Modular semi-direct drive device for conveyors, self-adapting control system and method

Abstract

This invention relates to a modular semi-direct drive device, adaptive control system, and method for conveyors. The modular semi-direct drive device (1) for conveyors includes a motor (C) and a planetary reducer (A), with a torque limiter (B) disposed between the motor (C) and the planetary reducer (A). A brake (D) is disposed on the end of the motor (C) away from the planetary reducer (A). The motor (C), the planetary reducer (A), the torque limiter (B), and the brake (D) are aligned along the same axis, and each of these components is a modular unit that can be disassembled and assembled. This invention reduces the axial dimension of the semi-direct drive device, saving installation space and meeting the high space utilization requirements of the conveyor's working surface.

Description

Technical Field

[0001] This invention relates to the technical field of semi-direct drive devices for conveyors; specifically, this invention relates to a modular semi-direct drive device, adaptive control system, and method for conveyors. Background Technology

[0002] In material handling systems of core industrial sectors such as mines and coal mines, scraper conveyors are key equipment for ensuring continuous production. The operation and maintenance efficiency of the conveyor directly affects the capacity and safety of the entire production chain, and the limited working space underground also places high demands on the high space utilization rate of the conveyor.

[0003] Existing semi-direct drive conveyor systems have the following disadvantages in terms of structural dimensions: the axial dimension of the semi-direct drive system is long, the overall structure is complex, and the volume is large, which is not conducive to production operations in the confined space of underground mines where space utilization efficiency is extremely important. Summary of the Invention

[0004] In view of this, the present invention provides a modular semi-direct drive device, adaptive control system and method for conveyors, thereby solving or at least alleviating one or more of the above-mentioned problems and other problems existing in the prior art.

[0005] To achieve the aforementioned objective, a first aspect of the present invention provides a modular semi-direct drive device for a conveyor, the modular semi-direct drive device for a conveyor including a motor and a planetary reducer, and a torque limiter is provided between the motor and the planetary reducer, and a brake is provided at the end of the motor away from the planetary reducer, the motor, the planetary reducer, the torque limiter and the brake are aligned along the same axis, and the motor, the planetary reducer, the torque limiter and the brake are all modular components that can be disassembled and combined.

[0006] In the modular semi-direct drive device for conveyors as described above, optionally, the housing of the torque limiter is connected to the housing of the motor and the housing of the planetary reducer respectively via flanges, and the modular semi-direct drive device for conveyors has a frequency converter for controlling the motor, one end of the frequency converter is connected to the motor, and the other end of the frequency converter is connected to the planetary reducer.

[0007] In the modular semi-direct drive device for conveyors as described above, optionally, the torque limiter includes a bushing and a motor shaft connecting plate. The output shaft of the motor is connected to the motor shaft connecting plate of the torque limiter, and the bushing of the torque limiter is connected to the sun gear shaft extension end of the planetary reducer. Furthermore, the connecting portion of the motor's output shaft has the same structure as the connecting portion of the bushing of the torque limiter, and the connecting portion of the motor shaft connecting plate of the torque limiter has the same structure as the connecting portion of the sun gear shaft extension end of the planetary reducer. The torque limiter can be removed to directly connect the planetary reducer to the motor.

[0008] In the modular semi-direct drive device for conveyors described above, optionally, the brake and the motor are an integrated structure. The motor includes a main motor housing and a rear end cover. The brake is integrated within a closed cavity structure formed by the main motor housing and the rear end cover. The brake is an electromagnetic toothed brake, including a drive disc and a set of engaging teeth. The set of engaging teeth includes a first and a second engaging tooth that are normally open and facing each other. The first engaging tooth is fixed to the rear end cover of the motor, and the second engaging tooth is fixed to the drive disc. An electromagnetic coil is embedded in the rear end cover of the motor. The drive disc is circumferentially fixed to the shaft of the motor. The drive disc is subjected to axial traction force, causing the second engaging tooth to disengage from the first engaging tooth. When the brake is working, the electromagnetic coil is energized and attracts the drive disc, causing the drive disc to overcome the axial traction force and drive the second engaging tooth to engage the first engaging tooth to achieve braking.

[0009] In the modular semi-direct drive device for conveyors as described above, optionally, an axially fixed retaining ring is provided on the rotating shaft of the motor, and a thrust spring is provided between the retaining ring and the drive disc, the thrust spring providing the axial traction force.

[0010] In the modular semi-direct drive device for conveyors described above, optionally, the planetary reducer includes a reducer housing, a high-speed stage mechanism, and a low-speed stage mechanism. The high-speed stage mechanism includes a first-stage sun shaft, a first-stage sun gear, a first-stage planetary gear, a first-stage planetary carrier, and a first-stage internal gear ring. The low-speed stage mechanism includes a second-stage sun shaft, a second-stage sun gear, a second-stage planetary gear, a second-stage planetary carrier, and a second-stage internal gear ring. The first-stage sun gear is mounted on the first-stage sun shaft. The first-stage planetary gear is disposed between the first-stage sun gear and the first-stage internal gear ring. The first-stage planetary carrier connects the first-stage planetary gears to the second-stage sun shaft. The outer cylindrical surface of the first-stage internal gear ring has a clearance fit with the inner cylindrical surface of the reducer housing. The second-stage sun gear is mounted on the second-stage sun shaft. The second-stage planetary gear is disposed between the second-stage sun gear and the second-stage internal gear ring. The second-stage planetary carrier connects the second-stage planetary gears and forms an internal spline output shaft. The second-stage internal gear ring and the reducer housing are an integral structure. The first-stage sun shaft is connected to the motor. The internal spline of the second-stage planetary carrier constitutes the output end of the planetary reducer.

[0011] In the modular semi-direct drive device for conveyors described above, optionally, the torque limiter is a friction torque limiter. The friction torque limiter includes a left pressure plate, a right pressure plate, and a group of partition plates and a group of friction plates arranged in sequence at intervals and with each plate in contact with the others. The group of friction plates is set on the bushing of the torque limiter by a spline. The friction torque limiter has a bolt that passes through the left pressure plate, the group of partition plates, and the right pressure plate and is fastened therethrough. The stud of the bolt is fitted with a spring for pressing the left pressure plate and the right pressure plate. The first end of the spring abuts against the bolt head of the bolt, and the second end of the spring abuts against the left pressure plate or the right pressure plate, thereby axially pressing the group of partition plates and the group of friction plates.

[0012] To achieve the aforementioned objective, a second aspect of the present invention provides an adaptive control system for a semi-direct drive device for a conveyor, the adaptive control system comprising a frequency converter control mechanism, a modular semi-direct drive device for a conveyor as described in any one of the first aspects, a position feedback system, and a control coordination unit, wherein:

[0013] The frequency conversion control mechanism includes a frequency converter and a built-in encoder, wherein the built-in encoder is integrated on the frequency converter;

[0014] The position feedback system includes a sensor module and a signal processing module. The sensor module includes a first magnetic block, a second magnetic block, a first Hall sensor, a second Hall sensor, and a rotary transformer. The first magnetic block is disposed on the shaft at the input end of the torque limiter, and the second magnetic block is disposed on the shaft at the output end of the torque limiter. The first and second magnetic blocks are disposed at the same angle. The first Hall sensor is disposed on the motor to collect a first pulse signal representing the motion law of the first magnetic block in real time and transmit it to the signal processing module. The second Hall sensor is disposed on the planetary reducer to collect a second pulse signal representing the motion law of the second magnetic block in real time and transmit it to the signal processing module. The rotary transformer is disposed inside the motor and connected to the output shaft of the motor. The rotary transformer is used to collect the operating condition signal of the motor in real time and transmit it to the signal processing module.

