Intelligent control device of belt conveyor

Abstract

The invention discloses an intelligent control device of a belt conveyor, which comprises a PLC (Programmable Logic Controller) control module, a motor power control module and a running speed control module, and is characterized in that the PLC control module comprises a sensing unit and a service diagnosis unit, and the sensing unit is electrically connected with the service diagnosis unit, the motor power control module and the running speed control module respectively; the sensing unit is used for collecting actual operation data of the belt conveyor, the service diagnosis unit is used for conducting fault diagnosis according to the actual operation data, the motor power control module is used for adjusting the frequency of the frequency converter according to current data in the actual operation data, and the operation speed control module is used for obtaining the total amount of materials to be conveyed. And the running speed of the belt conveyor is adjusted according to the comparison result of the actual carrying capacity, the total amount of the to-be-conveyed materials and the material threshold value in the actual running data. The frequency of the frequency converter is adjusted according to the current data, the running speed is reasonably distributed according to the carrying capacity, and energy consumption caused by running speed mismatching is avoided.

Description

Technical Field

[0001] This invention belongs to the field of belt conveyor control technology, and specifically relates to an intelligent control device for belt conveyors. Background Technology

[0002] Belt conveyors (also known as rubber belt conveyors) are key equipment in modern industrial automated production, widely used in various industries such as home appliances, electronics, machinery, food, logistics, and printing, undertaking important functions such as material conveying, product assembly, testing and debugging, and packaging and transportation. With the advancement of intelligent manufacturing and Industry 4.0, enterprises have placed higher demands on the operating efficiency, stability, and energy efficiency of conveyor systems.

[0003] Currently, most belt conveyors use programmable logic controllers (PLCs) as the core control unit to achieve automatic control of motor start / stop, running speed, direction, and linkage logic. PLCs collect sensor signals and execute preset logic operations, sequential control, timing, and counting instructions to coordinate the collaborative work of various conveyor components. They possess advantages such as high reliability, strong anti-interference capabilities, and flexible programming.

[0004] Although existing PLC control systems have achieved basic automation of belt conveyor operation, significant technical shortcomings remain. For example, current control strategies are mostly fixed modes or manually set, unable to dynamically adjust operating parameters (such as speed) according to actual production needs, resulting in unnecessary energy consumption and low energy efficiency. Furthermore, the systems lack intelligent analysis and adaptive adjustment capabilities for operating status, making it difficult to achieve the dual goals of energy-saving optimization and equipment protection. Therefore, a new type of PLC control device capable of achieving motor power balance regulation and on-demand intelligent control is urgently needed to improve the operational reliability and energy efficiency of belt conveyors. Summary of the Invention

[0005] In view of this, the present invention provides an intelligent control device for belt conveyors, the main purpose of which is to solve the problem that existing intelligent control devices for belt conveyors cannot dynamically adjust operating parameters according to actual production needs.

[0006] To address the aforementioned problems, this application provides an intelligent control device for a belt conveyor, comprising: a PLC control module, a motor power control module, and a running speed control module. The PLC control module includes a sensing unit and a service diagnostic unit.

[0007] The output terminal of the sensing unit is electrically connected to the input terminal of the service diagnostic unit, the input terminal of the motor power control module, and the input terminal of the running speed control module, respectively. The output terminal of the motor power control module is electrically connected to the frequency converter of the belt conveyor, and the output terminal of the running speed control module is electrically connected to the frequency converter of the belt conveyor.

[0008] The sensing unit is used to collect the actual operating data of the belt conveyor. The service diagnosis unit is used to perform fault diagnosis based on the actual operating data of the belt conveyor and output the fault diagnosis result. The motor power control module is used to adjust the frequency of the frequency converter based on the current data in the actual operating data of the belt conveyor. The running speed control module is used to obtain the total amount of material to be transported and adjust the running speed of the belt conveyor based on the comparison result of the actual carrying capacity, the total amount of material to be transported and the material threshold in the actual operating data.

