A device and method for real-time torsion detection of a circular pipe belt conveyor based on electromagnetic displacement feedback
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- TAI YUAN XIANG MING JI XIE ZHI ZAO YOU XIAN GONG SI
- Filing Date
- 2025-12-04
- Publication Date
- 2026-07-21
Smart Images

Figure CN121292046B_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the technical field of circular tube belt conveyors, specifically relating to a device and method for real-time torsion detection of circular tube belt conveyors based on electromagnetic displacement feedback. Background Technology
[0002] The circular tube belt conveyor is a new type of bulk material conveying equipment that rolls the conveyor belt into a circular tube shape. It can realize long-distance closed conveying of bulk materials, adapt to complex terrain, and easily realize complex spatial turning arrangements. There is no spillage or dust during transportation, truly achieving environmentally friendly transportation.
[0003] However, under complex operating conditions, the conveyor belt is prone to twisting. Chinese patent CN205221937U discloses an anti-twist detection system for a tubular belt conveyor, including a proximity switch and a control unit. The proximity switch is set at the torsion limit position of the conveyor belt of the tubular belt conveyor to detect when the conveyor belt twists to the point that its left or right edge reaches the torsion limit position and triggers a signal. The control unit issues an alarm or controls the tubular belt conveyor to stop based on the trigger signal. The torsional limit position is located above the front and / or rear unfolded sections of the conveyor belt, and within the longitudinal plane containing the vertical centerline of the pipe section of the conveyor belt. The distance L between the pipe section and the end of the pipe section is 4R to 6R, where R represents the pipe radius of the pipe section.
[0004] Existing torsion detection devices are mostly conveyor belt torsion detection systems based on photoelectric sensors, but they are easily affected by dust and external light, and the background algorithm is complex. Summary of the Invention
[0005] In order to solve at least one of the above-mentioned technical problems in the prior art, the present invention provides a device and method for real-time torsion detection of a circular tube belt conveyor based on electromagnetic displacement feedback.
[0006] The present invention is achieved by the following technical solution: a device for real-time torsion detection of a circular tube belt conveyor based on electromagnetic displacement feedback, comprising a control terminal and a torsion detection subsystem arranged at longitudinal intervals along the conveyor truss; The torsion detection subsystem includes an upper magnetostrictive displacement torsion detector, a lower magnetostrictive displacement torsion detector, and a local controller. The upper and lower magnetostrictive displacement torsion detectors are respectively installed on both sides of the window plate of each truss of the circular tube belt conveyor, with the upper magnetostrictive displacement torsion detector located at the lower end of the upper conveyor belt of the circular tube belt conveyor and the lower magnetostrictive displacement torsion detector located at the upper end of the lower conveyor belt of the circular tube belt conveyor. The local controllers of all torsion detection subsystems are connected to the control terminal. The upper magnetostrictive displacement torsion detector and the lower magnetostrictive displacement torsion detector have the same structure, both including a base frame, a pendulum wheel-gear-rack transmission assembly mounted on the base frame, and a displacement detection module for detecting displacement analog signals; The pendulum wheel-gear-rack transmission assembly includes a pendulum wheel, a gear, and a rack. The pendulum wheel includes an inner wheel, an inner spindle, a base, and a face plate. The inner spindle is shaft-connected to the gear. The base and face plate are fixed at both ends of the inner spindle. Multiple inner wheels are circumferentially spaced and connected within the space enclosed by the base and face plates, with their surfaces extending out to contact the conveyor belt. The surface of the inner wheels has raised patterns distributed at equal angles. The gear is coaxially connected to the pendulum wheel and meshes with the rack for transmission. The displacement detection module includes a magnetostrictive displacement sensor, a guide spindle, and a magnetic ring. The magnetic ring is fixedly connected to the rack via a connecting plate and slidably connected to the guide spindle. The magnetostrictive displacement sensor is located at one end of the guide spindle. When the conveyor belt is running normally, the inner wheel in contact with it rotates freely in its original position. When the conveyor belt twists, a rotational torque is generated through the contact of the raised patterns. The change in the position of the inner wheel drives the inner spindle to rotate, which in turn causes the gear to rotate, causing the rack to produce lateral displacement. A displacement analog signal is generated through the coupling effect between the magnetic ring and the magnetostrictive displacement sensor.
