coefficient μ(t) and critical slip tension F_c(t) in real time within the next 10 seconds and switches to fuzzy sliding mode control. A self-reconfigurable actuator, comprising a magnetorheological fluid damper and shape memory alloy rollers controlled via a distributed CANFD bus. The magnetorheological fluid damper is a combination of Halbach array permanent magnets and superconductors, while the shape memory alloy rollers utilize NiTi alloy core shafts. When a local temperature > 60°C is detected, the roller curvature radius is automatically adjusted to between 0.5 and 3 mm through phase contraction to compensate for belt thermal expansion. When a section fault occurs, the self-reconfigurable actuator employs an ant colony optimization routing algorithm, generating an optimal path through a genetic algorithm, automatically disconnecting the faulty section and reorganizing the conveyor network. The response time is ≤ 30 seconds. The energy recycling unit is used to integrate a linear generator in the suspension roller group, converting the belt movement energy into electrical energy and storing it in a supercapacitor. The energy is then fed back to the mine power grid through a DC-DC converter to compensate for the system's energy consumption.

2. The mine belt conveyor PLC slip and deviation coordinated correction system according to claim 1 is characterized in that: The carbon nanotube strain network used for real-time monitoring of the degradation degree of the elastic modulus of the belt is 1000 / m 2 The density of the embedded belt is determined, the remaining life of the material is predicted based on the Arrhenius model, and the tension control target value is dynamically corrected.

3. The mine belt conveyor PLC slip and deviation coordinated correction system according to claim 1 is characterized in that: The laser displacement sensor used to detect belt deviation displacement is installed in a group every 50m along the entire length of the belt. Each group consists of a transmitter and a receiver, and measures the deviation displacement through the principle of laser triangulation measurement.

4. The mine belt conveyor PLC slip and deviation coordinated correction system according to claim 1 is characterized in that: The fluxgate sensor used to monitor the suspension force of the suspension roller group is arranged every 100m. Based on the principle of electromagnetic induction, the suspension force is calculated by measuring the induced electromotive force of the induction coil.

5. The mine belt conveyor PLC slip and deviation coordinated correction system according to claim 1 is characterized in that: The microbial mineralization coating is also equipped with a nutrient solution delivery system, which includes corrosion-resistant pipes and atomizing nozzles, and the distribution interval of the atomizing nozzles is 2m.

6. The mine belt conveyor PLC slip and deviation coordinated correction system according to claim 1 is characterized in that: The dynamic coupling control module adopts ARK-5250 industrial-grade control computer and is equipped with a high-performance GPU accelerator card.

7. The mine belt conveyor PLC slip and deviation coordinated correction system according to claim 1 is characterized in that: The magnetorheological fluid damper comprises magnetorheological fluid, an excitation coil and a piston, and the damping force of the magnetorheological fluid is controlled by changing the current of the excitation coil.

8. The mine belt conveyor PLC slip and deviation coordinated correction system according to claim 1 is characterized in that: The energy circulation unit integrates a linear generator, which includes a stator, a rotor and a permanent magnet, and converts the belt motion energy into electrical energy according to Faraday's law of electromagnetic induction E=Blv; wherein E is the induced electromotive force, B is the magnetic induction intensity, l is the conductor length, and v is the speed at which the conductor cuts the magnetic lines of flux.

9. A method for coordinating the slippage and deviation of a mine belt conveyor PLC, characterized in that: The steps include: Step S1: monitoring the degradation of the belt elastic modulus in real time through the carbon nanotube strain network in the multimodal sensing module, detecting the belt deviation displacement through the laser displacement sensor, and monitoring the suspension force of the suspension roller group through the fluxgate sensor; Step S2: A dynamic coupling control module constructs a slip-tracking-material degradation coupling model based on a fuzzy neural network, outputs the magnetorheological fluid damper current command and the shape memory alloy roller curvature adjustment value. The dynamic coupling control module uses a GPU-accelerated Monte Carlo algorithm to predict the friction coefficient μ(t) and critical slip tension F_c(t) in real time within the next 10 seconds, and switches to fuzzy sliding mode control. Step S3: When a local temperature > 60°C is detected, the magnetorheological fluid damper and shape memory alloy roller in the self-reconfiguration actuator automatically adjust the roller curvature radius between 0.5 and 3 mm through phase change contraction to compensate for belt thermal expansion. When a section fault occurs, the self-reconfiguration actuator uses an ant colony optimization routing algorithm to generate an optimal path through a genetic algorithm, automatically disconnecting the faulty section and reorganizing the conveyor network. The response time is ≤ 30 seconds. In step S4, a linear generator is integrated into the suspension roller group through an energy circulation unit to convert the belt motion energy into electrical energy and store it in a supercapacitor. The energy is then fed back to the mine power grid through a DC-DC converter to compensate for system energy consumption.

10. The method for coordinating the slippage and deviation of a mine belt conveyor PLC according to claim 9 is characterized in that: The step S1 further includes: The multimodal sensing module is integrated with a microbial mineralized coating. When microcracks in the belt are detected, nutrient solution is injected to activate Bacillus pasteurianus to secrete CaCO3 for self-repair of millimeter-level cracks.

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