[0009] In one embodiment of the present invention, optionally, the actual operating data of the belt conveyor includes the real-time current of the frequency converter and the average current of the belt conveyor. The motor power control module is further configured to calculate a first ratio of the real-time current of the frequency converter to the average current of the belt conveyor. When the first ratio is greater than a ratio threshold, the frequency of the frequency converter is reduced by a preset value until the first ratio of the real-time current of the frequency converter to the average current of the belt conveyor is equal to the ratio threshold. When the first ratio is less than the ratio threshold, the frequency of the frequency converter is increased by a preset value until the ratio of the real-time current of the frequency converter to the average current of the belt conveyor is equal to the ratio threshold.

[0010] In one embodiment of the present invention, optionally, the operating speed control module is further configured to determine whether the total amount of material to be transported is within the preset transport range of the belt conveyor; if the total amount of material to be transported is not within the preset transport range of the belt conveyor, determine whether the total amount of material to be transported is greater than the upper limit of the preset transport range; when the total amount of material to be transported is greater than the upper limit of the preset transport range, calculate a second ratio of the difference between the total amount of material to be transported and the upper limit of the preset transport range to the upper limit; determine the increased carrying capacity of the belt conveyor based on the second ratio; obtain the actual carrying capacity of the belt conveyor after the increased carrying capacity; and calculate the operating speed of the belt conveyor based on the actual carrying capacity.

[0011] In one embodiment of the present invention, optionally, the operating speed control module is further configured to calculate a third ratio of the difference between the total amount of the material to be transported and the lower limit of the preset transportation range to the lower limit when the total amount of the material to be transported is less than the lower limit of the preset transportation range; determine the reduced carrying capacity of the belt conveyor based on the third ratio; obtain the actual carrying capacity of the belt conveyor after the reduction of the carrying capacity; and calculate the operating speed of the belt conveyor based on the actual carrying capacity.

[0012] In one embodiment of the present invention, optionally, the running speed control module is further configured to determine whether the total amount of the material to be transported is within the preset transport range of the belt conveyor; if the total amount of the material to be transported is within the preset transport range of the belt conveyor, the actual carrying capacity of the belt conveyor is obtained, and the running speed of the belt conveyor is calculated based on the actual carrying capacity.

[0013] In one embodiment of the present invention, the operating speed of the belt conveyor may optionally be calculated using the following method:

[0014]

[0015] Where Q is the actual carrying capacity of the belt conveyor, V is the operating speed of the belt conveyor, and q m This refers to the linear density of the belt conveyor.

[0016] In one embodiment of the present invention, optionally, the actual operating data of the belt conveyor includes current data, voltage data, vibration data generated during operation, temperature data, speed data, belt tearing status, and motor power of the belt conveyor. The PLC control module further includes an application unit, which is used to input the actual operating data of the belt conveyor within a preset time period before the current moment into the operation prediction model to obtain the predicted operating data of the belt conveyor at the current moment, calculate the difference between the actual operating data and the predicted operating data at the current moment, and output a warning signal when the difference is greater than a difference threshold.

[0017] In one embodiment of the present invention, the application unit is optionally further configured to acquire the operating data and operating status of each device of the belt conveyor, and store the operating data and operating status of each device of the belt conveyor.

[0018] In one embodiment of the present invention, optionally, the service diagnosis unit is further configured to input the actual operating data of the belt conveyor into the fault diagnosis model to obtain the fault diagnosis result of the belt conveyor, and based on the fault diagnosis result, obtain the fault handling result corresponding to the fault diagnosis result from historical fault handling data.

[0019] In one embodiment of the present invention, optionally, the service diagnostic unit is further configured to determine multiple sensitive parameters in the actual operating data of the belt conveyor, compare each sensitive parameter with its corresponding threshold, and output a fault signal when any sensitive parameter is greater than or equal to its corresponding threshold.

[0020] This invention provides an intelligent control device for a belt conveyor. It adjusts the frequency of the inverter based on the current data in the actual operating data of the belt conveyor, controlling the stability of the motor power during operation. This balances the motor power, allowing it to run smoothly within a reasonable power range, avoiding damage caused by power fluctuations, and extending the motor's lifespan. Furthermore, it adjusts the belt conveyor's operating speed based on a comparison of the actual load, the total amount of material to be transported, and the material threshold in the actual operating data. This rationally adjusts the belt conveyor's operating speed and allocates it according to the load, ensuring the belt conveyor operates in optimal condition. This avoids energy consumption caused by speed mismatch, saves electricity resources, and reduces transportation costs.