[0015] The frequency converter receives the first pulse signal and the second pulse signal from the signal processing module and determines the state of the torque limiter based on the first pulse signal and the second pulse signal. The control coordination unit receives the operating condition signal of the motor from the signal processing module. The control coordination unit determines the control torque of the motor based on the determined state of the torque limiter and the operating condition signal of the motor, and generates the output frequency parameter of the frequency converter based on the control torque. The frequency converter control mechanism receives and controls the motor through the frequency converter according to the output frequency parameter.

[0016] To achieve the foregoing objective, a third aspect of the present invention provides an adaptive control method for a semi-direct drive conveyor applicable to an adaptive control system for a semi-direct drive conveyor as described in any of the second aspects above, the adaptive control method comprising:

[0017] Step 1: The sensor module acquires the first pulse signal, the second pulse signal, and the operating condition signal of the motor and transmits them to the signal processing module;

[0018] Step II: The signal processing module processes the first pulse signal, the second pulse signal, and the operating condition signal of the motor, and transmits the processed first pulse signal and the second pulse signal to the frequency converter, and transmits the processed operating condition signal of the motor to the control coordination unit;

[0019] Step III: The frequency converter determines the state of the torque limiter based on the first pulse signal and the second pulse signal. When the state of the torque limiter is determined to be without torque limiter, proceed to step IV. When the state of the torque limiter is determined to be that the torque limiter is working normally, proceed to step V. When the state of the torque limiter is determined to be that the torque limiter is slightly slipping, the control coordination unit issues a warning signal. When the state of the torque limiter is determined to be that the torque limiter is severely slipping or malfunctioning, the control coordination unit brakes and stops the modular semi-direct drive device for the conveyor through the brake. When the state of the torque limiter is that the torque limiter has detached, the control coordination unit issues an alarm signal and brakes and stops the modular semi-direct drive device for the conveyor through the brake.

[0020] Step IV: The control and coordination unit processes the collected operating conditions and outputs a detection value α. Based on the detection value α, it determines whether the operating condition is light load, full load, heavy load, or impact condition. When the detection value α < the first threshold Q1 and the duration is greater than t, it is determined to be a light load condition. The output frequency parameter of the inverter is adjusted to make the motor run at a first torque T1. When the first threshold Q1 < the detection value α < the second threshold Q2 and the duration is greater than t, it is determined to be a full load condition. The output frequency parameter of the inverter is adjusted to make the motor run at a second torque T2. When the detection value α > the third threshold Q3 and the duration is greater than t, it is determined to be a heavy load condition. The output frequency parameter of the inverter is adjusted to make the motor run at a third torque T3. When the position feedback system detects that the torque value of the motor is ≥3Tn, it is determined to be an impact condition. The power limiting protection of the motor is performed by the overload protection algorithm of the inverter.

[0021] Step V: The control and coordination unit processes the collected operating conditions and outputs a detection value α. Based on the detection value α, it determines whether the operating condition is light load, full load, heavy load, or impact condition. When the detection value α < the first threshold Q1 and the duration is greater than t, it is determined to be a light load condition. The output frequency parameter of the inverter is adjusted to make the motor run at a first torque T1. When the first threshold Q1 < the detection value α < the second threshold Q2 and the duration is greater than t, it is determined to be a full load condition. The output frequency parameter of the inverter is adjusted to make the motor run at a second torque T2. When the detection value α > the third threshold Q3 and the duration is greater than t, it is determined to be a heavy load condition. The output frequency parameter of the inverter is adjusted to make the motor run at a third torque T3. When the position feedback system detects that the torque value of the motor is ≥ 3Tn, it is determined to be an impact condition. The torque limiter provides torque limiting protection for the modular semi-direct drive device of the conveyor.

[0022] Among them, the first threshold Q1, the second threshold Q2, the third threshold Q3, the first torque T1, the second torque T2, the third torque T3, the time period t, and the rated torque Tn are preset values, and Q1 <Q2<Q3,T1<T2<T3。

[0023] In the adaptive control method for the semi-direct drive device of the conveyor as described above, optionally,

[0024] The method by which the frequency converter determines the state of the torque limiter includes:

[0025] Step 1: Determine whether a torque limiter exists in the modular semi-direct drive device for the conveyor; and

[0026] Step 2: Determine if the torque limiter is working properly.

[0027] Step one includes: after the modular semi-direct drive device for the conveyor starts running, the frequency converter monitors in real time the first pulse period P1 of the first Hall sensor, the second pulse period P2 of the second Hall sensor, and the first pulse trigger time difference ΔS1 of the first Hall sensor and the second Hall sensor for three consecutive calibration pulse periods P. When the first Hall sensor and the second Hall sensor both have stable output signals for three consecutive calibration pulse periods P, and Furthermore, if the first pulse trigger time difference ΔS1 ≤ 10ms, it is determined that a torque limiter exists. This is further confirmed when either the first Hall sensor or the second Hall sensor has no output signal for three consecutive calibration pulse periods P. Furthermore, the first pulse period P1 did not recover within the duration of two consecutive calibration pulse periods P. Furthermore, if the second pulse period P2 fails to recover within the duration of two consecutive calibration pulse periods P, or if the first pulse trigger time difference ΔS1 > 20ms, it is determined to be an infinite torque device. The calibration pulse period P, the calibration pulse trigger time difference ΔS0 of the first Hall sensor and the second Hall sensor are obtained based on the pulse signal of the torque limiter during normal rotation recorded when the modular semi-direct drive device for the conveyor is running under no-load conditions.

[0028] Step two includes: after determining that a torque limiter is present, the frequency converter continuously monitors the first Hall sensor and the second Hall sensor, and obtains the second pulse trigger time difference ΔS2 and the pulse signal fluctuation coefficient K of the first Hall sensor and the second Hall sensor, wherein,

[0029]

[0030] P (real-time) is the real-time pulse period of the operation.

[0031] When ΔS2≤10ms and K≤15%, the torque limiter is considered to be working normally.

[0032] When the condition 10ms < ΔS2 < 50ms is met and continues for two consecutive real-time pulse cycles, it is determined that the torque limiter is slightly slipping.

[0033] When 50ms≤ΔS2 is satisfied and continues for one real-time pulse cycle, it is determined that the torque limiter is severely slipping or has failed.

[0034] The torque limiter is determined to have detached when any one of the following conditions is met: no signal from the first Hall sensor, no signal from the second Hall sensor, or K > 30%.