[0007] Preferably, the base frame is suspended from the conveyor frame by an elastic rod, and the height of the base frame is adjusted by the elastic rod to keep the inner wheel in contact with the conveyor belt.
[0008] Preferably, the inner wheel's surface is in contact with the conveyor belt, and the velocity direction of the contact point between the inner wheel and the conveyor belt is the same as the conveying direction of the conveyor belt.
[0009] Preferably, the rack is slidably connected to the base frame, and the base frame is provided with a lateral guide wheel and a vertical guide wheel for lateral and vertical sliding limit of the rack.
[0010] Preferably, the flower wheel also includes a separator assembly, which is circumferentially connected to the chassis and the front plate by bolts and is used to separate adjacent inner wheels.
[0011] Preferably, each truss section corresponds to a torsion detection subsystem, and the distance between the upper magnetostrictive displacement torsion detector and the lower magnetostrictive displacement torsion detector is the circumference of the conveyor belt.
[0012] Preferably, the local controller is enclosed in an IP67 protected enclosure and connects the sensor and actuator via an M12 interface.
[0013] In a second aspect, the present invention also provides a method for real-time torsion detection of a circular tube belt conveyor based on electromagnetic displacement feedback, comprising the following steps: S1: Perform preload calibration of the plum blossom wheel; and zero-point calibration of the upper and lower magnetostrictive displacement torsion detectors; S2: When the conveyor belt twists, the inner wheel in contact with it generates a rotational torque. The change in the position of the inner wheel drives the inner spindle to rotate, which in turn transmits the torque to the gear shaft, causing the gear to rotate and driving the rack to generate a lateral linear displacement. The rack drives the magnetic ring to slide on the guide spindle, changing the positional relationship with the magnetostrictive displacement sensor. Through the coupling effect between the magnetic ring and the magnetostrictive displacement sensor, the magnetostrictive displacement sensor generates a displacement analog signal. S3: The local controller processes data based on displacement analog signals to calculate the twist angle of the conveyor belt. S4: When the conveyor belt twist angle is less than or equal to ±45°, no adjustment is made. When the conveyor belt twist angle is detected to be greater than ±45°, the local controller sends a twist fault signal and the value of the conveyor belt twist angle for every 5° increase in the twist angle.
[0014] Preferably, in step S1, the preload calibration of the flower wheel includes: adjusting the height of the base frame by means of the elastic rod so that the contact pressure between the flower wheel and the conveyor belt is 200±10N; the zero point calibration step includes: when the conveyor belt is not running and the magnetic ring is in the middle position of the guide mandrel, recording the initial position of the magnetic ring on the magnetostrictive displacement sensor as the reference zero point; and manually calibrating the zero point drift through the HMI interface of the local controller.
[0015] Preferably, the formula for calculating the twist angle of the conveyor belt is: θ=k Δx In the formula, θ is the twist angle of the conveyor belt; Δx is the displacement data obtained from the displacement simulation signal; k=0.12 / mm is the calibration coefficient, which is based on the change of the conveyor belt diameter.
[0016] Compared with the prior art, the beneficial effects of the present invention are: This invention monitors the torsion angle of the conveyor belt in real time using symmetrically distributed magnetostrictive displacement torsion detectors. It solves the problem of torsion detection in existing circular tube belt conveyors, is less susceptible to dust and external light interference, and features a simple algorithm. It offers advantages such as improved conveyor operational stability, extended equipment lifespan, and reduced maintenance costs. Attached Figure Description
[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0018] Figure 1 This is an installation diagram of the overall structure of the present invention; Figure 2This is a schematic diagram showing the installation positions of the upper magnetostrictive displacement torsion detector and the lower magnetostrictive displacement torsion detector of the present invention; Figure 3 This is a schematic diagram of the structure of the upper magnetostrictive displacement torsion detector or the lower magnetostrictive displacement torsion detector of the present invention. Figure 4 yes Figure 3 Sectional view at point AA; Figure 5 yes Figure 4 Sectional view at point BB; Figure 6 yes Figure 4 Sectional view at CC; Figure 7 yes Figure 4 Sectional view at point DD.
