Centralized control system of belt conveyor

Abstract

The invention belongs to the technical field of control systems, and particularly relates to a belt conveyor centralized control system which comprises a distributed protocol adaptation layer, a dynamic parameter cooperation module, an equipment upgrading synchronous control module and a fault isolation decision module. The distributed protocol adaptation layer realizes cross-generation equipment communication compatibility through a protocol version management unit; the dynamic parameter cooperation module establishes a parameter linkage adjustment mechanism based on an equipment working condition coupling relationship; the equipment upgrading synchronous control module comprises an upgrading rehearsal unit and a protocol transition guarantee unit; the fault isolation decision module blocks an abnormal propagation path through a logic decoupling unit; and the protocol version management unit automatically activates a dual-protocol stack operation mode when detecting that new and old equipment coexist. Through a dual-protocol stack operation mode of a distributed protocol adaptation layer and protocol conversion middleware, smooth data interaction among different intergenerational devices is ensured, and a stable communication basis is provided for system upgrade transition.

Description

Technical Field

[0001] This invention belongs to the field of control system technology, and specifically relates to a centralized control system for a belt conveyor. Background Technology

[0002] In the current field of belt conveyor system operation, with the continuous upgrading and iteration of equipment, the compatibility issues between new and old equipment are becoming increasingly prominent. Traditional systems struggle to ensure smooth data exchange during equipment upgrades, easily leading to communication failures and hindering collaborative operations between devices. Furthermore, during equipment operation, parameter adjustments are mostly performed on a single machine basis, lacking a synchronous optimization mechanism for related equipment, often resulting in low overall system efficiency.

[0003] Furthermore, during equipment upgrades, the lack of effective compatibility testing and rollback strategies means that protocol conflicts can lead to anything from partial functional paralysis to cascading shutdowns, causing significant losses to production. When a fault occurs, it can also propagate abnormally, making it difficult to stop, further expanding the impact and increasing maintenance costs and time. In addition, the lack of flexibility in allocating equipment control, making it difficult to adjust based on real-time equipment status, affects the stability and reliability of the system. These technical challenges urgently need to be addressed. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention provides a centralized control system for belt conveyors. This control system aims to solve the problems of poor compatibility between new and old equipment, high upgrade risks, lack of parameter coordination, and ineffective fault propagation prevention in existing belt conveyor systems.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A centralized control system for a belt conveyor includes a distributed protocol adaptation layer, a dynamic parameter coordination module, an equipment upgrade synchronization control module, and a fault isolation decision module. The distributed protocol adaptation layer achieves cross-generational device communication compatibility through a protocol version management unit. The dynamic parameter coordination module establishes a parameter linkage adjustment mechanism based on the coupling relationship of equipment operating conditions. The equipment upgrade synchronization control module includes an upgrade pre-simulation unit and a protocol transition guarantee unit; The fault isolation decision module blocks the abnormal propagation path through a logical decoupling unit; The protocol version management unit automatically activates the dual protocol stack operation mode when it detects the coexistence of new and old devices.

[0006] The protocol version management unit includes: The protocol feature parsing subunit extracts the structural features of the device communication frames. The version mapping table sub-unit stores the field correspondence between historical protocol versions and the current version; The data bridging subunit enables real-time data translation between devices of different versions.

[0007] The dynamic parameter coordination module includes: Parameter influence tree building units are used to establish the relationship topology between device parameters; A collaborative adjustment strategy library stores parameter combination schemes for typical operating conditions; The dynamic compensation unit automatically calculates the adjustment amount of related equipment when the parameters of a single device change.

[0008] The equipment upgrade synchronization control module includes: Upgrade the path planning unit to generate a batch upgrade sequence plan for the equipment; A protocol transition buffer maintains data compatibility between the old and new protocols during the upgrade process; The rollback trigger unit automatically aborts the upgrade process when a protocol conflict risk is detected.