[0035] The modular semi-direct drive device for conveyors of the present invention adds a torque limiter between the motor and the planetary reducer, and arranges the brake, motor, torque limiter and planetary reducer coaxially in an I-shape on the motor shaft in sequence. The components can be disassembled independently, protecting the key components in the transmission and drive system from damage due to excessive torque, reducing the problem of excessive axial size of the semi-direct drive device for conveyors, reducing the structural complexity of the semi-direct drive device, and meeting the needs of high space utilization efficiency and high operation and maintenance efficiency for the conveyor working surface.

[0036] In a further optional technical solution of the present invention, the connection part of the motor output shaft is structurally consistent with the connection part of the torque limiter bushing, and the connection part of the motor shaft connecting plate of the torque limiter is structurally consistent with the connection part of the sun gear shaft extension end of the planetary reducer. By setting such a unified connection structure, the motor, torque limiter and planetary reducer can be arbitrarily disassembled and assembled in pairs. It is possible to choose whether to add a torque limiter between the motor and the planetary reducer to achieve the torque limiting function according to actual needs, thereby improving the structural flexibility of the semi-direct drive device and increasing the adaptability of the semi-direct drive device to various working scenarios.

[0037] In a further optional technical solution of the present invention, the brake is integrated inside the motor and uses the same housing as the motor, which further reduces the size of the device, simplifies the device structure, and saves installation space.

[0038] Among other alternative technical solutions, an electromagnetic jaw brake is used and integrated into the motor tail section for a unified design. This replaces the existing "hydraulic motor + large gear" braking structure, reducing the overall size of the semi-direct drive unit and enabling faster response to braking commands, thus improving system dynamic performance. Furthermore, integrating the electromagnetic jaw brake with the motor improves efficiency and reduces costs in actual production and development. A friction torque limiter protects all components of the semi-direct drive system, ensuring smooth operation.

[0039] In a further optional technical solution of the present invention, the planetary reducer also adopts a modular design, and the transmission ratio of the planetary reducer can be changed by replacing the high-speed stage mechanism. In application, two or more sets of high-speed stage mechanisms can be matched with the low-speed stage mechanism of the planetary reducer. These two or more sets of high-speed stage mechanisms share the same set of low-speed stage mechanisms. Different transmission ratios can be achieved through simple replacement, which increases the output speed range of the semi-direct drive system and improves the adaptability of the semi-direct drive system to different working conditions.

[0040] This invention further provides an adaptive control system for a semi-direct drive conveyor and an adaptive control method for the same system. By judging the state of the torque limiter, different control methods and early warning measures are implemented. Simultaneously, the operating conditions of the motor are correlated with the operating torque of the semi-direct drive, and the motor is dynamically regulated in real time by controlling the output frequency of the inverter. Timely protection measures are also implemented for impact conditions. This adaptive control system and method, which adjusts the control method and operating torque in real time according to the actual operating state of the semi-direct drive conveyor, can protect the semi-direct drive and the conveyor from damage caused by overload and impact conditions, increasing the operational stability of the semi-direct drive and the entire machine, and extending their service life. Attached Figure Description

[0041] The disclosure of this invention will become more apparent from the accompanying drawings. It should be understood that these drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention. In the drawings:

[0042] Figure 1 This is a structural cross-sectional view of an embodiment of a modular semi-direct drive device for conveyors according to the present invention.

[0043] Figure 2 This is a cross-sectional view of a planetary reducer according to an embodiment of the present invention.

[0044] Figure 3 This is a schematic block diagram of an embodiment of the adaptive control system according to the present invention.

[0045] Figure 4 This is a flowchart of an embodiment of the method for determining the state of the torque limiter in the adaptive control method according to the present invention.

[0046] Figure 5 This is a flowchart of an embodiment of the adaptive control method according to the motor operating conditions in the present invention.

[0047] Figure reference numerals: A-Planetary reducer; B-Torque limiter; C-Motor; D-Brake; E-Inverter; 1-Modular semi-direct drive device for conveyor; 2-Shaft sleeve; 3-Motor shaft connecting plate; 4-Output shaft; 5-Sun gear shaft extension end; 6-Motor main housing; 7-Motor rear end cover; 8-Electromagnetic coil; 9-Meshing gear assembly; 10-Drive disc; 11-Sleeve; 12-Left pressure plate; 13-Partition plate assembly; 14-Friction plate assembly; 15-Right pressure plate; 16-Input external spline; 17-Secondary spline; 18-First-stage planetary gear; 19-Connecting bolt; 20-Reducer housing; 21-Secondary internal gear ring; 22-Full complement cylindrical roller bearing; 23-Secondary planetary carrier outer bearing; 24-Output internal spline; 25-Secondary sun shaft; 26-Secondary planetary carrier; 27-Secondary planetary carrier inner bearing; 28-First-stage sun shaft; 29-First-stage sun gear; 30-First-stage internal gear ring; 31-Locking cylindrical pin; 32-First-stage planetary carrier; 33-Secondary planetary gear. Detailed Implementation

[0048] Referring to the accompanying drawings and specific embodiments, the structure, composition, features, and advantages of the modular semi-direct drive device, adaptive control system, and method for conveyors of the present invention will be described below by way of example. However, all descriptions should not be construed as limiting the present invention in any way.

[0049] Furthermore, for any single technical feature described or implied in the embodiments mentioned herein, or any single technical feature shown or implied in the various figures, the present invention still allows for any combination or deletion of these technical features (or their equivalents) without any technical obstacle, and thus these further embodiments according to the present invention should also be considered within the scope of this description.

[0050] It should also be noted that the terms "inner" and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship of an embodiment of the modular semi-direct drive device for conveyors according to the present invention, as shown in the accompanying drawings. They are only for the convenience of describing this disclosure and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this disclosure.

[0051] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature.

[0052] Figure 1 This is a structural cross-sectional view of an embodiment of a modular semi-direct drive device for conveyors according to the present invention.

[0053] like Figure 1 As shown, the modular semi-direct drive device 1 for the conveyor may include a planetary reducer A, a torque limiter B, a motor C, a brake D, and a frequency converter E. The figure shows the connection relationships between the planetary reducer A, torque limiter B, motor C, brake D, and frequency converter E in cross-sectional view. The housing of the torque limiter B is connected to the housing of the motor C and the housing of the planetary reducer A via flanges. One end of the frequency converter E is connected to the motor C, and the other end of the frequency converter E is connected to the planetary reducer A.

[0054] As shown in the diagram, the first-stage sun gear 29 below planetary reducer A has a convex shaft extension structure on its axis, while the upper axis of torque limiter B has a concave bushing 2. The outer circumferential surface of the sun gear shaft extension 5 of planetary reducer A and the inner circumferential surface of the bushing 2 of torque limiter B are interlocked and connected by splines or other means. Below torque limiter B is a motor shaft connecting plate 3, which has a convex connecting portion on its axis. The outer circumferential surface of the connecting portion of motor shaft connecting plate 3 is interlocked and connected by splines or other means to the inner circumferential surface of the output shaft 4 of motor C. Planetary reducer A, torque limiter B, and motor C are arranged in a coaxial I-type configuration along the same axis, and the three modules can be independently disassembled. This modular arrangement reduces the size and volume of the semi-direct drive device, meeting the high space utilization requirements of limited downhole working space. When a module malfunctions, it can be disassembled individually for maintenance or replacement, improving the operation and maintenance efficiency of the conveyor.