[0019] In the diagram: 10-Upper magnetostrictive displacement torsion detector; 11-Lower magnetostrictive displacement torsion detector; 101-Petal wheel; 1011-Inner wheel; 1012-Inner spindle; 1013-Chassis; 1014-Dial; 1015-Separation assembly; 102-Gear; 103-Rack; 104-Magnetostrictive displacement sensor; 105-Guide spindle; 106-Magnetic ring; 107-Connecting plate; 108-Elastic rod; 109-Horizontal guide wheel; 110-Vertical guide wheel; 111-Base frame; 2-Local controller; 3-Control terminal. Detailed Implementation
[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0021] It should be noted that the structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which the present invention can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportional relationships, or adjustments to the size, without affecting the effects and objectives that the present invention can produce, should fall within the scope of the technical content disclosed in the present invention. It should be noted that in this specification, relational terms such as "first" and "second" are only used to distinguish one entity from several other entities, and do not necessarily require or imply any actual relationship or order between these entities.
[0022] This invention provides an embodiment: like Figures 1 to 7 As shown, a device for real-time torsion detection of a circular tube belt conveyor based on electromagnetic displacement feedback includes a control terminal 3 and a torsion detection subsystem arranged at longitudinal intervals along the conveyor truss. The torsion detection subsystem includes an upper magnetostrictive displacement torsion detector 10, a lower magnetostrictive displacement torsion detector 11, and a local controller 2. The upper magnetostrictive displacement torsion detector 10 and the lower magnetostrictive displacement torsion detector 11 are respectively installed on both sides of the window plate of each truss of the circular tube belt conveyor, with the upper magnetostrictive displacement torsion detector 10 located at the lower end of the upper conveyor belt of the circular tube belt conveyor and the lower magnetostrictive displacement torsion detector 11 located at the upper end of the lower conveyor belt of the circular tube belt conveyor. The local controller 2 of all torsion detection subsystems is connected to the control terminal 3. The upper magnetostrictive displacement torsion detector 10 and the lower magnetostrictive displacement torsion detector 11 have the same structure, both including a base frame 111, a pendulum wheel-gear-rack transmission assembly mounted on the base frame 111, and a displacement detection module for detecting displacement analog signals; The pendulum wheel-gear-rack transmission assembly includes a pendulum wheel 101, a gear 102, and a rack 103. The pendulum wheel 101 includes an inner wheel 1011, an inner spindle 1012, a base 1013, and a face plate 1014. The inner spindle 1012 is shaft-connected to the gear 102. The base 1013 and face plate 1014 are respectively fixed to both ends of the inner spindle 1012. Multiple inner wheels 1011 are circumferentially spaced and rotatably connected within the space enclosed by the base 1013 and face plate 1014, with their surfaces extending out to contact the conveyor belt. The surface of the inner wheels 1011 is provided with equidistantly distributed raised patterns. The gear 102 is coaxially connected to the pendulum wheel 101 and meshes with the rack 103 for transmission. The displacement detection module includes a magnetostrictive... The system includes a magnetostrictive displacement sensor 104, a guide spindle 105, and a magnetic ring 106. The magnetic ring 106 is fixedly connected to the rack 103 via a connecting plate 107 and is slidably connected to the guide spindle 105. The magnetostrictive displacement sensor 104 is located at one end of the guide spindle 105. When the conveyor belt is running normally, the inner wheel 1011 in contact with it rotates freely in its original position. When the conveyor belt twists, it generates a rotational torque through the raised pattern contact. The change in position of the inner wheel 1011 drives the inner spindle 1012 to rotate, which in turn causes the gear 102 to rotate, driving the rack 103 to produce a lateral displacement. The magnetic ring 106 and the magnetostrictive displacement sensor 104 couple to generate a displacement analog signal.
