A belt conveyor turning device and control method

Abstract

This invention provides a belt conveyor turning device and control method, belonging to the field of mine conveying technology. It includes a steering frame and a redirecting frame. The redirecting frame is equipped with a redirecting roller, and the steering frame is equipped with a steering roller. An angle adjustment component includes an angle sensor, and a diameter adjustment component is installed on the steering roller. Tension data streams from the steering roller are acquired via a tension sensor, and an axial pressure distribution time-series matrix is ​​acquired via a pressure sensor array. Two sets of baffles are slidably mounted on the steering frame. A control module is installed on one side of the steering frame. It acquires the axial pressure distribution time-series matrix via the pressure sensor array and adjusts the roller angle based on the angle sensor data. The roller diameter is adjusted based on the tension sensor data. The material release point is determined according to the pressure field characteristics and the correction angle, and the baffle position is controlled. This solves the problems of belt misalignment and material ejection deviation caused by manual adjustment in traditional turning devices, ensuring stable belt operation.

Description

Technical Field

[0001] This invention belongs to the field of mine conveying technology, and more specifically, relates to a turning device and control method for a belt conveyor. Background Technology

[0002] In underground coal mining operations, belt conveyors serve as core transportation equipment, and their roadway layout is often constrained by complex geological conditions. Coal seams are often undulating or fault-cut, leading to frequent roadway detours. Traditional designs require conveyors to be laid in a straight line, but in actual engineering, to avoid faults, gas-rich areas, or fractured roof zones, over 80% of mining area roadways need to be laid with detours. Forcing straight-line excavation would significantly increase the amount of rock roadway engineering work.

[0003] For example, Chinese utility model patent No. 201020687067.4 provides a belt conveyor turning device. In use, the belt is wound around the steering drum and the redirecting drum at a fixed angle of 45° to complete the belt turning, realizing right-angle turning of the belt conveyor. However, the fixed angle between the axes of the steering drum and the redirecting drum is 45°, which can only be adapted to the turning point of the roadway at a specific angle. In fact, the turning angle of the underground conveyor roadway is diverse and not all of them are 45°. When encountering other angles of turning, the device is not applicable.

[0004] For example, Chinese utility model patent with patent number 201520429698.9 provides a device for turning at any angle on a belt conveyor. When in use, the device can adjust the angle between the steering roller and the return steering roller, and at the same time change the angle between the transport redirection roller and the return redirection roller, thereby achieving a turn at any angle.

[0005] Existing belt conveyors require manual adjustment of the angle between the guide roller and the idler roller during use. When the conveying angle of the belt does not match the axial angle of the guide roller, the contact force between one side of the belt and the guide roller is greater than the contact force between the other side and the guide roller, making the belt prone to deviation on the guide roller, which in turn causes the material throwing trajectory to deviate. Summary of the Invention

[0006] To address the aforementioned technical problems, this invention provides a belt conveyor turning device and control method to solve the problems mentioned above.

[0007] The purpose and effectiveness of the belt conveyor turning device and control method of the present invention are achieved by the following specific technical means:

[0008] A belt conveyor turning device, comprising:

[0009] A bogie frame, a redirecting frame on one side of the bogie frame, a redirecting roller on the redirecting frame, and a steering roller on the bogie frame for changing the direction of the belt conveyor line;

[0010] An angle adjustment component is used to adjust the angle between the steering roller axis and the redirecting roller axis, and to obtain initial roller angle data and correction angle data through an angle sensor;

[0011] The diameter adjustment assembly is installed on the steering drum. The diameter adjustment assembly is used to adjust the diameter of the steering drum and to obtain the tension data stream of the steering drum through a tension sensor and the axial pressure distribution time sequence matrix through a pressure sensor array.

[0012] Two sets of baffles are installed on the steering frame. The two sets of baffles are used to catch the material thrown out by the steering drum. The steering frame is equipped with two sets of first guide rails. The two sets of baffles slide along the two sets of first guide rails respectively.

[0013] The control module is installed on one side of the bogie frame and is used to control the operation of the turning device.

[0014] According to a preferred embodiment, the angle adjustment assembly includes a mounting plate. The mounting plate is provided on one side of the bogie frame, a rotating bracket is provided on the top of the mounting plate, and an angle sensor is provided on the bottom of the mounting plate. The bottom end of the rotating bracket passes through a through hole on the top of the mounting plate and is connected to the angle sensor. An arc-shaped bracket is provided on the other side of the bogie frame. An arc-shaped slide rail is provided on the arc-shaped slide rail. A movable bracket is connected to the arc-shaped slide rail by two sets of sliding blocks. The rotating bracket rotates as the movable bracket moves on the arc-shaped slide rail. The two ends of the steering roller are rotatably connected to the bearing seats on the top of the movable bracket and the rotating bracket.

[0015] According to a preferred embodiment, the angle adjustment assembly further includes an adjustment motor. The adjustment motor is installed inside the movable bracket. The main shaft at the bottom of the adjustment motor passes through the through hole at the bottom of the movable bracket and is connected to a gear. An arc-shaped rack is provided on one side of the arc-shaped bracket. The gear meshes with the teeth of the arc-shaped rack. Multiple sets of support columns are provided on the outer side of the arc-shaped bracket. One side of the support column is connected to the arc-shaped bracket and the arc-shaped rack through a connecting bracket.

[0016] According to a preferred embodiment, the diameter adjustment assembly includes multiple sets of expansion plates surrounding the steering drum. Rotating plates are provided at both ends of the steering drum. Multiple expansion grooves are formed on one side of each rotating plate, and these grooves are radially distributed relative to the axis of the steering drum. Moving rods at both ends of the expansion plates pass through one of the expansion grooves on the two rotating plates, allowing the expansion plates to move along the expansion grooves to adjust the diameter of the steering drum. The expansion plates are connected to the bearing housing via a tension sensor.

[0017] Multiple sets of expansion plates are equipped with multiple sets of mounting brackets, and multiple sets of mounting brackets are equipped with rotating rollers for contacting the belt. The axes of multiple sets of rotating rollers are perpendicular to the axis of the steering drum. One set of expansion plates is also equipped with multiple sets of pressure sensors connected to multiple sets of mounting brackets. The multiple sets of pressure sensors are distributed along the axis of the steering drum on one set of expansion plates to form a pressure sensor array.

[0018] According to a preferred embodiment, an adjustment through hole is provided at one end of the steering roller, and an adjustment column that moves along the axis of the steering roller is provided in the adjustment through hole. Multiple sets of adjustment rings are equidistantly arranged on the outer side of the adjustment column. The adjustment rings are multiple sets of first connecting seats arranged around the periphery of the adjustment column. Multiple sets of second connecting seats are provided at the bottom of the expansion plates corresponding to the multiple sets of adjustment rings. The periphery of the adjustment rings is rotatably connected to one set of second connecting seats at the bottom of the expansion plates through connecting rods. One side of one set of tension sensors is provided with an electric telescopic rod for pushing the adjustment column to the shrinking or expanding position. When the adjustment column moves to the shrinking position, the multiple sets of expansion plates move radially inward to narrow the diameter of the steering roller. When the adjustment column moves to the expanding position, the multiple sets of expansion plates move radially outward to widen the diameter of the steering roller.

[0019] According to a preferred embodiment, a receiving section is provided on the steering frame. The receiving section carries the material picked up by the baffle plate via a belt after the top turn. The receiving section includes multiple sets of first bearing supports, which are equidistantly distributed within the steering frame. Each set of first bearing supports has two sets of bearing columns at its top. Two sets of inclined guide rollers are respectively provided between the first bearing supports and the two sets of bearing columns. A horizontal bearing roller is provided between the two sets of bearing columns. A buffer layer for contacting the belt after the turn is provided on the outer side of both the inclined guide rollers and the horizontal bearing rollers. Bearings are provided at both ends of both the inclined guide rollers and the horizontal bearing rollers.

[0020] Two sets of second bearing supports are respectively set on both sides of the two sets of receiving sections. Two sets of first guide rails are respectively installed on the top of the two sets of second bearing supports. Second guide rails are set on both sides of the steering frame. Electric sliders are set on the second guide rails. One side of the electric slider is connected to the baffle plate. Two sets of photoelectric sensors are set on one end of the two sets of second bearing supports, respectively, corresponding to the two sets of baffle plates.