[0055] As shown in the figure, the brake D and the motor C are an integrated structure. The motor C may include a main motor housing 6 and a rear end cover 7. The rear end cover 7 is cylindrical and is fixedly connected to the main motor housing 6 by bolts or other means. The brake D is disposed in the cavity structure formed by the main motor housing 6 and the rear end cover 7, and is integrated on the rear end cover 7 of the motor C. This integrated design further reduces the spatial volume of the semi-direct drive device.

[0056] The housing of motor C has a flange structure with peripheral through holes, and the housing of frequency converter E has a stop structure. Motor C is connected to frequency converter E through the peripheral through holes of the flange. In other optional embodiments, motor C and frequency converter E can also use different connection methods. At the same time, frequency converter E is also connected to planetary reducer A, further ensuring the coaxial I-type layout of planetary reducer A, torque limiter B and motor C.

[0057] In an optional embodiment, the outer circumferential diameter of the sun gear shaft extension end 5 below planetary reducer A is the same as the outer circumferential diameter of the shaft extension end of the motor shaft connecting plate 3 below torque limiter B, and the inner circumferential diameter of the bushing 2 above torque limiter B is the same as the inner circumferential diameter of the output shaft 4 above motor C. This arrangement ensures that the connection structure between planetary reducer A, torque limiter B, and motor C remains consistent, allowing the three modules to be assembled in any pair. Either torque limiter B can be placed between planetary reducer A and motor C to protect the drive and transmission system components from damage caused by excessive torque, or planetary reducer A and motor C can be directly connected, reducing the overall size of the semi-direct drive device. This design increases the structural flexibility of the semi-direct drive device, better meets the needs of various operating environments, and improves the adaptability of the semi-direct drive device.

[0058] like Figure 1 As shown, torque limiter B can be a friction torque limiter, which may include bolts, a left pressure plate 12, a partition group 13, a friction plate group 14, a right pressure plate 15, and an elastic element. The torque limiter B also has a concave bushing 2 and a motor shaft connecting plate 3, with the bottom end face of the bushing 2 fixedly connected to the motor shaft connecting plate 3. Both the partition group 13 and the friction plate group 14 are annular, arranged sequentially at intervals, with each plate fitting against the others. The outer ring diameter of the partition group 13 is larger than that of the friction plate group 14. Bolts pass sequentially through the left pressure plate 12, the partition group 13, and the right pressure plate 15 and are tightened, causing the partition group 13 and the friction plate group 14 to fit against each other between the left and right pressure plates 12 and 15. Simultaneously, the left and right pressure plates 12 and 15 apply axial preload to the partition group 13 and the friction plate group 14 through the elastic element, axially pressing the partition group 13 and the friction plate group 14 together. In an optional embodiment, the elastic element can be a spring, with one end abutting the bolt head and the second end abutting the left pressure plate 12 or the right pressure plate 15, thereby forming axial compression. The inner circumferential surface of the friction plate assembly 14 and the outer circumferential surface of the bushing 2 are connected by splines or other means. The inner ring diameter of the partition plate assembly 13 is larger than the outer circumferential diameter of the bushing 2, and there is no direct connection between the partition plate assembly 13 and the bushing 2. Using a friction torque limiter can protect critical components of the drive system from damage caused by excessive torque due to instantaneous impacts and long-term overloads. In other optional embodiments, other types of torque limiters can also be selected, as long as they provide a protective effect.

[0059] As shown in the figure, brake D can be an electromagnetic toothed brake, which may include an electromagnetic coil 8, a set of engaging teeth 9, a drive disc 10, a thrust spring, and a sleeve 11. The electromagnetic coil 8 is embedded inside the rear end cover 7 of the motor. The set of engaging teeth 9 may include a first engaging tooth and a second engaging tooth, which are normally open and opposed to each other. The first engaging tooth is fixed to the rear end cover 7 of the motor, and the second engaging tooth is fixed to the drive disc 10. An axially fixed retaining ring is provided on the shaft of the motor C. The first end of the thrust spring abuts against the drive disc 10, and the second end abuts against the retaining ring. The thrust spring provides axial traction force to the drive disc 10, causing the drive disc 10 to disengage the second engaging tooth from the first engaging tooth. The inner circumferential surface of the drive disc 10 and the outer circumferential surface of the shaft of the motor C are connected by splines or other means, so that the drive disc 10 is circumferentially fixed to the shaft of the motor C.

[0060] When brake D is engaged, electromagnetic coil 8 is energized to engage drive disc 10. Drive disc 10 overcomes axial traction force, thereby driving the second meshing tooth to engage with the first meshing tooth, braking the shaft of motor C. When the brake is released, electromagnetic coil 8 is de-energized, and thrust spring disengages drive disc 10, which then rotates with bushing 2 along with the shaft. Using a jaw brake instead of the existing "hydraulic motor + large gear" braking structure eliminates the need for a hydraulic motor component, significantly reducing the overall size of the semi-direct drive device and saving installation space. Furthermore, integrating the electromagnetic jaw brake directly into the tail of motor C further reduces the size of the semi-direct drive system and improves its adaptability to the confined spaces of coal mine working faces.

[0061] Figure 2 This is a cross-sectional view of a planetary reducer according to an embodiment of the present invention.

[0062] The planetary reducer A in the figure is connected to the motor C. The first-stage sun shaft 28 of the planetary reducer A is connected to the output shaft 4 of the motor C via an input external spline 16, illustrating one assembly method of the modular semi-direct drive device 1 for conveyors of the present invention. If necessary, a torque limiter B can be added between the planetary reducer A and the motor C. The first-stage sun shaft 28 of the planetary reducer A is connected to the bushing of the torque limiter B via an input external spline 16. This flexible assembly method improves the adaptability of the semi-direct drive device to different working conditions.

[0063] As shown in the diagram, planetary reducer A is a two-stage planetary reducer, which may include a reducer housing 20, a high-speed stage mechanism, and a low-speed stage mechanism. The high-speed stage mechanism may include a first-stage sun shaft 28, a first-stage sun gear 29, first-stage planet gears 18, a first-stage planet carrier 32, and a first-stage internal gear ring 30. The first-stage sun gear 29 is mounted on the first-stage sun shaft 28. The first-stage planet gear 18 is positioned between the first-stage sun gear 29 and the first-stage internal gear ring 30, with the first-stage sun gear 29 meshing with the first-stage planet gear 18, and the first-stage planet gear 18 meshing with the first-stage internal gear ring 30. The first-stage planet gear 18 is connected to the first-stage planet carrier 32. The outer cylindrical surface of the first-stage internal gear ring 30 has a clearance fit with the inner cylindrical surface of the reducer housing 20. The first-stage internal gear ring 30 and the reducer housing 20 are radially positioned by a locating cylindrical pin 31 and axially connected by a connecting bolt 19. The first-stage sun shaft 28 is a fully floating, independently mounted part. It has no axial or radial positioning or connection constraints with the reducer housing 20. It can be inserted into the planetary reducer A from the input end after the planetary reducer A is assembled.