[0009] The fault isolation decision module includes: Anomaly propagation analysis unit constructs a fault impact chain model between devices; Logically isolated execution units cut off the abnormal propagation path by reconfiguring the control loop; The emergency resource allocation unit allocates independent control resources to equipment in the isolation zone.

[0010] It also includes a device digital twin module, which includes: Virtual mapping unit establishes a real-time mapping relationship between physical devices and digital models; The parameter derivation unit simulates the effects of parameter adjustments in a digital environment. The difference alarm unit detects operational deviations between the entity and the model.

[0011] It also includes a dynamic control allocation module, which includes: The control weight calculation unit allocates control permissions based on the device's health status. The permission switching unit enables seamless switching between primary and backup controllers. The authorization verification unit ensures the legitimacy of the source of control commands.

[0012] It also includes a device collaborative calibration module, which includes: The calibration trigger unit initiates collaborative calibration when the matching degree of the detection equipment parameters decreases. The calibration propagation unit automatically spreads the reference device parameters to associated devices. The calibration and verification unit confirms the validity of the calibration by comparing the operational data.

[0013] The working method of the protocol version management unit includes: Establish a dual-protocol operation channel during the equipment upgrade transition period; Add a version identifier field to the communication data of devices using older protocols; Cross-version data interaction is achieved through protocol conversion middleware.

[0014] The working method of the fault isolation decision module includes: Construct a logical dependency graph between devices; When an abnormal signal is detected, propagation suppression is performed along the dependent path; Create an independent control sandbox environment for the affected equipment group.

[0015] Compared with the prior art, the beneficial effects of this invention are: By employing a dual-protocol stack operating mode in the distributed protocol adaptation layer and a protocol conversion middleware, smooth data interaction between devices of different generations is ensured, providing a stable communication foundation for system upgrades and transitions, avoiding communication interruptions caused by protocol differences, and improving the overall stability of the system.

[0016] By utilizing parameter influence trees and a collaborative adjustment strategy library, related equipment can be optimized synchronously when equipment parameters are adjusted, thereby improving system operating efficiency, ensuring smooth operation of processes such as material transfer, and reducing system failures caused by changes in individual machine parameters.

[0017] The batch upgrade scheme and rollback trigger unit of the equipment upgrade synchronization control module can promptly stop the upgrade and restore the original configuration when compatibility risks occur, reduce upgrade risks, ensure that the upgrade process is controllable, and reduce downtime and production losses caused by upgrades.

[0018] The fault isolation decision module can accurately block the abnormal propagation path, and the emergency resource allocation unit provides backup protection for the equipment in the isolation area, minimizing the scope of the fault's impact, reducing maintenance costs, and improving system reliability.

[0019] The dynamic control allocation module adjusts control weights in real time based on device status, and the permission verification unit blocks unauthorized control requests, enhancing the system's ability to respond to emergencies and ensuring operational safety.

[0020] The automatic detection and calibration function of the equipment collaborative calibration module ensures accurate matching of parameters between equipment and maintains long-term stable operation of the system. Detailed Implementation

[0021] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0022] A centralized control system for a belt conveyor includes a distributed protocol adaptation layer, a dynamic parameter coordination module, an equipment upgrade synchronization control module, and a fault isolation decision module.

[0023] The system features a distributed protocol adaptation layer, whose protocol version management unit includes a protocol feature parsing component, a version mapping database, and a data bridging engine. When new and old devices coexist, the system automatically activates a dual-protocol stack operating mode. The protocol feature parsing component analyzes the header structure, data length, and verification method of device communication frames to identify the protocol version. The version mapping database stores the corresponding conversion rules between historical protocol fields and the current protocol. The data bridging engine uses the identification results to call the corresponding conversion rules to achieve real-time mutual translation.