[0021] A control method for a turning device of a belt conveyor, the method comprising:

[0022] The axial pressure distribution time series matrix is ​​obtained by a pressure sensor array, the initial roller angle data is obtained by an angle sensor, the angle matching status is determined based on the pressure field feature matrix and the initial roller angle data and a compensation command is generated, the compensation command is executed and the correction angle data is obtained.

[0023] Tension data stream is acquired based on tension sensor, tension fluctuation characteristics are obtained based on tension data stream, diameter adjustment strategy decision operation is performed based on tension fluctuation characteristics, diameter adjustment command is acquired and executed;

[0024] The coordinates of the material release point are obtained based on the pressure field feature matrix and correction angle data. The actual material conveying trajectory is obtained based on the spatial coordinates of the material release point. The baffle control command is obtained and executed based on the actual material conveying trajectory.

[0025] According to a preferred embodiment, an axial pressure distribution time-series matrix is ​​acquired through a pressure sensor array, initial roller angle data is acquired through an angle sensor, an angle matching state is determined based on the pressure field feature matrix and the initial roller angle data, a compensation command is generated, the compensation command is executed, and correction angle data is acquired, including:

[0026] Every N seconds, a pressure distribution vector is collected from the pressure sensor array, arranged according to the axial coordinates of the pressure sensors in the array. The pressure distribution vector is continuously collected for one rotation cycle of the steering roller. The collection time of each pressure distribution vector is used as a column, and multiple pressure distribution vectors are combined into an axial pressure distribution time sequence matrix.

[0027] The angle between the steering roller axis and the reference axis is read by the angle sensor as the initial roller angle data;

[0028] A pressure distribution coordinate system is established with the axial coordinate as the X-axis and the acquisition time as the Y-axis. Each pressure distribution vector is mapped to the pressure distribution coordinate system to form multiple pressure distribution lines.

[0029] The axial center coordinate of the roller on which the belt is wound on the reference axis is taken as the reference center coordinate, and the theoretical center coordinate is obtained based on the initial roller angle data and the reference center coordinate.

[0030] The theoretical center coordinates are mapped to the pressure distribution coordinate system and used as a reference. The pressure centroid coordinates are obtained based on multiple pressure distribution lines. The offset data is obtained based on the pressure centroid coordinates and the theoretical center coordinates. The angle offset result is obtained based on the offset data and the preset offset interval. The angle offset result includes the offset direction and the offset degree.

[0031] An angle compensation vector is obtained based on the angle offset result and preset control rules. The roller angle adjustment operation is performed based on the angle compensation vector, and the correction angle data is obtained.

[0032] According to a preferred embodiment, the process includes acquiring a tension data stream based on a tension sensor, acquiring tension fluctuation characteristics based on the tension data stream, performing a diameter adjustment strategy decision based on the tension fluctuation characteristics, acquiring and executing a diameter adjustment command, including:

[0033] The tension mean is obtained by summing all tension readings in the tension data stream and dividing by the number of readings. The deviation of each tension reading from the tension mean is calculated, the sum of the squares of these deviations is calculated, divided by the number of readings minus one, and then the square root is taken to obtain the tension standard deviation.

[0034] Set a threshold for the normal tension fluctuation range, extract all tension readings from the tension data stream, determine whether any tension reading exceeds the threshold for the normal tension fluctuation range, and obtain the state of abnormal tension fluctuation.

[0035] Set the target tension value range, and perform a tension level state determination operation based on the average tension value and the target tension value range to obtain the tension level state;

[0036] Set an allowable threshold for the standard deviation of fluctuation, and perform a fluctuation state determination operation based on the standard deviation of tension and the allowable threshold for the standard deviation of fluctuation to obtain the fluctuation state;

[0037] The diameter adjustment strategy decision is obtained based on the abnormal fluctuation state, tension level state, and fluctuation state. The diameter adjustment command is obtained and executed based on the diameter adjustment strategy decision and the correction angle data.

[0038] According to a preferred embodiment, the material ejection point coordinates are obtained based on the pressure field feature matrix and correction angle data; the actual material conveying trajectory is obtained based on the spatial coordinates of the material ejection point; and baffle control commands are obtained and executed based on the actual material conveying trajectory, including:

[0039] Select the pressure distribution vector containing the most pressure values ​​and the pressure distribution vector containing one less pressure value. Map the selected pressure distribution vector onto the axis with the axial coordinate as the reference to form multiple pressure distribution lines. Arrange the pressure distribution lines according to the acquisition time of the pressure distribution vector. Extract the pressure center coordinates of the first pressure distribution line along the acquisition time as the material release point coordinates.

[0040] The theoretical conveying direction angle is obtained based on the material ejection point coordinates and correction angle data, and the target position coordinates of the baffle are obtained based on the theoretical conveying direction angle and the material ejection point coordinates.

[0041] The current coordinates of the baffle are obtained by photoelectric sensors, and the difference in horizontal displacement between the current coordinates of the baffle and the target position coordinates of the baffle is used as the displacement command for the baffle.

[0042] Compared with the prior art, the present invention has the following beneficial effects:

[0043] First, the axial pressure distribution between the belt and the guide roller is collected in real time by a pressure sensor array, forming an axial pressure distribution time series matrix. Combined with the initial angle data obtained by the angle sensor, the matching status between the belt conveying angle and the roller axial angle can be dynamically determined. When the offset data between the belt pressure center coordinate and the theoretical center coordinate exceeds the preset offset range, a compensation command is generated and executed by the angle adjustment component. By adjusting the motor drive gear to move along the arc rack, the guide roller is driven to rotate around the rotating bracket until the correction angle data meets the matching requirements. This automated adjustment replaces the traditional manual operation and can respond to changes in the belt running status in real time. It solves the problem that the belt conveying angle is easily mismatched with the axial angle of the guide roller due to manual angle adjustment of traditional belt conveyors, and reduces belt deviation caused by angle mismatch.

[0044] Secondly, the diameter adjustment component relies on the tension data stream obtained by the tension sensor to extract features such as the average tension and fluctuation amplitude. When it is determined that the belt is too loose or too tight due to the angle adjustment, the adjustment column can be moved by the electric telescopic rod, which drives multiple sets of expansion plates to expand and contract synchronously in a radial pattern, thereby adjusting the diameter of the steering roller. This adjustment and angle correction are carried out in tandem, which can not only avoid tension abnormalities caused by angle changes, but also reduce tension fluctuations by rotating the rollers and making flexible contact with the belt, ensuring that the belt always fits the roller surface in a stable state, reducing belt slippage caused by uneven tension, and maintaining stable belt tension.

[0045] Finally, the coordinates of the material detaching from the steering roller are identified based on the pressure field feature matrix. The theoretical conveying direction angle can be obtained by combining the correction angle data. The target position coordinates of the baffle are obtained based on the theoretical conveying direction angle and the material detachment point coordinates. The current position of the baffle is monitored by a photoelectric sensor. The baffle is driven to slide along the first and second guide rails by an electric slider, so that the baffle moves to the target position coordinates. This ensures that no matter how the angle is adjusted or the material trajectory is deviated due to belt misalignment, the material can stably fall into the range of the baffle. This solves the problem of material throwing deviation caused by the lag of manual angle adjustment in traditional devices. Attached Figure Description

[0046] Figure 1 This is a schematic diagram of the assembled structure of a belt conveyor turning device according to the present invention;

[0047] Figure 2 This is a schematic diagram of the unfolded structure of a belt conveyor turning device according to the present invention;

[0048] Figure 3 This is a schematic diagram of the assembled angle adjustment component in a belt conveyor turning device according to the present invention;

[0049] Figure 4This is a schematic diagram of the disassembled angle adjustment component in a belt conveyor turning device according to the present invention;

[0050] Figure 5 This is a schematic diagram of the assembled diameter adjustment component in a belt conveyor turning device according to the present invention;

[0051] Figure 6 This is a schematic diagram of the disassembled diameter adjustment component in a belt conveyor turning device according to the present invention;

[0052] Figure 7 This is a schematic diagram of the structure of the baffle plate and the first guide rail assembled in the turning device of the belt conveyor of the present invention;

[0053] Figure 8 This is a schematic diagram of the structure of the baffle plate and the first guide rail after being separated in the turning device of the belt conveyor of the present invention;

[0054] Figure 9 This is a flowchart of the steps of a control method for a belt conveyor turning device according to the present invention;

[0055] Figure 10 This is a flowchart of the steps for obtaining and generating compensation commands in the control method of a belt conveyor turning device of the present invention;

[0056] Figure 11 This is a schematic diagram of a belt conveyor turning device for winding a belt according to the present invention;

[0057] Figure 12 This is a schematic diagram of the direction of the belt wound around the turning device of the belt conveyor of the present invention;

[0058] Figure 13 yes Figure 8 A magnified view of a portion of region A in the middle.