[0064] The low-speed stage mechanism may include a secondary sun shaft 25, a secondary sun gear, secondary planetary gears 33, a secondary planetary carrier 26, and a secondary internal gear ring 21. The secondary sun gear is mounted on the secondary sun shaft 25, and the secondary planetary gears 33 are positioned between the secondary sun gear and the secondary internal gear ring 21. The secondary sun gear meshes with the secondary planetary gears 33, and the secondary planetary gears 33 mesh with the secondary internal gear ring 21. The secondary planetary gears 33 are connected to the secondary planetary carrier 26 via full complement cylindrical roller bearings 22, and the secondary internal gear ring 21 is integrally formed with the reducer housing 20.

[0065] The inner cylindrical surface of the first-stage planetary carrier 32 in the high-speed stage mechanism is connected to the outer cylindrical surface of the second-stage sun gear in the low-speed stage mechanism through the second-stage spline 17, thereby connecting the first-stage planetary gear 18 to the second-stage sun shaft 25.

[0066] With this design, the high-speed stage mechanism of planetary reducer A can be disassembled and replaced. In an optional embodiment, two or more high-speed stage mechanisms of different specifications can be used, sharing the same low-speed stage mechanism. According to the speed requirements of the actual working environment, the transmission ratio of planetary reducer A can be changed by replacing the high-speed stage mechanism, thereby improving the adaptability of the semi-direct drive device.

[0067] As shown in the figure, the input end of planetary reducer A is the first-stage sun shaft 28, which is connected to motor C or torque limiter B via input external spline 16. The output end of planetary reducer A is the second-stage planet carrier 26, which is connected to the second-stage planet gears 33 to form output internal spline 24, through which output is achieved.

[0068] As shown in the figure, the secondary internal gear ring 21 and the reducer housing 20 are integrally formed. Meanwhile, the secondary planetary carrier 26 is supported by a pair of bearings of different specifications; the diameter of the inner bearing 27 is smaller than the diameter of the outer bearing 23. The secondary planetary carrier 26 has a recessed platform on its inner peripheral wall away from the output end, and the outer circumference of the inner bearing 27 engages with this platform. The secondary planetary carrier 26 also has an outer recessed platform on its outer peripheral wall near the output end, and the inner circumference of the outer bearing 23 engages with this platform. This design reduces the axial dimension and volume of the planetary reducer A, further reducing the size of the semi-direct drive device.

[0069] Figure 3 This is a schematic block diagram of an embodiment of the adaptive control system according to the present invention.

[0070] As shown in the figure, the adaptive control system may include a frequency converter control mechanism, a position feedback system, a control coordination unit, and the modular semi-direct drive device for conveyors of the present invention. The frequency converter control mechanism may include a frequency converter E and a built-in encoder, with the built-in encoder integrated on the frequency converter E.

[0071] The position feedback system may include a sensor module and a signal processing module. In an optional embodiment, the sensor module includes a first magnetic block, a second magnetic block, a first Hall sensor, a second Hall sensor, and a rotary transformer. The first magnetic block is disposed on the shaft at the input end of the torque limiter B, and the second magnetic block is disposed on the shaft at the output end of the torque limiter B. The first and second magnetic blocks are positioned at the same angle, ensuring that their signal triggering sequence is identical during normal synchronous rotation. The first and second Hall sensors are respectively positioned at the locations of their corresponding rotational trajectories. When the semi-direct drive device is running, the torque limiter B in normal operation drives the first and second magnetic blocks to rotate synchronously, causing the first and second Hall sensors to generate consistent first and second pulse signals. These signals reflect the motion pattern of the first and second magnetic blocks. When the torque limiter B slips, fails, or detaches, the first and second pulse signals will exhibit phase differences or abnormal fluctuations.

[0072] In an optional embodiment, the first Hall sensor can be mounted on motor C, and the second Hall sensor can be mounted on planetary reducer A. In other optional embodiments, a cover can be provided on the outside of torque limiter B, and the first Hall sensor and the second Hall sensor can be mounted at corresponding positions on the inside of the cover. The positions of the Hall sensors can be set according to actual conditions, but must meet the sensing threshold requirements with the magnetic block, so that the distance between the first magnetic block and the first Hall sensor, and between the second magnetic block and the second Hall sensor, can obtain accurate sensing results. Generally, the distance between the sensor and the magnetic block is 3-5mm. With this setting, the first Hall sensor can collect the first pulse signal in real time, and the second Hall sensor can collect the second pulse signal in real time, and transmit the first pulse signal and the second pulse signal to the signal processing module, which then transmits them to the frequency converter E. The frequency converter E determines the state of torque limiter B based on the received first pulse signal and second pulse signal.

[0073] The rotary transformer can be installed inside the motor C, such as integrated into the rear end cover 7 of the motor, and connected to the output shaft 4 to collect the operating condition signals of the motor C in real time. The rotary transformer transmits the operating condition signals to the signal processing module, which then transmits them to the control coordination unit. Based on the received operating condition signals, the control coordination unit divides the real-time operating conditions and correlates them with the operating torque of the modular semi-direct drive device 1 for the conveyor, thereby determining the control torque of the motor C. Based on the correlated control torque, it generates the output frequency parameters of the frequency converter E and transmits them to the frequency converter control mechanism. The frequency converter control mechanism controls the motor C through the frequency converter E based on the received output frequency parameters. In other optional embodiments, different sensor types and setting methods can be selected according to actual needs, such as Hall sensors, gear encoders, displacement sensors, etc., as long as they can collect the working status of the semi-direct drive device in real time.

[0074] Figure 4 This is a flowchart of an embodiment of the method for determining the state of the torque limiter in the adaptive control method according to the present invention.

[0075] The adaptive control method of this invention first determines the state of the torque limiter B. When there is no torque limiter in the semi-direct drive device, the motor C is controlled by different control torques and the overload protection algorithm of the frequency converter E. When a torque limiter is present in the semi-direct drive device and the torque limiter is working normally, the semi-direct drive device is controlled by different control torques and the torque limiter B. When the torque limiter is in a state of slight slippage, the control coordination unit issues a warning signal. When the torque limiter is in a state of severe slippage or failure, the control coordination unit brakes and stops the modular semi-direct drive device 1 for the conveyor through the brake D. When the torque limiter is in a state of detachment, the control coordination unit issues an alarm signal and brakes and stops the modular semi-direct drive device 1 for the conveyor through the brake D.

[0076] As shown in the figure, when determining the state of torque limiter B, the presence of torque limiter B in the modular semi-direct drive device 1 for the conveyor is first determined. When the modular semi-direct drive device 1 for the conveyor is running under no-load conditions, the pulse signal of torque limiter B under normal rotation is recorded, and the calibration pulse period P and the calibration pulse trigger time difference ΔS0 between the first Hall sensor and the second Hall sensor are obtained. Generally, when ΔS0 ≤ 5ms, it can be considered that the first and second magnetic blocks are operating synchronously. In different embodiments, different judgment threshold standards can be adjusted according to the actual situation.