[0024] During the upgrade transition period, a dual-protocol communication channel is established, and a version identifier field is added to the old protocol data packets. The protocol conversion middleware maintains data interaction between different generations of devices, thus achieving seamless compatibility between different generations of devices. Specifically, through the collaborative work of each subunit of the distributed protocol adaptation layer, the structural features of the old device's communication frames are extracted and matched with the historical protocol version field stored in the version mapping table. Then, the data bridging subunit establishes a bidirectional conversion channel to complete the format conversion of the old protocol data packets, ensuring smooth data interaction between the new and old devices.

[0025] In the dynamic parameter coordination module, the configuration parameter influence tree construction engine constructs a parameter association topology based on the material transfer relationship and dynamic coupling coefficient between devices. The collaborative adjustment strategy library pre-stores the optimal parameter combination schemes under different load conditions, and the dynamic compensation unit calculates the compensation adjustment amount of related devices based on real-time operating data. When a single device parameter is adjusted, the system automatically retrieves the related nodes in the influence tree, generates a compensation parameter set based on the current operating status, and issues it for execution, forming a parameter linkage adjustment mechanism. For example, if the speed of a belt conveyor increases, the system can automatically calculate the compensation amount for the opening and closing degree of the feed inlet of the downstream device.

[0026] The upgrade path planning unit of the equipment upgrade synchronization control module generates a batch upgrade plan based on the physical location and functional dependencies of the equipment, prioritizing the upgrade of devices at the end of the critical path. The protocol transition buffer maintains the parallel parsing capability of the old and new protocols during the upgrade process, using a message queue to temporarily store data packets of the old and new protocols. The upgrade rehearsal unit simulates the upgrade process in a digital twin environment. When a protocol compatibility risk is detected, the rollback trigger unit immediately stops the upgrade process and restores the original configuration. The protocol transition assurance unit ensures control continuity during the upgrade by dynamically adjusting the data encapsulation format, thereby ensuring a smooth upgrade process. For example, when rehearsing the upgrade process in a virtual environment, the protocol simulation unit continuously detects communication conflicts during the actual upgrade. If a data packet parsing anomaly occurs, the upgrade is stopped and the original protocol stack is restored.

[0027] In the fault isolation decision module, the anomaly propagation analysis unit constructs a fault impact chain model based on the equipment control logic dependency graph. The logic isolation execution unit cuts off the anomaly propagation path by reconstructing the control loop topology; for example, when a motor controller fault is detected, its control link with the upstream feeding equipment is severed. The emergency resource allocation unit allocates independent control channels and backup actuators to the equipment in the isolation zone, while simultaneously creating a sandbox environment to isolate anomaly signals. The system monitors the state coupling strength between equipment in real time, and automatically activates preset isolation strategies when anomaly characteristics are detected, effectively blocking fault propagation and maintaining local system operation.

[0028] The virtual mapping unit of the equipment digital twin module establishes a digital image of the physical equipment through multi-source sensor fusion. The parameter extrapolation unit simulates the impact of parameter adjustments on the overall system operation in a virtual environment, such as rehearsing speed adjustment schemes. The difference alarm unit continuously compares the operating indicators of the physical equipment with those of the digital model. If the deviation exceeds a threshold, a calibration command is triggered to ensure accurate mapping between the digital model and the physical equipment.

[0029] Under the dynamic control allocation module, the control weight calculation unit dynamically allocates control permissions based on the equipment's remaining lifespan assessment value and real-time health score. The permission switching unit automatically activates the backup controller and maintains control sequence continuity when the main controller fails, completing the transfer of control within one working cycle. The permission verification unit employs a two-way authentication verification mechanism to verify the source of control commands, preventing unauthorized control requests and ensuring the security and reliability of the control system.

[0030] The calibration trigger unit of the equipment collaborative calibration module monitors the parameter matching degree between devices and initiates the calibration process when a collaborative deviation is detected. The calibration propagation unit pushes the calibration parameters of the reference device to the associated devices according to a preset propagation path. The calibration verification unit verifies the calibration effect by analyzing the distribution of operating data before and after adjustment, thereby ensuring accurate parameter matching and collaborative operation between devices.