[0021] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, and in order to make the above and other objects, features and advantages of the present invention more apparent and understandable, specific embodiments of the present invention are described below. Attached Figure Description

[0022] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0023] Figure 1 This is a structural block diagram of an intelligent control device for a belt conveyor, which is an exemplary embodiment of the present invention.

[0024] Figure 2 This is a flowchart illustrating the adjustment of the frequency of a frequency converter by an intelligent control device for a belt conveyor, as an exemplary embodiment of the present invention.

[0025] Figure 3A flowchart illustrating the adjustment of the operating speed of a belt conveyor using an intelligent control device, which is an exemplary embodiment of the present invention.

[0026] Figure 4 This is another structural block diagram of an intelligent control device for a belt conveyor, which is an exemplary embodiment of the present invention.

[0027] in,

[0028] The following are the labels: 1-PLC control module; 2-motor power control module; 3-running speed control module; 11-sensing unit; 12-service diagnostic unit. Detailed Implementation

[0029] The present invention will be described in detail below with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in the embodiments of the present invention can be combined with each other.

[0030] To further illustrate the technical means and effects adopted by the present invention to achieve the intended purpose, the specific embodiments, structures, features, and effects according to the present invention will be described in detail below with reference to the accompanying drawings and preferred embodiments. In the following description, different "an embodiment" or "an embodiment" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics in one or more embodiments can be combined in any suitable form.

[0031] The following is combined Figure 1 A smart control device for a belt conveyor is described according to some embodiments of the present invention.

[0032] In one embodiment, such as Figure 1 As shown, an intelligent control device for a belt conveyor includes: a PLC control module 1, a motor power control module 2, and a running speed control module 3. The PLC control module 1 includes a sensing unit 11 and a service diagnostic unit 12.

[0033] The output terminal of the sensing unit 11 is electrically connected to the input terminal of the service diagnostic unit 12, the input terminal of the motor power control module 2, and the input terminal of the running speed control module 3, respectively. The output terminal of the motor power control module 2 is electrically connected to the frequency converter of the belt conveyor, and the output terminal of the running speed control module 3 is electrically connected to the frequency converter of the belt conveyor.

[0034] The sensing unit 11 is used to collect the actual operating data of the belt conveyor. The service diagnosis unit 12 is used to perform fault diagnosis based on the actual operating data of the belt conveyor and output the fault diagnosis results. The motor power control module 2 is used to adjust the frequency of the frequency converter based on the current data in the actual operating data of the belt conveyor. The running speed control module 3 is used to obtain the total amount of material to be transported and adjust the running speed of the belt conveyor based on the comparison results of the actual carrying capacity, the total amount of material to be transported and the material threshold in the actual operating data.

[0035] Specifically, the intelligent control device for the belt conveyor includes a PLC control module, a motor power control module, and a running speed control module. The PLC control module includes an application unit, a service diagnostic unit, a transmission unit, and a sensing unit.

[0036] The sensing unit includes voltage / current sensors, vibration sensors, temperature sensors, speed sensors, belt misalignment sensors, longitudinal tear sensors, locking sensors, and power sensors. The sensing unit collects the actual operating data of the belt conveyor during operation and sends it to the service diagnostic unit, the motor power control module, and the running speed control module.

[0037] The service diagnostic unit includes a fault diagnosis unit, an equipment operation status debugging unit, and a database. The fault diagnosis unit determines whether the belt conveyor is faulty based on the actual operating data of the belt conveyor and the threshold corresponding to each data point. It can also compare the actual operating data with historical data records in the database to determine whether the belt conveyor is faulty and output the fault diagnosis results.

[0038] The transmission layer includes a wireless transmission unit that establishes a device control local area network via Bluetooth signals and transmits data wirelessly between the sensing unit and the service diagnostic unit via Bluetooth signals.

[0039] The operating speed control module includes a data acquisition unit, a motor signal analysis unit, and a frequency converter. The data acquisition unit wirelessly connects with the sensing unit in the PLC control module to obtain the actual operating data of the belt conveyor collected by the sensing unit. The motor signal analysis unit analyzes and processes the current data in the actual operating data of the belt conveyor and adjusts the frequency of the frequency converter according to the ratio of the actual current of the frequency converter to the average current of the belt conveyor.