[0077] After the modular semi-direct drive device 1 for the conveyor is started and running, the inverter E monitors in real time the first pulse period P1 of the first Hall sensor, the second pulse period P2 of the second Hall sensor, and the first pulse trigger time difference ΔS1 of the first Hall sensor and the second Hall sensor during the duration of three consecutive calibration pulse periods P.

[0078] When the first Hall sensor and the second Hall sensor both have stable output signals for three consecutive calibration pulse periods P, and If the first pulse trigger time difference ΔS1 ≤ 10ms, then the state of torque limiter B is determined to be that a torque limiter exists.

[0079] When the first Hall sensor or the second Hall sensor has no output signal for three consecutive calibration pulse periods P, Furthermore, the first pulse period P1 did not recover within the duration of two consecutive calibration pulse periods P. Furthermore, if the second pulse period P2 fails to recover within the duration of two consecutive calibration pulse periods P, or if the first pulse trigger time difference ΔS1 > 20ms and fluctuates irregularly at any of these times, the state of the torque limiter B will be determined as an unlimited torque device.

[0080] In other optional embodiments, the deviation thresholds of the first pulse period P1 and the calibration pulse period P, the deviation thresholds of the second pulse period P2 and the calibration pulse period P, and the time difference threshold of the first pulse trigger time difference ΔS1 can also be selected with different values ​​according to the actual situation. Among them, the deviation threshold of the pulse period needs to be sufficient to exclude signal abnormalities caused by sensor failure or missing magnetic blocks, and the time difference threshold of the pulse trigger time difference needs to allow for slight mechanical errors. If the deviation exceeds the threshold range, the first magnetic block and the second magnetic block are considered to be rotating out of sync.

[0081] After determining that torque limiter B exists, the operating state of torque limiter B is further assessed. Inverter E continuously monitors and acquires the second pulse trigger time difference ΔS2 and the pulse signal fluctuation coefficient K from the first Hall sensor and the second Hall sensor.

[0082]

[0083] P (real-time) is the real-time pulse cycle of the operation.

[0084] When ΔS2 ≤ 10ms and K ≤ 15%, the torque limiter B is considered to be working normally. When 10ms < ΔS2 < 50ms is met for two consecutive real-time pulse cycles, the torque limiter B is considered to be slightly slipping. When 50ms ≤ ΔS2 or an irregular phase difference is met for one real-time pulse cycle, the torque limiter B is considered to be severely slipping or malfunctioning. When any one of the following conditions is met: no signal from the first Hall sensor, no signal from the second Hall sensor, or K > 30%, the torque limiter B is considered to be detached.

[0085] In other optional embodiments, the time difference threshold of the second pulse trigger time difference ΔS2 and the deviation threshold of the pulse signal fluctuation coefficient K can also be selected with different values ​​according to the actual situation. Specifically, the time difference threshold of the second pulse trigger time difference ΔS2 needs to be sufficient to determine whether the rotational synchronization of the first and second magnetic blocks is normal, and the deviation threshold of the fluctuation coefficient K needs to be sufficient to determine whether the periodicity of the pulse signal is abnormal.

[0086] By determining the state of the torque limiter, corresponding adaptive control methods can be implemented for two different situations, with and without the addition of a torque limiter, thereby improving the adaptability of the control method to different operating conditions.

[0087] Figure 5 This is a flowchart of an embodiment of the adaptive control method according to the motor operating conditions in the present invention.

[0088] As can be seen from the figure, after the semi-direct drive device of the present invention starts to operate, the frequency converter E issues a target speed and controls the rotation of the motor C according to the target speed shown. During operation, the control coordination unit receives the operating condition signal of the motor C collected by the sensor through the signal processing module, thereby obtaining the current speed of the motor C and judging the magnitude of the current load torque. According to the load torque situation, the control coordination unit takes different control measures for the semi-direct drive device, such as controlling the rotation of the motor C according to the target speed shown, performing torque limiting or electronic overload protection, and performing braking.

[0089] In an optional embodiment, the position feedback system transmits the collected operating condition signal to the signal processing module, and the signal processing module transmits it to the control coordination unit. The control coordination unit processes and calculates the collected real-time operating condition information and outputs it as a detection value α, and records the duration corresponding to the detection value α. The processing and calculation method is designed according to the type of sensor used and the actual control requirements.

[0090] Set the time period t, the first threshold Q1, the second threshold Q2, and the third threshold Q3 according to the actual situation, where Q1 < Q2 < Q3. The control coordination unit compares the detection value α with the preset threshold to judge the working condition. When the detection value α < the first threshold Q1 and the duration is greater than t, the working condition is judged as a light load condition; when the first threshold Q1 < the detection value α < the second threshold Q2 and the duration is greater than t, the working condition is judged as a full load condition; when the detection value α > the third threshold Q3 and the duration is greater than t, the working condition is judged as a heavy load condition.

[0091] The control coordination unit performs correlation analysis on the judged working condition and the control torque of the motor C, and adjusts the output frequency parameter of the frequency converter E according to the target control torque, thereby controlling the rotation of the motor C. Set the first torque T1, the second torque T2, and the third torque T3 according to the actual requirements, where T1 < T2 < T3. When in the light load condition, the frequency converter E controls the motor C to operate at the first torque T1; when in the full load condition, the frequency converter E controls the motor C to operate at the second torque T2; when in the heavy load condition, the frequency converter E controls the motor C to operate at the third torque T3.

[0092] Set the rated torque Tn according to the actual situation. As can be seen from the figure, when the position feedback system detects that the torque value of the motor C ≥ 3Tn, in an optional embodiment, the working condition can be judged as an impact condition, and different control methods are implemented according to the two situations where the torque converter and the torque limiter are working properly.

[0093] Under impact conditions, when torque limiter B is present in the semi-direct drive unit and is functioning normally, the modular semi-direct drive unit 1 of the conveyor protects the semi-direct drive unit and the entire machine through torque limiter B. At this time, the working surface of the scraper conveyor transmits a large peak torque to the semi-direct drive unit for a short period. The friction plate group 14 and the partition group 13 inside torque limiter B slip and rub against each other, converting the impact kinetic energy into frictional heat energy, thereby smoothing out the peak torque, i.e., controlling the transmitted torque within a set range to protect the entire semi-direct drive unit. When the peak torque disappears, the transmitted torque returns to the set range, torque limiter B returns to the locked state, and the system continues to operate normally.

[0094] When the torque converter B is in place in the semi-direct drive unit, the modular semi-direct drive unit 1 of the conveyor protects the semi-direct drive unit and the entire machine through the electrical overload protection algorithm of the frequency converter E. The electrical overload protection algorithm is a control algorithm set in the frequency converter E, which adjusts the output frequency of the frequency converter E according to the real-time current of the motor C. Under impact conditions, the frequency converter E reduces the output frequency through the electrical overload protection algorithm, thereby suppressing the torque of the motor C to within the set range.