[0059] In the diagram, the correspondence between component names and drawing numbers is as follows:

[0060] 11. Bogie frame; 12. Idling frame; 13. Idling roller; 14. Steering roller; 15. Angle sensor; 16. Tension sensor; 17. Baffle plate; 18. First guide rail; 19. Control module; 20. Mounting plate; 21. Rotating bracket; 22. Arc-shaped bracket; 23. Arc-shaped slide rail; 24. Moving bracket; 25. Adjusting motor; 26. Gear; 27. Arc-shaped rack; 28. Support column; 29. ​​Connecting bracket; 30. Expansion plate; 31. Rotating plate; 32. Expansion groove; 33. 34. Moving rod; 35. Mounting bracket; 36. Rotating roller; 37. Pressure sensor; 38. Adjusting through hole; 39. Adjusting column; 40. First connecting seat; 41. Second connecting seat; 42. Connecting rod; 43. Electric telescopic rod; 44. First bearing bracket; 45. Bearing column; 46. Inclined guide roller; 47. Horizontal bearing roller; 48. Buffer layer; 49. Second bearing bracket; 50. Second guide rail; 51. Electric slider; 52. Photoelectric sensor; 53. Return redirecting roller; 54. Return steering roller. Detailed Implementation

[0061] The embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate the technical solutions of the present invention, but should not be used to limit the scope of protection of the present invention.

[0062] Example:

[0063] As attached Figures 1 to 13 As shown:

[0064] This invention provides a turning device for a belt conveyor, comprising:

[0065] The steering frame 11 is a rectangular metal frame structure, which is fixed to the foundation at the corner of the underground roadway of the coal mine by anchor bolts. A redirecting frame 12 is provided on one side of the steering frame 11. The redirecting frame 12 and the steering frame 11 are distributed at a preset angle. A redirecting roller 13 is rotatably mounted on the top of the redirecting frame 12 through a bearing seat. The axis of the redirecting roller 13 is parallel to the length direction of the redirecting frame 12. A redirecting roller 14 for changing the direction of the belt conveyor line is provided on the top of the steering frame 11 through an adjustable bracket. The belt passes around the outer circumference of the redirecting roller 14 and the redirecting roller 13 in sequence.

[0066] An angle adjustment component is used to drive the angle of the steering roller 14 relative to the axis of the redirecting roller 13, and to acquire initial roller angle data and correction angle data through the angle sensor 15.

[0067] A diameter adjustment assembly is installed on the steering roller 14. The diameter adjustment assembly is used to adjust the diameter of the steering roller 14 and to acquire the tension data stream of the steering roller 14 through the tension sensor 16. Multiple sets of pressure sensors are evenly distributed on the outer surface of the steering roller 14 along its axial direction. The detection surfaces of the multiple sets of pressure sensors are in contact with the outer surface of the belt, forming a pressure sensor array for collecting the contact pressure between the belt and the steering roller 14. This array can generate an axial pressure distribution time series matrix that reflects the pressure changes at different axial positions.

[0068] Furthermore, both the steering frame 11 and the redirecting frame 12 are equipped with return redirecting rollers 52 and return steering rollers 53, which are used to connect with the return section of the belt to form a complete belt drive mechanism.

[0069] Two sets of baffle plates 17, which are arc-shaped metal plates, are located on one side of the steering roller 14. The bottom ends of the two sets of baffle plates 17 are connected to the two sets of first guide rails 18 on the top of the steering frame 11 via sliders. The two sets of baffle plates 17 can slide along the two sets of first guide rails 18 to adjust their position relative to the material throwing trajectory.

[0070] For example, a clamping plate, a screw passing through the clamping plate, and a motor driving the screw to rotate are installed on one side of the slider. The clamping plate is in contact with the side of the slide rail, and the screw is connected to the clamping plate by a thread. A friction plate is provided at the end of the screw. When the baffle plate 17 slides on the slide rail, the motor rotates the screw to make the friction plate at the end of the screw move away from the slide rail. At this time, the baffle plate 17 can move freely along the slide rail. When it moves to the desired position, the motor rotates the screw in the opposite direction to make the friction plate at the end of the screw press against the side of the slide rail. The pressure of the friction plate on the slide rail increases the static friction between the baffle plate 17 and the slide rail, thereby restricting the sliding of the baffle plate 17.

[0071] The control module 19 is installed on one side of the bogie frame 11. The input end of the control module 19 is connected to the angle sensor 15, the tension sensor 16 and the pressure sensor array via cables, and the output end is connected to the angle adjustment component, the diameter adjustment component and the drive mechanism of the baffle plate 17 via cables. It is used to receive the data transmitted by each sensor and generate control commands to coordinate the operation of each part of the turning device.

[0072] Please see as follows Figure 2 , Figure 3 and Figure 4As shown, the angle adjustment assembly includes a mounting plate 20, which is fixed to one side of the bogie frame 11 by bolts. A rotating bracket 21 is provided on the top of the mounting plate 20. The rotating shaft at the bottom of the rotating bracket 21 passes through a pre-set through hole on the top of the mounting plate 20 and is connected to an angle sensor 15 at the bottom of the mounting plate 20. The angle sensor 15 is fixed to the bottom surface of the mounting plate 20 by the bracket and can synchronously collect angle change data as the rotating bracket 21 rotates. An arc-shaped bracket 22 is welded to the crossbeam on the other side of the bogie frame 11. The arc of the arc-shaped bracket 22 corresponds to the angle adjustment range of the steering roller 14. An arc-shaped slide rail 23 is fixed to the top plane of the arc-shaped bracket 22 by bolts. The opening of the arc-shaped slide rail 23 faces the inside of the steering frame 11. Two sets of sliding blocks are provided on the arc-shaped slide rail 23. The top of the sliding blocks is connected to the moving bracket 24 by bolts. The moving bracket 24 is arranged parallel to the rotating bracket 21. When the moving bracket 24 slides along the arc-shaped slide rail 23, the steering roller 14 moves with the moving bracket 24 and rotates around the rotating shaft at the bottom of the rotating bracket 21. The two ends of the steering roller 14 are respectively installed in the bearing seats at the top of the moving bracket 24 and the bearing seats at the top of the rotating bracket 21 through bearings. It can rotate freely around its own axis and adjust the angle between its own axis and the axis of the redirecting roller 13 according to the position of the moving bracket 24 and the angle of the rotating bracket 21.

[0073] Specifically, the sliding of the movable bracket 24 along the arc-shaped slide rail 23 drives the steering roller 14 to rotate. The two work together to continuously adjust the axis angle of the steering roller 14, while the angle sensor 15 records the angle data in real time during this process.

[0074] The angle adjustment assembly also includes an adjustment motor 25, which is a servo motor and is fixed to a mounting base inside the movable bracket 24 by bolts. The main shaft at the bottom of the adjustment motor 25 passes through a pre-set through hole at the bottom of the movable bracket 24, and a gear 26 is connected to its end. An arc-shaped rack 27 is fixed to the side of the arc-shaped bracket 22 facing the movable bracket 24 by bolts. The arc of the arc-shaped rack 27 is consistent with that of the arc-shaped slide rail 23, and its teeth mesh with the teeth of the gear 26 to form a transmission engagement. Multiple sets of support columns 28 are evenly distributed along the arc direction on the outer side of the arc-shaped bracket 22. The support columns 28 are metal square columns, and their tops are connected to the arc-shaped bracket 22 and the arc-shaped rack 27 by connecting brackets 29. The connecting brackets 29 are L-shaped metal plates, one side of which is welded to the top of the support column 28, and the top is fixed to the bottom of the arc-shaped bracket 22 and the arc-shaped rack 27 by bolts, enhancing the structural stability of the arc-shaped bracket 22 and the arc-shaped rack 27.