[0040] Compared with existing technologies, the intelligent control device for a belt conveyor provided in this application adjusts the frequency of the inverter based on the current data in the actual operating data of the belt conveyor, controls the stability of the motor power during the operation of the belt conveyor, balances the power of the motor during operation, and allows the motor to run smoothly within a reasonable operating power range, avoiding damage caused by power fluctuations and extending the service life of the motor. The device also adjusts the operating speed of the belt conveyor based on a comparison of the actual load, the total amount of material to be transported, and the material threshold in the actual operating data, rationally adjusting the operating speed of the belt conveyor and allocating the operating speed according to the load to ensure that the belt conveyor operates in optimal condition, avoiding energy consumption caused by speed mismatch, saving electricity resources, and reducing transportation costs.

[0041] In one embodiment, the actual operating data of the belt conveyor includes the real-time current of the frequency converter and the average current of the belt conveyor. The motor power control module 2 is also used to calculate a first ratio of the real-time current of the frequency converter to the average current of the belt conveyor. When the first ratio is greater than the ratio threshold, the frequency of the frequency converter is reduced by a preset value until the first ratio of the real-time current of the frequency converter to the average current of the belt conveyor is equal to the ratio threshold. When the first ratio is less than the ratio threshold, the frequency of the frequency converter is increased by a preset value until the ratio of the real-time current of the frequency converter to the average current of the belt conveyor is equal to the ratio threshold.

[0042] Specifically, the real-time current of the frequency converter is the instantaneous current of the motor during operation. It is affected by factors such as fluctuations in material quantity and changes in the instantaneous resistance of the equipment. The average current of the belt conveyor refers to the average value of the motor current under normal operating conditions (such as rated load and stable operation), reflecting the normal load level of the equipment. When the first ratio is greater than the ratio threshold, it indicates that the real-time current is too high, which may lead to motor overheating or increased equipment wear due to overload. At this time, the frequency converter frequency is reduced by a preset value (such as decreasing by 0.5Hz each time). The frequency reduction will cause the motor speed to decrease, the belt conveyor speed to slow down, thereby reducing the material carrying capacity, reducing the motor load, and causing the real-time current to decrease accordingly. When the first ratio is less than the ratio threshold, it indicates that the real-time current is too low, the motor is in a light load state, and there is energy waste (motor efficiency will decrease under low load). At this time, the module increases the frequency converter frequency by a preset value (such as increasing by 0.5Hz each time). The frequency increase will cause the motor speed to increase, the conveyor carrying capacity to increase, the motor load to increase, and the real-time current to increase. Based on the ratio of the real-time current to the average current of the frequency converter, the frequency of the frequency converter is dynamically adjusted to stabilize the motor load and ensure the safe and efficient operation of the equipment.

[0043] For example, such as Figure 2As shown, when the ratio of the real-time current l to the average current lp of the inverter is greater than 95%, the inverter frequency is reduced by 5% each time until the ratio of the current l to the average current lp is equal to 95%. When the ratio of the real-time current l to the average current lp of the inverter is less than 95%, the inverter frequency is increased by 5% each time until the ratio of the current l to the average current lp is equal to 95%.

[0044] In one embodiment, the running speed control module 3 is further used to determine whether the total amount of material to be transported is within the preset transport range of the belt conveyor. If the total amount of material to be transported is not within the preset transport range of the belt conveyor, it is determined whether the total amount of material to be transported is greater than the upper limit of the preset transport range. When the total amount of material to be transported is greater than the upper limit of the preset transport range, the difference between the total amount of material to be transported and the upper limit of the preset transport range is calculated as a second ratio to the upper limit. Based on the second ratio, the increased carrying capacity of the belt conveyor is determined, the actual carrying capacity of the belt conveyor after the increased carrying capacity is obtained, and the running speed of the belt conveyor is calculated based on the actual carrying capacity.