[0095] When braking of the semi-direct drive unit is required, the control coordination unit brakes the modular semi-direct drive unit 1 of the conveyor via brake D, causing the speed of motor C to decrease rapidly until the semi-direct drive unit stops operating. The semi-direct drive unit is restarted when necessary. In other alternative embodiments, different measures can be taken according to the requirements of safe operation and efficient maintenance.

[0096] This adaptive control system and method dynamically adjusts the control torque and emergency protection methods of the semi-direct drive unit based on the actual state of the torque limiter and the real-time load of the motor. This allows the control torque to match changes in load such as transport volume and material resistance in real time, improving transport efficiency and stability. Simultaneously, it enables rapid response and timely handling of different operating conditions, preventing irreversible damage to the semi-direct drive unit and the entire machine from impact conditions, thus enhancing production safety and extending the service life of the semi-direct drive unit and the entire machine.

[0097] The technical scope of this invention is not limited to the contents of the above specification. Those skilled in the art can make various modifications and variations to the above embodiments without departing from the technical concept of this invention, and all such modifications and variations should fall within the scope of this invention.

Claims

1. A modular semi-direct drive device (1) for conveyors, characterized by, The modular semi-direct drive device (1) for the conveyor includes a motor (C) and a planetary reducer (A), and a torque limiter (B) is provided between the motor (C) and the planetary reducer (A). A brake (D) is provided at one end of the motor (C) away from the planetary reducer (A). The motor (C), the planetary reducer (A), the torque limiter (B) and the brake (D) are aligned along the same axis, and the motor (C), the planetary reducer (A), the torque limiter (B) and the brake (D) are all independently detachable modules. The housing of the torque limiter (B) is connected to the housing of the motor (C) and the housing of the planetary reducer (A) respectively via flanges; The modular semi-direct drive device (1) for the conveyor is also equipped with a frequency conversion control mechanism, a position feedback system, and a control coordination unit, wherein, The frequency conversion control mechanism includes a frequency converter (E) and a built-in encoder, wherein the built-in encoder is integrated on the frequency converter (E); The position feedback system includes a sensor module and a signal processing module. The sensor module includes a first magnetic block, a second magnetic block, a first Hall sensor, a second Hall sensor, and a rotary transformer. The first magnetic block is disposed on the shaft at the input end of the torque limiter (B), and the second magnetic block is disposed on the shaft at the output end of the torque limiter (B). The first magnetic block and the second magnetic block are disposed at the same angle. The first Hall sensor is disposed on the motor (C) to collect a first pulse signal representing the motion law of the first magnetic block in real time and transmit it to the signal processing module. The second Hall sensor is disposed on the planetary reducer (A) to collect a second pulse signal representing the motion law of the second magnetic block in real time and transmit it to the signal processing module. The rotary transformer is disposed inside the motor (C) and connected to the output shaft (4) of the motor (C). The rotary transformer is used to collect the operating condition signal of the motor (C) in real time and transmit it to the signal processing module. The inverter receives the first pulse signal and the second pulse signal from the signal processing module and determines the state of the torque limiter (B) based on the first pulse signal and the second pulse signal. The control coordination unit receives the operating condition signal of the motor (C) from the signal processing module. The control coordination unit determines the control torque of the motor (C) based on the determined state of the torque limiter (B) and the operating condition signal of the motor (C), and generates the output frequency parameter of the inverter (E) based on the control torque. The frequency conversion control mechanism receives and controls the motor (C) through the inverter (E) according to the output frequency parameter. The control method of the frequency converter control mechanism includes: Step 1: The sensor module collects the first pulse signal, the second pulse signal, and the operating condition signal of the motor (C) and transmits them to the signal processing module; Step II: The signal processing module processes the first pulse signal, the second pulse signal, and the operating condition signal of the motor (C), and transmits the processed first pulse signal and the second pulse signal to the frequency converter (E), and transmits the processed operating condition signal of the motor (C) to the control coordination unit; Step III: The inverter (E) determines the state of the torque limiter (B) based on the first pulse signal and the second pulse signal. When the state of the torque limiter (B) is determined to be an indefinite torque limiter, it proceeds to step IV. When the state of the torque limiter (B) is determined to be a normal torque limiter, it proceeds to step V. When the state of the torque limiter (B) is determined to be a slight slippage, the control coordination unit issues a warning signal. When the state of the torque limiter (B) is determined to be a severe slippage or failure, the control coordination unit brakes and stops the modular semi-direct drive device (1) for the conveyor through the brake (D). When the state of the torque limiter (B) is a torque limiter detachment, the control coordination unit issues an alarm signal and brakes and stops the modular semi-direct drive device (1) for the conveyor through the brake (D). Step IV: The control and coordination unit processes the collected operating conditions and outputs a detection value α. Based on the detection value α, it determines whether the operating condition is light load, full load, heavy load, or impact condition. When the detection value α < the first threshold Q1 and the duration is greater than t, it is determined to be a light load condition. The output frequency parameter of the inverter (E) is adjusted to make the motor (C) run at a first torque T1. When the first threshold Q1 < the detection value α < the second threshold Q2 and the duration is greater than t, it is determined to be a full load condition. The inverter (E) is adjusted to make the motor (C) run at a second torque T2. When the detected value α > the third threshold Q3 and the duration is greater than t, it is determined to be a heavy load condition. The inverter (E) is adjusted to make the motor (C) run at a third torque T3. When the position feedback system detects that the torque value of the motor (C) is ≥3Tn, it is determined to be an impact condition. The inverter (E)'s overload protection algorithm is used to limit the power of the motor (C). Step V: The control and coordination unit processes the collected operating conditions and outputs a detection value α. Based on the detection value α, it determines whether the operating condition is light load, full load, heavy load, or impact condition. When the detection value α < the first threshold Q1 and the duration is greater than t, it is determined to be a light load condition. The output frequency parameter of the inverter (E) is adjusted to make the motor (C) run at a first torque T1. When the first threshold Q1 < the detection value α < the second threshold Q2 and the duration is greater than t, it is determined to be a full load condition. By adjusting the output frequency parameters of the inverter (E), the motor (C) is made to run at the second torque T2; when the detected value α > the third threshold Q3 and the duration is greater than t, it is determined to be a heavy load condition, and by adjusting the output frequency parameters of the inverter (E), the motor (C) is made to run at the third torque T3; when the position feedback system detects that the torque value of the motor (C) is ≥3Tn, it is determined to be an impact condition, and the torque limiter (B) is used to limit the torque of the modular semi-direct drive device (1) for the conveyor. Among them, the first threshold Q1, the second threshold Q2, the third threshold Q3, the first torque T1, the second torque T2, the third torque T3, the time period t, and the rated torque Tn are preset values, and Q1 <Q2<Q3,T1<T2<T3。 2. Modular semi-direct drive device (1) for conveyors according to claim 1, characterized in that, The modular semi-direct drive device (1) for the conveyor has a frequency converter (E) for controlling the motor (C), one end of the frequency converter (E) is connected to the motor (C), and the other end of the frequency converter (E) is connected to the planetary reducer (A).