[0075] Specifically, a pressure sensor array distributed along the axial direction on the outer surface of the steering roller 14 collects pressure data at different axial positions on the contact surface between the belt and the roller in real time, generating a pressure distribution vector at fixed intervals. Multiple vectors are combined to form an axial pressure distribution time sequence matrix. Angle sensor 15 is connected to the bottom of the rotating bracket 21 and outputs initial angle data in real time as the rotating bracket 21 rotates. After receiving the above matrix and data, the control module 19 obtains the coordinates of the belt pressure center by analyzing the pressure distribution characteristics, compares them with the theoretical center coordinates calculated based on the initial angle data, and obtains the offset data. When the offset data exceeds the preset offset range, the control module 19 generates a compensation command and sends it to the adjusting motor 25. The adjusting motor 25 drives the gear 26 to rotate. The moving bracket 24 slides along the arc-shaped slide rail 23 through meshing with the arc-shaped rack 27. The moving bracket 24 drives one end of the steering roller 14 to make an arc-shaped movement, and the other end of the steering roller 14 pushes the rotating bracket 21 to rotate around its bottom end, so that the axial angle of the steering roller 14 changes. The angle sensor 15 provides real-time feedback of the adjusted angle data until the offset between the pressure center coordinate and the theoretical center coordinate corresponding to the corrected angle data returns to the preset range, thus completing the adjustment. This automated adjustment process led by the control module 19 replaces the traditional manual operation method, which can adjust the angle in real time according to the changes in the belt running state, avoiding the mismatch between the belt conveying angle and the axial angle of the steering roller 14, thereby reducing the belt deviation caused by angle deviation.

[0076] Please see as follows Figure 5 and Figure 6 As shown, the diameter adjustment assembly includes multiple sets of expansion plates 30, which are evenly distributed around the circumference of the steering roller 14, with gaps between adjacent sets of expansion plates 30. Rotating plates 31 are bolted to both ends of the steering roller 14. The rotating plates 31 are circular metal plates with a diameter larger than that of the steering roller 14. Multiple expansion grooves 32 are formed on the surface of the rotating plates 31 near the expansion plates 30. These grooves are elongated and radially distributed relative to the axis of the steering roller 14. Moving rods 33 are welded to both ends of the expansion plates 30. The moving rod 33 is a cylindrical metal rod with a diameter slightly smaller than the width of the expansion groove 32. The ends of the two sets of moving rods 33 away from the expansion plate 30 are respectively inserted into a set of expansion grooves 32 on the two sets of rotating plates 31. The moving rods 33 can slide along the length of the expansion groove 32, causing the expansion plate 30 to move closer to or away from the axis of the steering roller 14, thereby adjusting the diameter of the steering roller 14. The side of the expansion plate 30 away from the steering roller 14 contacts the belt. The two ends of the steering roller 14 are connected to the bearing seats through tension sensors 16, which can detect the tension generated when the expansion plate 30 contacts the belt in real time.

[0077] Specifically, when the moving rod 33 slides along the expansion groove 32 toward the edge of the rotating plate 31, the expansion plate 30 moves away from the axis of the steering roller 14, increasing the overall diameter of the steering roller 14. At this time, the tension value detected by the tension sensor 16 changes accordingly. When the moving rod 33 slides along the expansion groove 32 toward the center of the rotating plate 31, the expansion plate 30 moves toward the axis of the steering roller 14, decreasing the overall diameter of the steering roller 14. The detection value of the tension sensor 16 also changes accordingly. Through this sliding adjustment, the diameter of the steering roller 14 is continuously changed to adapt to the tension requirements of the belt at different angles.

[0078] Multiple sets of expansion plates 30 are fixed with multiple sets of mounting brackets 34 on the side facing the belt. Each mounting bracket 34 is a U-shaped metal frame with its opening facing away from the expansion plate 30. The mounting brackets 34 are evenly distributed along the length of the expansion plate 30. Between the two arms of each mounting bracket 34, a rotating roller 35 is rotatably mounted via a bearing for contacting the belt. The rotating roller 35 is a cylindrical metal roller with a rubber layer on its outer surface. The axes of all rotating rollers 35 are perpendicular to the axis of the steering drum 14. The belt wraps obliquely around the steering drum. As the belt wraps around the steering drum, the center point of the belt moves along the axis of the steering drum. Therefore, the belt wrapped around the steering drum is prone to damage. Slippage or wear, and since the axis of the rotating roller 35 is perpendicular to the axis of the steering drum 14, when the center point of the belt moves along the axis of the steering drum, the rotating roller 35 can reduce the friction between itself and the belt through rolling contact, ensuring that the belt always fits the surface of the steering drum 14 in a stable state; multiple sets of pressure sensors 36 are also respectively provided between the multiple sets of mounting brackets 34 on one set of expansion plates 30 and the expansion plates 30. The two ends of the pressure sensors 36 are respectively fixed to the bottom of the mounting bracket 34 and the surface of the expansion plate 30 by bolts. The multiple sets of pressure sensors 36 are arranged sequentially along the axial direction of the steering drum 14 to form a pressure sensor array for detecting the pressure of the belt at different axial positions. An adjustment through hole 37 is provided on the end face of the steering roller 14 away from the rotating bracket 21. An adjustment column 38, which can move along the axis of the steering roller 14, is inserted inside the adjustment column 38. The adjustment column 38 is a metal cylinder, and multiple sets of adjustment rings are equidistantly arranged on its outer side along the axis. Each set of adjustment rings consists of multiple sets of first connecting seats 39 evenly distributed around the circumference of the adjustment column 38. The bottom of the multiple sets of expansion plates 30 is provided with multiple sets of second connecting seats 40 corresponding to the multiple sets of adjustment rings. The first connecting seats 39 on the circumference of the adjustment rings and the corresponding second connecting seats 40 on the bottom of the expansion plates 30 are connected by connecting rods 41. The two ends of the connecting rods 41 are rotatably connected to the first connecting seats 39 and the second connecting seats 40 by pins, respectively. Multiple sets of through slots are provided on the circumference of the steering roller 14, and the multiple sets of connecting rods 41 pass through the multiple sets of through slots. The passageway is described; one set of tension sensors 16 is provided with an electric telescopic rod 42 on the side near the adjustment through hole 37. The telescopic end of the electric telescopic rod 42 is connected to the end of the adjustment column 38 through a coupling. The electric telescopic rod 42 is located between the rotating plate 31 and the adjustment column 38, and can push the adjustment column 38 to move along the axis to the shrinking position or the expanding position. When the adjustment column 38 moves to the shrinking position, the connecting rod 41 pulls the second connecting seat 40 at the bottom of the expanding plate 30, so that multiple sets of expanding plates 30 move radially towards the axis of the steering roller 14, narrowing the diameter of the steering roller 14. When the adjustment column 38 moves to the expanding position, the connecting rod 41 pushes the second connecting seat 40, so that multiple sets of expanding plates 30 move radially away from the axis of the steering roller 14, widening the diameter of the steering roller 14.

[0079] Specifically, when the diameter adjustment component is working, the tension sensor 16 continuously collects tension data between the belt and the expansion plate 30, forming a tension data stream. The control module 19 processes the data stream and extracts features such as the average tension and fluctuation amplitude. When it is determined that the belt is too loose or too tight due to the angle adjustment, the control module 19 sends a command to the electric telescopic rod 42. The electric telescopic rod 42 pushes the adjustment column 38 to move along the axis, which drives multiple sets of expansion plates 30 to expand or converge radially through the connecting rod 41, thereby adjusting the diameter of the steering roller 14. This adjustment process is carried out in conjunction with the angle correction of the angle adjustment component. When the angle changes, the diameter is adjusted synchronously, which can avoid tension abnormalities caused by angle changes. At the same time, when the rotating roller 35 contacts the belt, it rotates with the belt. The rolling contact reduces friction between the roller and the belt, reduces tension fluctuations, and ensures that the belt always fits the surface of the steering roller 14 in a stable state, reducing belt slippage caused by uneven tension and maintaining the belt tension within a stable range.