[0045] Specifically, when the total amount of material to be transported exceeds the upper limit of the preset transport range, the overload adjustment mechanism is triggered. This is because operating directly at the original speed could lead to material accumulation, insufficient conveying efficiency, or even equipment failure due to overload. Therefore, the carrying capacity is increased to the optimal level. Based on the actual carrying capacity, the corresponding operating speed is calculated. By quantifying the degree of material overload, the carrying capacity is reasonably increased and matched with the appropriate operating speed to ensure efficient material transport and safe equipment operation. Figure 3 As shown.

[0046] For example, when the actual total amount of materials to be transported is higher than the upper limit of the preset transportation range but not higher than the maximum total amount, the transport capacity of the belt conveyor will be increased by 5 tons for every 1% increase.

[0047] In one embodiment, the running speed control module 3 is further configured to calculate a third ratio between the difference between the total amount of material to be transported and the lower limit of the preset transportation range and the lower limit when the total amount of material to be transported is less than the lower limit of the preset transportation range; determine the reduced carrying capacity of the belt conveyor based on the third ratio; obtain the actual carrying capacity of the belt conveyor after the reduction of the carrying capacity; and calculate the running speed of the belt conveyor based on the actual carrying capacity.

[0048] Specifically, when the actual total amount of material to be transported is lower than the lower limit of the preset transport range, a speed reduction adjustment mechanism is triggered. This is because high-speed operation of a belt conveyor under "low load" conditions leads to energy waste and equipment wear. Therefore, the load is reduced to the optimal load, and the corresponding operating speed is calculated based on the actual load. By dynamically calculating the difference between the material quantity and the preset range, the load is reasonably reduced and the corresponding operating speed is matched to achieve the goals of energy saving and reducing equipment wear. Figure 3 As shown.

[0049] For example, when the actual total amount of material to be transported is lower than the lower limit of the preset transportation range but not lower than the minimum total amount, the belt conveyor's transport capacity is reduced by 5 tons for every 1% below the lower limit of the preset transportation range.

[0050] In one embodiment, the running speed control module 3 is also used to determine whether the total amount of material to be transported is within the preset transport range of the belt conveyor. If the total amount of material to be transported is within the preset transport range of the belt conveyor, the actual load of the belt conveyor is obtained, and the running speed of the belt conveyor is calculated based on the actual load.

[0051] Specifically, the operating speed control module also includes a range detection unit, a demand detection unit, and a speed analysis unit. The range detection unit detects the total amount of material to be transported. The speed analysis unit determines whether the total amount of material is within the preset transport range. When the total amount is within the preset range, the demand detection unit detects the actual transport capacity of the belt conveyor to obtain the actual transport capacity. Based on the actual transport capacity, the operating speed of the belt conveyor is calculated to achieve energy-saving control. When the total amount of material is outside the preset transport range, it is determined whether it is below the lower limit or above the upper limit of the preset transport range. Based on the difference between the total amount of material and the upper or lower limit of the preset transport range, a material replenishment amount is calculated. The system runs repeatedly to achieve energy-saving speed regulation control.

[0052] In one embodiment, the operating speed of the belt conveyor is calculated using the following method:

[0053]

[0054] Where Q is the actual carrying capacity of the belt conveyor, V is the operating speed of the belt conveyor, and q m This refers to the linear density of the belt conveyor.

[0055] In one embodiment, the actual operating data of the belt conveyor includes current data, voltage data, vibration data generated during operation, temperature data, speed data, belt tearing status, and motor power. The PLC control module also includes an application unit, which is used to input the actual operating data of the belt conveyor within a preset time period before the current moment into the operation prediction model to obtain the predicted operating data of the belt conveyor at the current moment, calculate the difference between the actual operating data and the predicted operating data at the current moment, and output a warning signal when the difference is greater than the difference threshold.

[0056] Specifically, the sensing unit is used to collect various parameters during the operation of the belt conveyor. The sensing unit includes voltage / current sensors, vibration sensors, temperature sensors, speed sensors, belt misalignment sensors, tear sensors, locking sensors, and power sensors. The voltage / current sensors collect current and voltage data during belt conveyor operation; the vibration sensors monitor the vibration generated during belt conveyor operation and issue warnings when significant vibration occurs, prompting personnel to perform maintenance; the temperature sensors monitor the temperature during belt conveyor operation; the speed sensors monitor the transmission speed of the belt conveyor; the belt misalignment sensors ensure that the belt conveyor does not run off-track; the tear sensors monitor the tearing of the conveyor belt; the locking sensors ensure that the belt conveyor is locked in an unsafe state; and the power sensors collect data on the operating power of the belt conveyor motor and the frequency converter.