[0023] In this embodiment, each truss section corresponds to a torsion detection subsystem, located on the window panel and additional vertical members of the conveyor belt truss. The distance between the upper magnetostrictive displacement torsion detector 10 and the lower magnetostrictive displacement torsion detector 11 is the circumference of the conveyor belt (designed to be 1.6m for a φ600mm conveyor belt). The local controller 2 is encapsulated in an IP67 protective enclosure and connects the sensors and actuators via an M12 interface. The upper magnetostrictive displacement torsion detector 10, the lower magnetostrictive displacement torsion detector 11, and the magnetostrictive displacement sensor 104 are connected to the local controller 2 via signal cables; the local controller 2 is interconnected via control cables and forms a network topology with the control terminal 3 via a communication bus.
[0024] In this embodiment, the magnetostrictive displacement sensor is model MTS RHM1500MR, with a range of ±500mm, linearity of ±0.05% FS, and a response frequency of 1kHz. The inner wheel of the swivel wheel is made of a special polyurethane composite material with a Shore hardness of 85A and a wear resistance coefficient ≥1.5 million revolutions / mm². The actuator torque controller corresponding to the detection device of this application is an embedded industrial computer with a dual-core ARM Cortex-A9 processor, a real-time operating system (RTOS), and a communication cycle ≤10ms. It is only briefly described in this document and is a supporting component.
[0025] The base frame 111 is suspended from the conveyor frame by an elastic hanger 108. The height of the base frame 111 is adjusted by the elastic hanger 108 to maintain the contact pressure between the inner wheel 1011 and the conveyor belt. The wheel surface of the inner wheel 1011 is in contact with the conveyor belt, and the velocity direction of the contact point between the inner wheel 1011 and the conveyor belt is the same as the conveying direction of the conveyor belt. The swivel wheel 101 also includes a separator assembly 1015. Multiple separator assemblies 1015 are circumferentially and spaced on the chassis 1013 and the face plate 1014 by bolts and are used to separate adjacent inner wheels 1011. The rack 103 is slidably connected to the base frame 111. The base frame 111 is provided with a transverse guide wheel 109 and a vertical guide wheel 110 for lateral and vertical sliding limit of the rack 103.
[0026] In a second aspect, the present invention also provides a method for real-time torsion detection of a circular tube belt conveyor based on electromagnetic displacement feedback, comprising the following steps: S1: Perform preload calibration of the plum blossom wheel 101; and zero-point calibration of the upper magnetostrictive displacement torsion detector 10 and the lower magnetostrictive displacement torsion detector 11; S2: When the conveyor belt twists, the inner wheel 1011 in contact with it generates rotational torque. The change in position of the inner wheel 1011 drives the inner spindle 1012 to rotate, which in turn transmits the torque to the gear shaft, causing the gear 102 to rotate and drive the rack 103 to generate lateral linear displacement. The rack 103 drives the magnetic ring 106 to slide on the guide spindle 105, changing its positional relationship with the magnetostrictive displacement sensor 104. Through the coupling effect between the magnetic ring 106 and the magnetostrictive displacement sensor 104, the magnetostrictive displacement sensor 104 generates a displacement analog signal (4-20mA signal). S3: Local controller 2 processes data based on displacement simulation signals to calculate the conveyor belt twist angle; S4: When the conveyor belt twist angle is less than or equal to ±45°, no adjustment is made. When the conveyor belt twist angle is detected to be greater than ±45°, the local controller 2 sends a twist fault signal and the value of the conveyor belt twist angle for every 5° increase in the twist angle.