[0031] The system effectively solves the communication conflicts and cascading downtime problems caused by equipment upgrades through a triple mechanism of protocol compatibility assurance, parameter coordination adjustment, and fault propagation blocking.

[0032] The above description only illustrates preferred embodiments of the present invention, but the present invention is not limited to the above embodiments.

Claims

1. A centralized control system for a belt conveyor, characterized in that, It includes a distributed protocol adaptation layer, a dynamic parameter coordination module, a device upgrade synchronization control module, and a fault isolation decision module; The distributed protocol adaptation layer achieves cross-generational device communication compatibility through a protocol version management unit. The dynamic parameter coordination module establishes a parameter linkage adjustment mechanism based on the coupling relationship of equipment operating conditions. The equipment upgrade synchronization control module includes an upgrade pre-simulation unit and a protocol transition guarantee unit; The fault isolation decision module blocks the abnormal propagation path through a logical decoupling unit; The protocol version management unit automatically activates the dual protocol stack operation mode when it detects the coexistence of new and old devices.

2. The centralized control system for a belt conveyor according to claim 1, characterized in that, The protocol version management unit includes: The protocol feature parsing subunit extracts the structural features of the device communication frames. The version mapping table sub-unit stores the field correspondence between historical protocol versions and the current version; The data bridging subunit enables real-time data translation between devices of different versions.

3. The centralized control system for a belt conveyor according to claim 1, characterized in that, The dynamic parameter coordination module includes: Parameter influence tree building units are used to establish the relationship topology between device parameters; A collaborative adjustment strategy library stores parameter combination schemes for typical operating conditions; The dynamic compensation unit automatically calculates the adjustment amount of related equipment when the parameters of a single device change.

4. The centralized control system for a belt conveyor according to claim 1, characterized in that, The equipment upgrade synchronization control module includes: Upgrade the path planning unit to generate a batch upgrade sequence plan for the equipment; A protocol transition buffer maintains data compatibility between the old and new protocols during the upgrade process; The rollback trigger unit automatically aborts the upgrade process when a protocol conflict risk is detected.

5. The centralized control system for a belt conveyor according to claim 1, characterized in that, The fault isolation decision module includes: Anomaly propagation analysis unit constructs a fault impact chain model between devices; Logically isolated execution units cut off the abnormal propagation path by reconfiguring the control loop; The emergency resource allocation unit allocates independent control resources to equipment in the isolation zone.

6. The centralized control system for a belt conveyor according to claim 1, characterized in that, It also includes a device digital twin module, which includes: Virtual mapping unit establishes a real-time mapping relationship between physical devices and digital models; The parameter derivation unit simulates the effects of parameter adjustments in a digital environment. The difference alarm unit detects operational deviations between the entity and the model.

7. The centralized control system for a belt conveyor according to claim 1, characterized in that, It also includes a dynamic control allocation module, which includes: The control weight calculation unit allocates control permissions based on the device's health status. The permission switching unit enables seamless switching between primary and backup controllers. The authorization verification unit ensures the legitimacy of the source of control commands.

8. The centralized control system for a belt conveyor according to claim 1, characterized in that, It also includes a device collaborative calibration module, which includes: The calibration trigger unit initiates collaborative calibration when the matching degree of the detection equipment parameters decreases. The calibration propagation unit automatically spreads the reference device parameters to associated devices. The calibration and verification unit confirms the validity of the calibration by comparing the operational data.

9. A centralized control system for a belt conveyor according to claim 1, characterized in that, The working method of the protocol version management unit includes: Establish a dual-protocol operation channel during the equipment upgrade transition period; Add a version identifier field to the communication data of devices using older protocols; Cross-version data interaction is achieved through protocol conversion middleware.

10. A centralized control system for a belt conveyor according to claim 1, characterized in that, The working method of the fault isolation decision module includes: Construct a logical dependency graph between devices; When an abnormal signal is detected, propagation suppression is performed along the dependent path; Create an independent control sandbox environment for the affected equipment group.