[0057] The application unit provides safety-compliant control software for the belt conveyor. The application unit includes an equipment status detection and display unit, an equipment information management unit, an equipment safety monitoring unit, a data management unit, and a human-machine interaction unit. Through these units, the software enables equipment status display, equipment information management, equipment alarms, data storage and retrieval, and human-machine interaction functions. This allows for accurate perception of the belt conveyor's operating condition, ensuring safety during transportation and stable operation of the internal equipment.

[0058] Compared with existing technologies, this invention uses a PLC control module to intelligently control the operation of the belt conveyor. It collects various data during the operation of the belt conveyor through sensors, performs unmanned monitoring of the collected data, and issues alarms when abnormal data occurs. This allows for timely detection of faults during the operation of the belt conveyor, provides early warning and analysis of faults, and provides a data foundation for the daily maintenance of the belt conveyor. Remote control ensures the operational stability of the belt conveyor and ensures that the belt conveyor operates automatically according to the set operating mode.

[0059] In one embodiment, the application unit is further configured to acquire the operating data and operating status of each device of the belt conveyor, and store the operating data and operating status of each device of the belt conveyor.

[0060] Specifically, the PLC control module also has the functions of comprehensive equipment data management and data analysis. The application units include the equipment management unit, the equipment operation status debugging unit and the database. The equipment management unit and the equipment operation status debugging unit manage and debug the operation of the belt conveyor equipment, respectively.

[0061] In one embodiment, the service diagnosis unit 12 is further configured to input the actual operating data of the belt conveyor into the fault diagnosis model to obtain the fault diagnosis result of the belt conveyor, and based on the fault diagnosis result, obtain the fault handling result corresponding to the fault diagnosis result from the historical fault handling data.

[0062] Specifically, the fault diagnosis model is a model trained on historical data. It extracts features from the input actual running data, determines whether a fault exists and the type of fault based on the extracted features, and outputs the fault diagnosis result if a fault exists.

[0063] When a fault is identified, the system retrieves solutions for similar faults from the "historical fault handling data" and outputs specific solutions. This allows for rapid fault location and standardized solutions, avoiding the time-consuming manual troubleshooting required in traditional methods. It achieves a fully automated closed loop of "fault diagnosis and handling".

[0064] In one embodiment, the service diagnostic unit 12 is further configured to determine multiple sensitive parameters in the actual operating data of the belt conveyor, compare each sensitive parameter with its corresponding threshold, and output a fault signal when any sensitive parameter is greater than or equal to its corresponding threshold.

[0065] Specifically, the service diagnostic unit acts as a "real-time health monitor" in the belt conveyor system. It abstracts the operating status of the entire conveyor into several "sensitive parameters," each with a predefined threshold. When any sensitive parameter touches or exceeds its corresponding threshold, a fault signal is issued. Sensitive parameters include current, voltage, belt speed deviation, misalignment, and vibration.

[0066] In one embodiment, such as Figure 4 As shown, the intelligent control device of the belt conveyor includes a PLC control module, a motor power balance control module (also called a motor power control module) and an energy-saving speed regulation control module (also called a running speed control module). The PLC control module consists of an application layer (also called an application unit), a service layer (also called a service diagnostic unit), a transmission layer and a perception layer (also called a perception unit).

[0067] The application layer includes a device status detection and display unit, a device information management unit, a device safety monitoring unit, a data management unit, and a human-machine interaction unit;

[0068] The service layer includes an equipment management unit, a fault diagnosis unit, an equipment operation status debugging unit, and a database;

[0069] The transport layer includes a wireless transmission unit that establishes a device control local area network via Bluetooth signals and transmits wireless data between the perception layer and the service layer via Bluetooth signals.

[0070] The sensing layer includes voltage / current sensors, vibration sensors, temperature sensors, speed sensors, belt misalignment sensors, longitudinal tear sensors, locking sensors, and power sensors;

[0071] The motor power balance control module includes a data acquisition unit, a motor signal analysis unit, and a frequency converter. The data acquisition unit is wirelessly connected to the sensing layer in the PLC control module. The motor signal analysis unit analyzes and processes the acquired signals, analyzes the ratio of the frequency converter current to the system average current, and adjusts the frequency of the frequency converter. The frequency converter is electrically connected to the input end of the belt conveyor motor.