[0080] Please see as follows Figure 7 , Figure 8 and Figure 13 As shown, the steering frame 11 is equipped with a receiving section located below the steering roller 14. This section receives material guided onto the belt by the baffle plate 17 and then transports it to the next stage via the belt after the top turn. The receiving section includes multiple sets of first bearing supports 43, which are equidistantly distributed along the conveying direction of the belt. The spacing between adjacent sets of first bearing supports 43 is consistent, providing support for other components of the receiving section. Two sets of bearing columns 44 are vertically welded to the top of each set of first bearing supports 43. Two sets of inclined guide rollers 45 are rotatably connected to the top side of the first bearing supports 43 and the middle of the two sets of bearing columns 44 via bearing seats. The inclined guide rollers 45 are cylindrical metal rollers with an inclined axis, one end of which is connected to the first bearing support 43. The other end extends to the top of the support column 44, which is used to bend the two sides of the belt upward after the turn, which is conducive to the material handling. The tops of the two sets of support columns 44 are rotatably connected by a bearing seat to a horizontal support roller 46. The axis of the horizontal support roller 46 is perpendicular to the conveying direction of the belt and is used to support the bottom of the belt. The outer circumference of the inclined guide roller 45 and the horizontal support roller 46 are both covered with a buffer layer 47. The buffer layer 47 is made of elastic rubber, and its surface is flat and has a certain friction. It can contact the surface of the belt after the turn, reducing the hard friction between the belt and the roller. Bearings are embedded in the center of both ends of the inclined guide roller 45 and the horizontal support roller 46. The inner ring of the bearing is interference-fitted with the shaft of the roller, and the outer ring is fixedly connected to the bearing seat, so that the roller can rotate flexibly with the movement of the belt.

[0081] Specifically, when the material is guided by the baffle plate 17 and falls onto the belt after the turn, the belt picks up the material and transports it under the action of the inclined guide roller 45 and the horizontal bearing roller 46. The inclined guide roller 45 contacts one side of the belt through the inclined axis to prevent the belt from shifting laterally during the material receiving process. The horizontal bearing roller 46 supports the belt from the bottom and counteracts the downward force of the material's weight on the belt. When the buffer layer 47 contacts the belt surface, it can increase the friction between the two to prevent the belt from slipping, and it can also absorb the vibration generated when the material falls through its own elasticity, reducing belt wear and ensuring that the material is stably carried on the belt and transported to the subsequent stage with the belt.

[0082] Two sets of second bearing brackets 48 are fixed to both sides of the two sets of receiving sections by bolts. The top plane of the second bearing brackets 48 is parallel to the belt running plane of the receiving section. Two sets of first guide rails 18 are respectively installed on the top of the two sets of second bearing brackets 48 by bolts. The two sides of the steering frame 11 are fixed with second guide rails 49. Electric sliders 50 are provided on the second guide rails 49. The electric sliders 50 slide with the second guide rails 49. One side is connected to the side of the baffle plate 17 through a connecting column, which can drive the baffle plate 17 to move along the length direction of the second guide rail 49. Two sets of photoelectric sensors 51 are set at the ends of the two sets of second bearing brackets 48 near the steering roller 14, corresponding to the initial positions of the two sets of baffle plates 17. The photoelectric sensors 51 are fixed to the side of the second bearing brackets 48 by brackets. Their detection ends face the edge of the baffle plate 17. The current coordinates of the baffle plate 17 can be obtained by the change of the blocking signal.

[0083] Specifically, the control module 19 receives the pressure field feature matrix transmitted by the pressure sensor array, and identifies the spatial coordinates of the material detaching from the deflector roller 14 by analyzing the abrupt change in pressure value from present to absent in the matrix; combined with the correction angle data fed back by the angle sensor 15, it calculates the theoretical conveying direction angle when the material detaches; based on the theoretical conveying direction angle and the coordinates of the material detachment point, it determines the target position coordinates that the baffle plate 17 needs to reach; the photoelectric sensor 51 monitors the edge position of the baffle plate 17 in real time and feeds back the current coordinates to the control module 19; the control module 19 compares the current coordinates with the target position coordinates, generates a drive signal and sends it to the electric slider 50, the electric slider 50 drives the baffle plate 17 to slide along the first guide rail 18 and the second guide rail 49, so that the receiving area of ​​the baffle plate 17 coincides with the falling range of the material throwing trajectory; no matter how the angle of the deflector roller 14 is adjusted, or the belt deviates due to various factors, causing the material trajectory to deviate, this adjustment process can respond in real time, ensuring that the material falls stably into the range of the baffle plate 17, avoiding the problem in traditional devices where the reliance on manual angle adjustment has a lag, resulting in the inability to correct the material throwing deviation in time.

[0084] Please see as follows Figure 9 and Figure 10As shown, the present invention also provides a control method for a belt conveyor turning device, the method comprising:

[0085] S1, obtain the axial pressure distribution time sequence matrix through the pressure sensor array, obtain the initial roller angle data through the angle sensor, determine the angle matching state based on the pressure field feature matrix and the initial roller angle data and generate a compensation command, execute the compensation command and obtain the correction angle data;

[0086] Specifically, in this implementation, obtaining the compensation generation instruction includes the following steps:

[0087] S10: Every N seconds, a pressure distribution vector is acquired by a pressure sensor array arranged according to the axial coordinates of the pressure sensors 36 in the array. The pressure sensor array consists of multiple pressure sensors 36 fixed on one set of expansion plates 30 along the axial direction of the steering roller 14. The spacing between adjacent pressure sensors 36 is consistent. The detection surface of each pressure sensor 36 is in contact with the corresponding rotating roller 35. When the belt passes over the steering roller 14, the pressure of the belt on the rotating roller 35 is transmitted to the pressure sensor 36, causing it to output the corresponding pressure value. During acquisition, the control system triggers acquisition once every N seconds. Each pressure sensor 36 synchronously records the current pressure value. Then, the pressure values ​​are arranged sequentially according to the coordinate order of these pressure sensors 36 along the axis of the steering roller 14 to form a pressure distribution vector. When the steering roller 14 rotates, the control system continuously acquires data from the start of its rotation until it completes one revolution, i.e., continuously acquires data for one rotation cycle. Afterward, each pressure distribution vector is used as the column of a matrix according to the order of acquisition time, and each pressure value in each pressure distribution vector is used as the row of the matrix according to the order of axial coordinates. This combination forms an axial pressure distribution time sequence matrix.

[0088] For example, suppose there are 5 pressure sensors distributed along the axial direction of the steering roller 14, with axial coordinates of 0mm, 20mm, 40mm, 60mm, and 80mm respectively. The pressure values ​​collected at 0.01 seconds are 10N, 12N, 11N, 13N, and 10N respectively, forming a pressure distribution vector of [10, 12, 11, 13, 10]. The pressure values ​​collected at 0.02 seconds are 11N, 13N, 12N, 14N, and 11N respectively, forming a pressure distribution vector of [11, 13, 12, 14, 11]. And so on. After the steering roller 14 rotates one revolution, these vectors combine to form an axial pressure distribution time sequence matrix, thereby completely recording the pressure changes of the belt at different axial positions during one revolution of the steering roller 14.

[0089] S11, the angle between the axis of the steering roller 14 and the reference axis is read by the angle sensor 15 as the initial roller angle data. The angle sensor 15 is installed at the bottom of the mounting plate 20, and its detection end is connected to the bottom end of the rotating bracket 21. When the steering roller 14 is in the initial state, the angle sensor 15 detects the angle between the axis of the steering roller 14 and the preset reference axis in real time. This angle value is the initial roller angle data. Its function is to provide the reference parameter of the current angle of the steering roller 14, and to provide the initial basis for subsequent angle matching judgment. A planar rectangular pressure distribution coordinate system is established with the axial direction of the steering roller 14 as the axial coordinate as the X-axis and the acquisition time of the pressure distribution vector as the Y-axis. The value range of the X-axis covers the entire axial length of the steering roller 14, and the value range of the Y-axis covers one rotation cycle of the steering roller 14. Each pressure value in each group of pressure distribution vectors is assigned according to its corresponding axial coordinate and acquisition time. Each moment is marked as a point in the pressure distribution coordinate system. All points at the same acquisition moment are then connected in X-axis order to form a pressure distribution line. Multiple pressure distribution lines correspond to the axial pressure distribution at different moments. Their function is to transform abstract pressure data into visual lines, intuitively presenting the pressure change characteristics of the belt at different positions during the rotation of the steering drum 14. The coordinates of the midpoint of the belt width along the axis of the drum when the belt is wound around the drum on the reference axis under standard operating conditions are taken as the reference center coordinates. These coordinates are the ideal center position when the belt contacts the drum. Based on the angle between the axis of the steering drum 14 and the reference axis in the initial drum angle data, combined with the reference center coordinates, the ideal center position when the belt contacts the steering drum 14 at the current initial angle is obtained through geometric projection. This position is the theoretical center coordinate, which serves as a reference standard for judging whether the actual center of the belt has deviated.