[0027] In step S1, the preload calibration of the swivel wheel 101 includes: adjusting the height of the base frame 111 via the elastic suspension rod 108 to make the contact pressure between the swivel wheel 101 and the conveyor belt 200±10N. The zero-point calibration steps include: when the conveyor belt is not running and the magnetic ring 106 is in the middle position of the guide spindle 105, recording the initial position of the magnetic ring 106 on the magnetostrictive displacement sensor 104 as the reference zero point; and manually calibrating the zero-point drift through the HMI interface of the local controller 2.
[0028] Data processing includes: ADC sampling (16-bit resolution, 1kHz sampling rate); digital filtering (second-order Butterworth low-pass filter, 50Hz cutoff frequency).
[0029] The formula for calculating the twist angle of the conveyor belt is: θ=k Δx In the formula, θ is the twist angle of the conveyor belt; Δx is the displacement data obtained from the displacement simulation signal; k=0.12 / mm is the calibration coefficient, which is based on the change of the conveyor belt diameter.
[0030] The data terminal collects data from the entire system every 30 seconds. Based on the torsion data fed back by the local controller 2 of each subsystem, it calculates the torsion angle using the built-in function: θ=k Δx is the output torque adjustment parameter. The output torque adjustment parameters include: the target displacement of each push rod, the tilt angle of the idler group, and the timing of the torque adjustment action. The parameters are then fed back to the centralized control system of the circular tube belt conveyor.
[0031] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.
Claims
1. A device for real-time torsion detection of a circular tube belt conveyor based on electromagnetic displacement feedback, characterized in that: Includes a control terminal (3) and a torsion detection subsystem arranged at longitudinal intervals along the conveyor truss; The torsion detection subsystem includes an upper magnetostrictive displacement torsion detector (10), a lower magnetostrictive displacement torsion detector (11), and a local controller (2). The upper magnetostrictive displacement torsion detector (10) and the lower magnetostrictive displacement torsion detector (11) are respectively installed on both sides of the window plate of each truss of the circular tube belt conveyor. The upper magnetostrictive displacement torsion detector (10) is located at the lower end of the upper conveyor belt of the circular tube belt conveyor, and the lower magnetostrictive displacement torsion detector (11) is located at the upper end of the lower conveyor belt of the circular tube belt conveyor. The local controller (2) of all torsion detection subsystems is connected to the control terminal (3). The upper magnetostrictive displacement torsion detector (10) and the lower magnetostrictive displacement torsion detector (11) have the same structure, both including a base frame (111), a plum blossom wheel-gear-rack transmission assembly mounted on the base frame (111), and a displacement detection module for detecting displacement analog signals; The pendulum wheel-gear-rack transmission assembly includes a pendulum wheel (101), a gear (102), and a rack (103). The pendulum wheel (101) includes an inner wheel (1011), an inner spindle (1012), a chassis (1013), and a face plate (1014). The inner spindle (1012) is connected to the shaft of the gear (102). The chassis (1013) and the face plate (1014) are respectively fixed at both ends of the inner spindle (1012). Multiple inner wheels (1011) are circumferentially spaced and rotated within the space enclosed by the chassis (1013) and the face plate (1014), with their surfaces extending out to contact the conveyor belt. The surface of the inner wheel (1011) is provided with raised patterns distributed at equal angles. The gear (102) is coaxially connected to the pendulum wheel (101) and meshes with the rack (103) for transmission. The displacement detection module includes... The system includes a magnetostrictive displacement sensor (104), a guide spindle (105), and a magnetic ring (106). The magnetic ring (106) is fixedly connected to the rack (103) via a connecting plate (107). The magnetic ring (106) is slidably connected to the guide spindle (105). The magnetostrictive displacement sensor (104) is located at one end of the guide spindle (105). When the conveyor belt is running normally, the inner wheel (1011) in contact with it rotates freely in its original position. When the conveyor belt twists, it generates a rotational torque through the contact of the raised pattern. The change in position of the inner wheel (1011) drives the inner spindle (1012) to rotate, which in turn causes the gear (102) to rotate, which drives the rack (103) to generate a lateral displacement. The magnetic ring (106) and the magnetostrictive displacement sensor (104) generate a displacement simulation signal.