[0072] The energy-saving speed control module includes a running speed acquisition unit, a running speed analysis unit, a range detection unit, and a demand detection unit. The running speed acquisition unit acquires the running speed of the belt conveyor from the sensing layer of the PLC control module. The running speed analysis unit adjusts the speed based on the total storage capacity of the transported goods obtained by the range detection unit and the total transport volume obtained by the demand detection unit.

[0073] In this embodiment, the integrated database is a crucial component of the intelligent operation and maintenance system for the conveyor. It stores raw data, performs data analysis and processing, and serves as the key link between the knowledge base, the inference engine, and the human-machine interface. Therefore, the data identifiers must match those in the knowledge base. The design of the integrated database tables balances simplicity and non-redundancy. Simplicity means that the created data structure should be as simple and clear as possible for easy user understanding; non-redundancy means that the created database should not have duplicate copies or file attributes. Based on the characteristics of this system, a relational database is adopted. Secondly, data analysis and inference involve analyzing the conveyor's operating data, representing the analysis results with symbols related to the problem, transmitting them to the knowledge base, and outputting intelligent operation and maintenance instructions. In the inference flowchart, inference is based on the knowledge in the knowledge base, reasoning about the data in the integrated database, and incorporating the experience of experts and knowledge engineers.

[0074] It should be understood that various modifications can be made to the embodiments described herein. Therefore, the above description should not be considered as limiting, but merely as an example of embodiments. Other modifications within the scope and spirit of this application will be apparent to those skilled in the art.

[0075] The accompanying drawings, which are included in and form part of this specification, illustrate embodiments of the present application and, together with the general description of the present application given above and the detailed description of the embodiments given below, serve to explain the principles of the present application.

[0076] These and other features of this application will become apparent from the following description of preferred forms of embodiments given as non-limiting examples, with reference to the accompanying drawings.

[0077] It should also be understood that although this application has been described with reference to some specific examples, those skilled in the art can certainly implement many other equivalent forms of this application.

[0078] The above and other aspects, features and advantages of this application will become more apparent when taken in conjunction with the accompanying drawings and in view of the following detailed description.

[0079] Specific embodiments of this application are described thereafter with reference to the accompanying drawings; however, it should be understood that the claimed embodiments are merely examples of this application, which can be implemented in various ways. Well-known and / or repeated functions and structures are not described in detail to avoid unnecessary or redundant details that could obscure the application. Therefore, the specific structural and functional details claimed herein are not intended to be limiting, but merely serve as the basis and representative basis for the claims to teach those skilled in the art to use this application in a variety of substantially any suitable detailed structures.

[0080] This specification may use the phrases “in one embodiment,” “in another embodiment,” “in yet another embodiment,” or “in other embodiments,” all of which may refer to one or more of the same or different embodiments according to this application.

[0081] The above embodiments are merely exemplary embodiments of this application and are not intended to limit this application. The scope of protection of this application is defined by the claims. Those skilled in the art can make various modifications or equivalent substitutions to this application within its substance and scope of protection, and such modifications or equivalent substitutions should also be considered to fall within the scope of protection of this application.

Claims

1. An intelligent control device for a belt conveyor, characterized in that include: The system includes a PLC control module, a motor power control module, and a running speed control module. The PLC control module further includes a sensing unit and a service diagnostic unit. The output terminal of the sensing unit is electrically connected to the input terminal of the service diagnostic unit, the input terminal of the motor power control module, and the input terminal of the running speed control module, respectively. The output terminal of the motor power control module is electrically connected to the frequency converter of the belt conveyor, and the output terminal of the running speed control module is electrically connected to the frequency converter of the belt conveyor. The sensing unit is used to collect the actual operating data of the belt conveyor. The service diagnosis unit is used to perform fault diagnosis based on the actual operating data of the belt conveyor and output the fault diagnosis result. The motor power control module is used to adjust the frequency of the frequency converter based on the current data in the actual operating data of the belt conveyor. The running speed control module is used to obtain the total amount of material to be transported and adjust the running speed of the belt conveyor based on the comparison result of the actual carrying capacity, the total amount of material to be transported and the material threshold in the actual operating data.