[0090] For example, the axial length of the steering roller 14 is 100mm, and five pressure sensors are distributed along the axial direction with axial coordinates of 10mm, 30mm, 50mm, 70mm, and 90mm. The reference axis is the axis of the redirecting roller 13, the initial roller angle data is 10 degrees, and the reference center coordinate is 50mm. After establishing the pressure distribution coordinate system, the pressure distribution vector [8N, 12N, 15N, 11N, 7N] collected at 0.02 seconds will form a pressure distribution line in the coordinate system. The pressure at point X=10mm at Y=0.02s is 8N, and the pressure at point X=50mm at Y=0.02s is 15N. Combining the initial roller angle data of 10 degrees with the reference center coordinate of 50mm, the theoretical center coordinate is calculated to still be 50mm. Subsequently, the deviation between the actual pressure center and this theoretical center coordinate can be compared to determine whether the angle matches. The above data is only used to express logical relationships, and the specific data needs to be determined according to the specific situation.

[0091] S12, the theoretical center coordinates are mapped to the pressure distribution coordinate system and used as a reference. Specifically, based on the X-axis value of the theoretical center coordinates, a corresponding point is marked on the X-axis of the pressure distribution coordinate system. This point runs through the entire Y-axis, forming a vertical reference line, which serves as a reference for determining whether the actual pressure center of the belt has shifted. The pressure centroid coordinates are obtained based on multiple pressure distribution lines. For each pressure distribution line, the axial coordinates of each pressure sensor 36 are used as variables, and the pressure value at the corresponding position is used as a weight. A weighted average is calculated for the pressure centroid of that pressure distribution line. Then, the arithmetic mean of the X-values ​​of the centroids of all pressure distribution lines is taken to obtain the pressure centroid coordinates over the entire rotation cycle. These coordinates reflect the concentration of actual pressure when the belt contacts the steering roller 14. Axial position; Obtain offset data based on the coordinates of the pressure center of gravity and the theoretical center coordinates. Subtract the X value of the theoretical center coordinate from the X value of the pressure center of gravity coordinate; the difference is the offset data. A positive difference indicates that the pressure center of gravity has shifted towards one end of the axis of the steering roller 14, while a negative difference indicates that it has shifted towards the other end. The absolute value reflects the distance of the offset. Obtain the angle offset result based on the offset data and a preset offset range. The preset offset range is an axial distance range. When the offset data is within this range, it is determined that the angle matches and there is no offset. When the offset data exceeds this range, the positive or negative value of the offset corresponds to the direction of the angle offset, and the absolute value of the offset corresponds to the degree of angle offset. The larger the absolute value, the larger the angle that needs to be adjusted.

[0092] For example, the theoretical center coordinate is 50mm, forming a vertical reference line of X=50mm in the pressure distribution coordinate system; the steering roller 14 has 100 pressure distribution lines in one rotation cycle, one of which has pressure values ​​of 8N, 15N, and 7N at axial coordinates of 30mm, 50mm, and 70mm respectively. The centroid X value of this line = (30×8+50×15+70×7)÷(8+15+7) = (240+750+490)÷30 = 1480÷30≈49.3mm. Similarly, after calculating the centroids of the other 99 lines and taking the average, the overall pressure centroid coordinate is 54mm; then the offset data = 54mm-50mm=4mm. If the preset offset range is -3mm to 3mm, 4mm exceeds this range. The above data is only used to express logical relationships, and the specific data needs to be determined according to the specific situation.

[0093] S13: Based on the angle offset result and preset control rules, an angle compensation vector is obtained. The offset direction in the angle offset result determines the direction of the compensation vector. The degree of offset is converted into a compensation angle value through preset control rules. The two are combined to form an angle compensation vector containing the compensation direction and compensation angle. Its function is to clarify the specific direction and angle that the steering roller 14 needs to be adjusted, providing precise instructions for the adjustment operation. Based on the angle compensation vector, the roller angle adjustment operation is executed. The control module 19 converts the angle compensation vector into a drive signal for the adjustment motor 25. After receiving the signal, the adjustment motor 25 drives the gear 26 to rotate. The gear 26 meshes with the arc-shaped rack 27, driving the moving bracket 24 along... The arc-shaped slide rail 23 slides, and the moving bracket 24 drives one end of the steering roller 14 to move along the arc-shaped trajectory. The other end of the steering roller 14 pushes the rotating bracket 21 to rotate around its bottom end, so that the axis angle of the steering roller 14 changes according to the direction and angle of the compensation vector. During the adjustment process, the angle sensor 15 detects the angle change of the steering roller 14 in real time and feeds it back to the control module 19. When the actual adjustment angle is detected to reach the compensation angle in the compensation vector, the control module 19 stops the drive of the adjustment motor 25. At this time, the angle value detected by the angle sensor 15 is the correction angle data. This data is used to record the angle state after adjustment and provide the current angle reference for subsequent steps.

[0094] For example, if the angle offset is 4mm, with the offset direction towards the 70mm end of the axis of the steering roller 14, and the preset control rule is that every 1mm offset corresponds to a 0.5-degree reverse compensation angle, then the angle compensation vector is towards the 30mm end with a compensation angle of 2 degrees. Based on this, the control module 19 sends a drive command to the adjustment motor 25, which drives the gear 26 to rotate. Through meshing with the arc-shaped rack 27, the gear 26 drives the moving bracket 24 to slide along the arc-shaped slide rail 23 towards the 30mm end. The moving bracket 24 drives one end of the steering roller 14 to move, causing the axis of the steering roller 14 to rotate towards the 30mm end. The angle sensor 15 monitors the angle change in real time. When the feedback angle shows that it has rotated by 2 degrees, the control module 19 stops adjusting. At this time, the reading of the angle sensor 15 is the corrected angle data. This data indicates that the steering roller 14 has completed angle compensation and can proceed to the next stage of detection and adjustment. The above data is only used to express logical relationships, and the specific data needs to be determined according to the specific situation.

[0095] S2, based on the tension sensor 16, acquire the tension data stream and obtain tension fluctuation characteristics. Specifically, this includes calculating the tension mean and tension standard deviation. All tension readings in the tension data stream are summed and then divided by the total number of readings; the result is the tension mean, which reflects the overall tension level of the belt. The difference between each tension reading and the tension mean is calculated. These deviations are squared, summed, divided by the number of readings minus one, and the square root of the result is the tension standard deviation, which reflects the dispersion of the tension data, i.e., the severity of tension fluctuations. A threshold for the normal tension fluctuation range is set; this threshold is a preset tension value. The tension range is defined by extracting all tension readings from the tension data stream and comparing them one by one with a threshold. If any tension reading exceeds this range, it is considered an abnormal tension fluctuation; otherwise, it is considered a normal fluctuation. Its purpose is to identify sudden instances of excessive or insufficient tension. A target tension range is set, representing the tension interval the belt should maintain during normal operation. The calculated average tension is compared to this range. If the average is below the lower limit, the tension level is considered "too low"; if the average is above the upper limit, it is considered "too high"; and if the average is within the range, it is considered "normal". Its purpose is to determine the overall tension level of the belt. Whether it meets the operating requirements; set an allowable threshold for the standard deviation of fluctuation, compare the calculated standard deviation of tension with this threshold. If the standard deviation is greater than the threshold, the fluctuation state is "excessive fluctuation"; if it is less than or equal to the threshold, it is "normal fluctuation". Its function is to assess whether the stability of tension fluctuation is within an acceptable range; obtain diameter adjustment strategy decisions based on abnormal fluctuation state, tension level state, and fluctuation state. For example, when the tension level state is "excessive tension", the fluctuation state is "normal fluctuation" and there is no abnormal fluctuation, the decision is to "reduce the diameter of the steering roller 14"; when the tension level state is "excessive tension", the fluctuation state is "excessive fluctuation" and there is abnormal fluctuation, the decision is to "reduce the diameter of the steering roller 14". When fluctuations occur, the decision is to "increase the diameter of the steering roller 14". Different state combinations correspond to different adjustment directions and adjustment amounts, which serve to provide a clear operational basis for diameter adjustment. Based on the diameter adjustment strategy decision and correction angle data, a diameter adjustment command is obtained, which includes the adjustment direction and adjustment amount. The control module 19 sends the command to the electric telescopic rod 42. The electric telescopic rod 42 pushes the adjustment column 38 to move along the axis of the steering roller 14. The adjustment column 38 drives multiple sets of expansion plates 30 to move synchronously along the expansion groove 32 through the connecting rod 41, thereby changing the diameter of the steering roller 14 until the tension mean and standard deviation reflected by the tension data stream return to the preset range.