2. The device for real-time torsion detection of a circular tube belt conveyor based on electromagnetic displacement feedback according to claim 1, characterized in that: The base frame (111) is suspended on the conveyor frame by an elastic rod (108). The height of the base frame (111) is adjusted by the elastic rod (108) so that the inner wheel (1011) maintains contact pressure with the conveyor belt.
3. The device for real-time torsion detection of a circular tube belt conveyor based on electromagnetic displacement feedback according to claim 1, characterized in that: The inner wheel (1011) is in contact with the conveyor belt, and the velocity direction of the contact point between the inner wheel (1011) and the conveyor belt is the same as the conveying direction of the conveyor belt.
4. The device for real-time torsion detection of a circular tube belt conveyor based on electromagnetic displacement feedback according to claim 1, characterized in that: The rack (103) is slidably connected to the base frame (111), and the base frame (111) is provided with a horizontal guide wheel (109) and a vertical guide wheel (110) for lateral and vertical sliding limit of the rack (103).
5. The device for real-time torsion detection of a circular tube belt conveyor based on electromagnetic displacement feedback according to claim 1, characterized in that: The swivel wheel (101) also includes a separator assembly (1015), which is circumferentially connected to the chassis (1013) and the front panel (1014) by bolts and is used to separate adjacent inner wheels (1011).
6. The device for real-time torsion detection of a circular tube belt conveyor based on electromagnetic displacement feedback according to claim 1, characterized in that: Each truss section corresponds to a torsion detection subsystem. The distance between the upper magnetostrictive displacement torsion detector (10) and the lower magnetostrictive displacement torsion detector (11) is the circumference of the conveyor belt.
7. The device for real-time torsion detection of a circular tube belt conveyor based on electromagnetic displacement feedback according to claim 1, characterized in that: The local controller (2) is encapsulated in an IP67 protective enclosure and connects the sensor and actuator via an M12 interface.
8. A method for real-time torsion detection of a circular tube belt conveyor based on electromagnetic displacement feedback, relying on the device for real-time torsion detection of a circular tube belt conveyor based on electromagnetic displacement feedback as described in any one of claims 1 to 7, characterized in that, Includes the following steps: S1: Perform preload calibration of the plum blossom wheel (101); and zero-point calibration of the upper magnetostrictive displacement torsion detector (10) and the lower magnetostrictive displacement torsion detector (11); S2: When the conveyor belt twists, the inner wheel (1011) in contact with it generates a rotational torque. The position of the inner wheel (1011) changes, causing the inner spindle (1012) to rotate, which in turn transmits to the gear shaft to make the gear (102) rotate, causing the rack (103) to generate a lateral linear displacement. The rack (103) drives the magnetic ring (106) to slide on the guide spindle (105), changing the positional relationship with the magnetostrictive displacement sensor (104). Through the coupling effect between the magnetic ring (106) and the magnetostrictive displacement sensor (104), the magnetostrictive displacement sensor (104) generates a displacement analog signal. S3: The local controller (2) performs data processing based on the displacement simulation signal and calculates the twist angle of the conveyor belt; S4: When the twist angle of the conveyor belt is less than or equal to ±45°, no adjustment is made. When the twist angle of the conveyor belt is detected to be greater than ±45°, the local controller (2) sends a twist fault signal and the value of the twist angle of the conveyor belt for every 5° increase in the twist angle.
9. A method for real-time torsion detection of a circular tube belt conveyor based on electromagnetic displacement feedback according to claim 8, characterized in that: In step S1, the preload calibration of the flower wheel (101) includes: adjusting the height of the base frame (111) by means of the elastic rod (108) so that the contact pressure between the flower wheel (101) and the conveyor belt is 200±10N; the zero point calibration step includes: when the conveyor belt is not running and the magnetic ring (106) is in the middle position of the guide mandrel (105), recording the initial position of the magnetic ring (106) on the magnetostrictive displacement sensor (104) as the reference zero point; and manually calibrating the zero point drift through the HMI interface of the local controller (2).