2. The intelligent control device for a belt conveyor according to claim 1, characterized in that, The actual operating data of the belt conveyor includes the real-time current of the frequency converter and the average current of the belt conveyor. The motor power control module is also used to calculate a first ratio of the real-time current of the frequency converter to the average current of the belt conveyor. When the first ratio is greater than a ratio threshold, the frequency of the frequency converter is reduced by a preset value until the first ratio of the real-time current of the frequency converter to the average current of the belt conveyor is equal to the ratio threshold. When the first ratio is less than the ratio threshold, the frequency of the frequency converter is increased by a preset value until the ratio of the real-time current of the frequency converter to the average current of the belt conveyor is equal to the ratio threshold.

3. The intelligent control device for a belt conveyor of claim 1, wherein, The operating speed control module is also used to determine whether the total amount of material to be transported is within the preset transport range of the belt conveyor. If the total amount of material to be transported is not within the preset transport range of the belt conveyor, it determines whether the total amount of material to be transported is greater than the upper limit of the preset transport range. When the total amount of material to be transported is greater than the upper limit of the preset transport range, it calculates the second ratio of the difference between the total amount of material to be transported and the upper limit of the preset transport range to the upper limit. Based on the second ratio, it determines the increased carrying capacity of the belt conveyor, obtains the actual carrying capacity of the belt conveyor after the increased carrying capacity, and calculates the operating speed of the belt conveyor based on the actual carrying capacity.

4. The intelligent control device for the belt conveyor according to claim 3, characterized in that, The operating speed control module is also used to calculate a third ratio of the difference between the total amount of the material to be transported and the lower limit of the preset transportation range to the lower limit when the total amount of the material to be transported is less than the lower limit of the preset transportation range. Based on the third ratio, the reduced carrying capacity of the belt conveyor is determined, the actual carrying capacity of the belt conveyor after the reduced carrying capacity is obtained, and the operating speed of the belt conveyor is calculated based on the actual carrying capacity.

5. The intelligent control device for the belt conveyor according to claim 3, characterized in that, The operating speed control module is also used to determine whether the total amount of material to be transported is within the preset transport range of the belt conveyor. If the total amount of material to be transported is within the preset transport range of the belt conveyor, the actual carrying capacity of the belt conveyor is obtained, and the operating speed of the belt conveyor is calculated based on the actual carrying capacity.

6. The intelligent control device for the belt conveyor according to any one of claims 3-5, characterized in that, The operating speed of the belt conveyor is calculated using the following method: where Q is the actual load of the belt conveyor, V is the running speed of the belt conveyor, q m is the linear density of the belt conveyor.

7. The intelligent control device for the belt conveyor according to claim 1, characterized in that, The actual operating data of the belt conveyor includes current data, voltage data, vibration data, temperature data, speed data, belt tearing status, and motor power during operation. The PLC control module also includes an application unit, which is used to input the actual operating data of the belt conveyor within a preset time period before the current moment into the operation prediction model to obtain the predicted operating data of the belt conveyor at the current moment, calculate the difference between the actual operating data and the predicted operating data at the current moment, and output a warning signal when the difference is greater than a threshold.

8. The intelligent control device for the belt conveyor according to claim 7, characterized in that, The application unit is also used to acquire the operating data and operating status of each device of the belt conveyor, and to store the operating data and operating status of each device of the belt conveyor.

9. The intelligent control device for the belt conveyor according to claim 1, characterized in that, The service diagnosis unit is also used to input the actual operating data of the belt conveyor into the fault diagnosis model to obtain the fault diagnosis result of the belt conveyor, and based on the fault diagnosis result, to obtain the fault handling result corresponding to the fault diagnosis result from the historical fault handling data.

10. The intelligent control device for the belt conveyor according to claim 1, characterized in that, The service diagnostic unit is also used to determine multiple sensitive parameters in the actual operating data of the belt conveyor, compare each sensitive parameter with its corresponding threshold, and output a fault signal when any sensitive parameter is greater than or equal to its corresponding threshold.

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