[0096] The following explanation uses hypothetical data; the actual data will depend on the specific situation. For example, the tension data stream contains 10 readings: 140N, 160N, 150N, 170N, 180N, 160N, 190N, 170N, 150N, and 160N. The calculated average tension is (140+160+150+170+180+160+190+170+150+160)÷10=163N. The deviations of each reading from the average are -23N, -3N, -13N, 7N, 17N, -3N, 27N, 7N, -13N, and -3N, respectively. The sum of squared deviations is 529+9+169+49+289+9+729+49+169+9=2019, and the standard deviation of tension is approximately 15N. If the threshold for normal tension fluctuation is 100N... 300N, all readings are within the range, so the tension fluctuation status is "no abnormality"; the target tension value range is 150N-250N, the average value of 163N is within the range, so the tension level status is "normal"; the allowable threshold for the standard deviation of fluctuation is 20N, 15N is less than 20N, so the fluctuation status is "normal"; based on comprehensive judgment, no diameter adjustment is needed, and the steering roller 14 maintains its current diameter; if the average value of another set of tension data streams is 280N, which is less than the allowable threshold of 20N, and the standard deviation is 18N, which is also less than the allowable threshold of 20N, then the decision is to "reduce the diameter". Combined with the correction angle data, a command to reduce the diameter by 3mm is generated. The electric telescopic rod 42 pulls the adjusting column 38 to move, which drives the expansion plate 30 to retract inward through the connecting rod 41, so that the diameter of the steering roller 14 is reduced by 3mm until the average tension value returns to the target range.

[0097] S3. The coordinates of the material release point are obtained based on the pressure field feature matrix and the correction angle data. The pressure field feature matrix is ​​obtained by processing the axial pressure distribution time series matrix collected by the pressure sensor array, which records the axial distribution and change of the contact pressure between the belt and the roller during the rotation of the steering roller 14. The correction angle data is the axial angle of the steering roller 14 after angle adjustment. The combination of the two can accurately locate the position where the material releases from the steering roller 14. The actual material conveying trajectory is obtained based on the spatial coordinates of the material release point, and the motion path of the material after release is analyzed by kinematic analysis. The baffle control command is obtained according to the actual material conveying trajectory, and the baffle 17 is driven to move to a suitable position to catch the material and execute the command. Specifically, two pressure distribution vectors are selected: one containing the maximum number of pressure values ​​and the other containing one less pressure value. Since the belt and steering roller 14 are in full contact when the material is still attached, the pressure sensor 36 detects the maximum number of pressure values. As the material begins to detach, the contact decreases, and the number of pressure values ​​decreases by one. These two vectors reflect the pressure changes before and after material detachment. The selected pressure distribution vectors are mapped onto an axis with the axial coordinate as the reference, meaning each pressure value corresponds to its axial coordinate. These points are connected to form multiple pressure distribution lines. The pressure distribution lines are arranged according to the time of acquisition. Observing along the acquisition time sequence, the pressure center coordinates of the first pressure distribution line are the material detachment point coordinates. The pressure center coordinates are calculated using a weighted average. These coordinates mark the axial position where the material detaches from the surface of the steering roller 14, and their function is to determine the starting point of material ejection. The theoretical conveying direction angle is obtained based on the material release point coordinates and correction angle data. The correction angle data reflects the deflection angle of the steering roller 14. Combining this angle with the tangent direction when the material leaves, the theoretical motion direction angle of the material after leaving the steering roller 14 is obtained through geometric calculation. This angle determines the horizontal direction of the material ejection. Based on the theoretical conveying direction angle and the material release point coordinates, combined with the speed when the material leaves, the position of the material when it falls to the height of the baffle plate 17 is calculated through the trajectory equation. This position is the target position coordinate of the baffle plate, which is used to determine the position that the baffle plate 17 needs to reach to catch the material. The current coordinates of the baffle plate 17 are obtained by photoelectric sensor 51, which is mounted on the second support bracket 48. Its transmitting end and receiving end are located on both sides of the baffle plate 17. When the baffle plate 17 moves, it will block the sensor light. The current coordinates can be determined by the scale corresponding to the blocking position. The difference between the current coordinates of the baffle plate and the target position coordinates of the baffle plate is calculated in the horizontal direction. This difference is the baffle plate displacement command. The command is sent to the electric slider 50 to drive the baffle plate 17 to move along the guide rail to the target position.

[0098] For example, a pressure distribution vector may contain a maximum of 5 pressure values, and the next adjacent vector may contain a maximum of 4 pressure values, which is a vector that can be reduced by one. Mapping these two vectors onto axial coordinates (10mm, 30mm, 50mm, 70mm, 90mm) forms two pressure distribution lines. The pressure values ​​of the first line are 12N, 15N, 18N, 14N, and 11N, respectively. The coordinates of its pressure center are (10×12+30×15+50×18+70×14+90×11)÷(12+15+18+14+11)=(120+450+900+980+990)÷70=3440÷70≈49.1mm. This is the material desorption... The distance from the point is calculated as follows: the correction angle is 8 degrees, and the theoretical conveying direction angle is 30 degrees. Based on the 30-degree direction angle and the 49.1mm distance from the point, the position of the material when it falls to the height of the baffle plate 17 is calculated to be X=60mm, that is, the target position coordinate of the baffle plate is 60mm. The photoelectric sensor 51 detects that the current coordinate of the baffle plate 17 is 50mm, and the horizontal displacement difference is 60mm-50mm=10mm. This difference is sent to the electric slider 50 as a displacement command for the baffle plate. The electric slider 50 drives the baffle plate 17 to move 10mm along the first guide rail 18 to reach the target position, ensuring that the material falls within the range of the baffle plate 17. The above data is used for logical explanation, and the specific data needs to be determined according to the actual situation.

[0099] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be included within the protection scope of the present invention.

Claims

1. A belt conveyor turn around device characterized by, The device comprises: a steering frame, one side of the steering frame is provided with a redirection frame, the redirection frame is provided with a redirection roller, and the steering frame is provided with a steering roller for changing the direction of the belt conveying line; an angle adjusting assembly for adjusting the angle between the axis of the steering roller and the axis of the redirection roller, and obtaining initial roller angle data and correction angle data through an angle sensor; a diameter adjusting assembly installed on the steering roller, the diameter adjusting assembly is used to adjust the diameter of the steering roller, and the tension data stream of the steering roller is obtained through a tension sensor, and the axial pressure distribution time matrix is obtained through a pressure sensor array; two sets of material blocking plates, both of which are installed on the steering frame, and are used to receive the materials thrown out by the steering roller, the steering frame is provided with two sets of first guide rails, and the two sets of material blocking plates slide along the two sets of first guide rails respectively; a control module installed on one side of the steering frame, which is used to control the operation of the belt conveyor turning device; the diameter adjusting assembly comprises a plurality of expansion plates, which are arranged around the steering roller, both ends of the steering roller are provided with rotating plates, one side of the rotating plate is provided with a plurality of expansion sliding grooves, the expansion sliding grooves are distributed radially relative to the axis of the steering roller, the moving rods at both ends of the expansion plate are respectively arranged in one of the expansion sliding grooves of the two rotating plates, so that the expansion plate can move along the expansion sliding groove to adjust the diameter of the steering roller, and the expansion plate and the bearing seat are connected through a tension sensor; a plurality of expansion plates are provided with a plurality of mounting racks, and a plurality of rotating rollers for contacting the belt are arranged on the mounting racks, the axes of the rotating rollers are perpendicular to the axis of the steering roller, a plurality of pressure sensors are arranged on one of the expansion plates and connected with the mounting racks, and the pressure sensors are distributed along the axis of the steering roller to form a pressure sensor array; one end of the steering roller is provided with an adjusting through hole, and an adjusting column moving along the axis of the steering roller is arranged in the adjusting through hole, a plurality of adjusting rings are equidistantly arranged on the outer side of the adjusting column, the adjusting rings are a plurality of first connecting seats arranged around the outer side of the adjusting column, a plurality of second connecting seats are arranged on the bottom of the expansion plate corresponding to the plurality of adjusting rings, the outer side of the adjusting ring is rotationally connected with one of the second connecting seats on the bottom of the expansion plate through a connecting rod, one side of one of the tension sensors is provided with an electric telescopic rod for pushing the adjusting column to a reduced position or an expanded position, when the adjusting column moves to the reduced position, the plurality of expansion plates move radially inward to narrow the diameter of the steering roller, when the adjusting column moves to the expanded position, the plurality of expansion plates move radially outward to expand the diameter of the steering roller, the adjustment process is coordinated with the angle correction of the angle adjusting assembly, the diameter is adjusted synchronously when the angle changes, and the tension abnormality caused by the change of the angle can be avoided.