3. Modular semi-direct drive device (1) for conveyors according to claim 1, characterized in that, The torque limiter (B) includes a bushing (2) and a motor shaft connecting plate (3). The output shaft (4) of the motor (C) is connected to the motor shaft connecting plate (3) of the torque limiter (B). The bushing (2) of the torque limiter (B) is connected to the sun gear shaft extension end (5) of the planetary reducer (A). The connection part of the output shaft (4) of the motor (C) has the same structure as the connection part of the bushing (2) of the torque limiter (B). The connection part of the motor shaft connecting plate (3) of the torque limiter (B) has the same structure as the connection part of the sun gear shaft extension end (5) of the planetary reducer (A). The torque limiter (B) can be removed so that the planetary reducer (A) can be directly connected to the motor (C).

4. Modular semi-direct drive device (1) for conveyors according to claim 1, characterized in that, The brake (D) and the motor (C) are an integrated structure. The motor (C) includes a main motor housing (6) and a rear end cover (7). The brake (D) is integrated within a closed cavity structure formed by the main motor housing (6) and the rear end cover (7). Furthermore, the brake (D) is an electromagnetic toothed brake, including a drive disc (10) and a set of engaging teeth (9). The set of engaging teeth (9) includes a first and a second engaging tooth that are normally open and facing each other. The first engaging tooth is fixed to the rear end cover (7). The second engagement tooth is fixed to the drive disc (10), and an electromagnetic coil (8) is embedded in the rear end cover (7) of the motor. The drive disc (10) is circumferentially fixed to the shaft of the motor (C), and the drive disc (10) is subjected to axial traction force, causing the second engagement tooth to disengage from the first engagement tooth. When the brake (D) is working, the electromagnetic coil (8) is energized and attracts the drive disc (10), so that the drive disc (10) overcomes the axial traction force and drives the second engagement tooth to engage the first engagement tooth to achieve braking.

5. Modular semi-direct drive device (1) for conveyors according to claim 4, characterized in that, An axially fixed retaining ring is provided on the rotating shaft of the motor (C), and a thrust spring is provided between the retaining ring and the drive disc (10), the thrust spring providing the axial traction force.

6. Modular semi-direct drive device (1) for conveyors according to claim 1, characterized in that, The planetary reducer (A) includes a reducer housing (20), a high-speed stage mechanism, and a low-speed stage mechanism. The high-speed stage mechanism includes a first-stage sun shaft (28), a first-stage sun gear (29), a first-stage planetary gear (18), a first-stage planetary carrier (32), and a first-stage internal gear ring (30). The low-speed stage mechanism includes a second-stage sun shaft (25), a second-stage sun gear, a second-stage planetary gear (33), a second-stage planetary carrier (26), and a second-stage internal gear ring (21). The first-stage sun gear (29) is mounted on the first-stage sun shaft (28), the first-stage planetary gear (18) is disposed between the first-stage sun gear (29) and the first-stage internal gear ring (30), and the first-stage planetary carrier (32) is connected to the first-stage internal gear ring (21). The first-stage planetary gear (18) is connected to the second-stage sun shaft (25). The outer cylindrical surface of the first-stage internal gear ring (30) is clearance-fitted with the inner cylindrical surface of the reducer housing (20). The second-stage sun gear is installed on the second-stage sun shaft (25). The second-stage planetary gear (33) is located between the second-stage sun gear and the second-stage internal gear ring (21). The second-stage planetary carrier (26) connects to the second-stage planetary gear (33) and forms an internal spline output shaft. The second-stage internal gear ring (21) and the reducer housing (20) are an integral structure. The first-stage sun shaft (28) is connected to the motor (C). The internal spline of the second-stage planetary carrier (26) constitutes the output end of the planetary reducer (A).

7. Modular semi-direct drive device (1) for conveyors according to claim 1, characterized in that, The torque limiter (B) is a friction torque limiter, which includes a left pressure plate (12), a right pressure plate (15), and a partition plate group (13) and a friction plate group (14) arranged in sequence at intervals and with each plate in contact with the others. The friction plate group (14) is set on the bushing (2) of the torque limiter (B) by a spline. The friction torque limiter has a bolt that passes through the left pressure plate (12), the partition plate group (13) and the right pressure plate (15) for fastening. The stud of the bolt is fitted with a spring for pressing the left pressure plate (12) and the right pressure plate (15). The first end of the spring abuts against the bolt head of the bolt, and the second end of the spring abuts against the left pressure plate (12) or the right pressure plate (15), thereby axially pressing the partition plate group (13) and the friction plate group (14).

8. Modular semi-direct drive device (1) for conveyors according to claim 1, characterized in that, The method by which the frequency converter (E) determines the state of the torque limiter (B) includes: Step 1: Determine whether a torque limiter exists in the modular semi-direct drive device (1) for the conveyor; and Step 2: Determine if the torque limiter is working properly. Step one includes: after the modular semi-direct drive device (1) for the conveyor is started, the frequency converter (E) monitors in real time the first pulse period P1 of the first Hall sensor, the second pulse period P2 of the second Hall sensor, and the first pulse trigger time difference ΔS1 of the first Hall sensor and the second Hall sensor for three consecutive calibration pulse periods P. When the first Hall sensor and the second Hall sensor both have stable output signals for three consecutive calibration pulse periods P, and Furthermore, if the first pulse trigger time difference ΔS1 ≤ 10ms, it is determined that a torque limiter exists. This is further confirmed when either the first Hall sensor or the second Hall sensor has no output signal for three consecutive calibration pulse periods P. Furthermore, the first pulse period P1 did not recover within the duration of two consecutive calibration pulse periods P. Furthermore, if the second pulse period P2 fails to recover within the duration of two consecutive calibration pulse periods P, or if the first pulse trigger time difference ΔS1 > 20ms and fluctuates irregularly, it is determined to be an infinite torque device. The calibration pulse period P, the calibration pulse trigger time difference ΔS0 of the first Hall sensor and the second Hall sensor are obtained based on the pulse signal of the torque limiter (B) during normal rotation recorded by the modular semi-direct drive device (1) for the conveyor during no-load operation. Step two includes: after determining that a torque limiter exists, the inverter (E) continuously monitors the first Hall sensor and the second Hall sensor, and obtains the second pulse trigger time difference ΔS2 and the pulse signal fluctuation coefficient K of the first Hall sensor and the second Hall sensor, wherein, P (real time) is the running real-time pulse period, When ΔS2≤10ms and K≤15%, the torque limiter is considered to be working normally. When the condition 10ms < ΔS2 < 50ms is met and continues for two consecutive real-time pulse cycles, it is determined that the torque limiter is slightly slipping. When 50ms≤ΔS2 is satisfied and continues for one real-time pulse cycle, it is determined that the torque limiter is severely slipping or has failed. The torque limiter is determined to have detached when any one of the following conditions is met: no signal from the first Hall sensor, no signal from the second Hall sensor, or K > 30%.

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