2. The belt conveyor turning device according to claim 1, wherein The angle adjusting assembly comprises a mounting plate, the mounting plate is arranged on one side of the steering frame, a rotating support is arranged on the top of the mounting plate, an angle sensor is arranged on the bottom of the mounting plate, the bottom end of the rotating support is connected with the angle sensor through the through hole on the top of the mounting plate, an arc-shaped support is arranged on the other side of the steering frame, an arc-shaped sliding rail is arranged on the arc-shaped support, a moving support is connected with the arc-shaped sliding rail through two groups of sliding blocks, the rotating support rotates with the moving support moving on the arc-shaped sliding rail, and the two ends of the steering roller are rotationally connected with the moving support and the bearing seat on the top of the rotating support.

3. A belt conveyor turning device according to claim 2, wherein: The angle adjusting assembly further comprises an adjusting motor, the moving support is internally provided with the adjusting motor, the main shaft at the bottom end of the adjusting motor is connected with a gear through the through hole on the bottom of the moving support, an arc-shaped rack is arranged on one side of the arc-shaped support, the gear is engaged with the tooth portion of the arc-shaped rack, a plurality of support columns are arranged on the outer side of the arc-shaped support, and the support columns are connected with the arc-shaped support and the arc-shaped rack through a connecting support on one side.

4. A belt conveyor turning device according to claim 1, wherein: A material receiving part is arranged on the steering frame, the material receiving part receives the material taken by the belt after turning through the material blocking plate, the material receiving part comprises a plurality of first bearing supports, the plurality of first bearing supports are equidistantly distributed in the steering frame, two groups of bearing columns are arranged on the top of each of the plurality of first bearing supports, two groups of inclined guide rollers are arranged between the first bearing support and the two groups of bearing columns, a horizontal bearing roller is arranged between the two groups of bearing columns, a buffer layer for contacting the belt after turning is arranged on the outer side of the inclined guide roller and the horizontal bearing roller, and bearings are arranged at the two ends of the inclined guide roller and the horizontal bearing roller; Two groups of second bearing supports are arranged on the two sides of the two groups of material receiving parts, two groups of first guide rails are arranged on the top of the two groups of second bearing supports, second guide rails are arranged on the two sides of the steering frame, electric sliding blocks are arranged on the second guide rails, the electric sliding blocks are connected with the material blocking plates on one side, and two groups of photoelectric sensors are arranged on one end of the two groups of second bearing supports and correspond to the two groups of material blocking plates.

5. A control method for a belt conveyor turn-around device according to any one of the preceding claims 1-4, characterized in that The method comprises: An axial pressure distribution time sequence matrix is acquired through the pressure sensor array, initial roller angle data is acquired through the angle sensor, an angle matching state is determined based on the pressure field characteristic matrix and the initial roller angle data, and a compensation instruction is generated, the compensation instruction is executed, and corrected angle data is acquired; Tension data flow is acquired based on the tension sensor, tension fluctuation characteristics are acquired based on the tension data flow, diameter adjustment strategy decision operation is performed based on the tension fluctuation characteristics, diameter adjustment instructions are acquired and executed; Material separation point coordinates are acquired based on the pressure field characteristic matrix and the corrected angle data, actual material conveying tracks are acquired based on the material separation point spatial coordinates, material blocking plate control instructions are acquired according to the actual material conveying tracks, and the instructions are executed.

6. A control method of a belt conveyor turning device according to claim 5, characterized in that, An axial pressure distribution time sequence matrix is acquired through the pressure sensor array, initial roller angle data is acquired through the angle sensor, an angle matching state is determined based on the pressure field characteristic matrix and the initial roller angle data, and a compensation instruction is generated, the compensation instruction is executed, and corrected angle data is acquired, comprising: A set of pressure distribution vectors arranged according to the axial coordinates of the pressure sensors in the pressure sensor array is collected every N seconds by the pressure sensor array, a rotating cycle of the rotating drum is continuously collected, the axial pressure distribution time sequence matrix is combined according to the collection time of each set of pressure distribution vectors as the column; The angle between the axis of the rotating drum and the reference axis is read by the angle sensor as the initial drum angle data; The axial coordinate is the X axis, and the collection time is the Y axis to establish the pressure distribution coordinate system, and each set of pressure distribution vectors is mapped into the pressure distribution coordinate system to form a plurality of pressure distribution lines; The axial center coordinate of the drum around the reference axis is taken as the reference center coordinate, and the theoretical center coordinate is obtained according to the initial drum angle data and the reference center coordinate; The theoretical center coordinate is mapped into the pressure distribution coordinate system and taken as a reference to obtain the pressure barycenter coordinate based on the plurality of pressure distribution lines, and the offset data is obtained according to the pressure barycenter coordinate and the theoretical center coordinate, and the angle offset result is obtained according to the offset data and the preset offset interval, wherein the angle offset result includes the offset direction and the offset degree; The angle offset result and the preset control rule are used to obtain the angle compensation vector, and the drum angle adjustment operation is performed based on the angle compensation vector to obtain the correction angle data.

7. The control method of a belt conveyor turning device according to claim 5, characterized in that, A tension data stream is obtained based on the tension sensor, a tension fluctuation feature is obtained based on the tension data stream, and a diameter adjustment strategy decision operation is performed based on the tension fluctuation feature to obtain a diameter adjustment instruction and execute it, including: The tension mean value is obtained by adding all tension readings in the tension data stream and then dividing by the number of readings, the deviation of each tension reading from the tension mean value is calculated, the sum of the squares of these deviations is calculated, divided by the number of readings minus one, and then the square root is taken to obtain the tension standard deviation; A tension normal fluctuation range threshold is set, all tension readings in the tension data stream are extracted, and it is determined whether any tension reading exceeds the tension normal fluctuation range threshold to obtain a tension abnormal fluctuation state; A tension target value range is set, and a tension level state determination operation is performed based on the tension mean value and the tension target value range to obtain a tension level state; A fluctuation standard deviation allowable threshold is set, and a fluctuation state determination operation is performed based on the tension standard deviation and the fluctuation standard deviation allowable threshold to obtain a fluctuation state; The diameter adjustment strategy decision is obtained according to the abnormal fluctuation state, the tension level state and the fluctuation state, and the diameter adjustment instruction is obtained based on the diameter adjustment strategy decision and the correction angle data and executed.

8. A control method of a belt conveyor turning device according to claim 6, characterized in that, The material separation point coordinate is obtained based on the pressure field feature matrix and the correction angle data, the actual material conveying track is obtained based on the material separation point spatial coordinate, the material blocking plate control instruction is obtained according to the actual material conveying track and executed, including: The pressure distribution vector containing the most number of pressure values is selected, and the pressure distribution vector containing the most number of pressure values minus one is selected, the selected pressure distribution vector is mapped to the axis line with the axial coordinate as the reference to form a plurality of pressure distribution lines, and the pressure center coordinate of the first pressure distribution line is extracted along the collection time to obtain the material separation point coordinate. The theoretical conveying direction angle is obtained based on the material separation point coordinate and the correction angle data, and the target position coordinate of the material blocking plate is obtained according to the theoretical conveying direction angle and the material separation point coordinate; The current coordinate of the material blocking plate is obtained through the photoelectric sensor, and the horizontal displacement difference value is obtained as the displacement instruction of the material blocking plate according to the current coordinate of the material blocking plate and the target position coordinate of the material blocking plate.

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