Adjustable movable wide belt thickness measuring system and structure

Abstract

The invention relates to the technical field of belt thickness measurement, and discloses an adjustable movable wide belt thickness measurement system and structure, and the system comprises the steps: positioning a pin hole through a crossed roller bearing, fitting a roller axis and a laser plane, and newly adding bolt pre-tightening torque control and sliding window filtering; the edge of the belt is dynamically recognized through the laser gray scale difference value, and stroke redundancy is preset to adapt to belt deviation; predicting a deviation trend in combination with historical data; self-adaptive correction is carried out, and the vertical distance is corrected in real time; a wear form analysis model is constructed, and the complete section thickness is obtained; a steel wire is identified by combining a gray threshold value, a corrosion coefficient is introduced to correct a safety distance, a cross section area is added, and wear gradient calculation is performed, so that the problem of no overall wear evaluation is solved, elevation angle and horizontal angle adjustment is synchronously driven through thickness deviation, laser alignment deviation accumulation and dynamic measurement errors are solved, and environmental parameters are triggered to be recalibrated. The deviation caused by environmental interference is solved; and the module stroke is corrected in real time by combining the belt width.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of belt thickness measurement, in particular to an adjustable mobile wide belt thickness measurement system and structure. BACKGROUND

[0002] The technical background of the current belt thickness measurement field presents the characteristics of strong dependence on manual operation, significant defects of traditional solutions, and blankness of wide belt adaptation. The wide belt thickness measurement in the mining, port and other industries has long relied on manual shutdown inspection, which requires interrupting production, visually judging belt damage, and only identifying obvious cracks and measuring specific thickness. Walking inspection of ultra-wide / long-distance belts is time-consuming and labor-intensive, potential wear and tear risks are difficult to identify, and the reliability is poor. In the prior art, the thickness is calculated by separately arranging distance sensors above and below the conveyor belt, but the bending, tilting and fluctuation of the belt during operation can cause the detection data to be greater than the actual value. Laser detection requires linear laser sensors on the upper and lower sides of the belt, which wastes redundant sensors and cannot locate the steel wire position of the steel wire lined belt, making it difficult to measure the actual safety distance between the wear surface and the steel wire. The existing technology can only achieve single-point / local line measurement, and the face laser technology cannot obtain the complete cross-sectional shape of the roller and the belt, and there is no straight line module along the roller axis, which cannot cover the edge area of the ultra-wide belt, resulting in a measurement blind area and the inability to reflect the overall wear uniformity. The core premise of face laser measurement is that the face laser and the roller axis are accurately overlapped to ensure the correctness of the cross-sectional measurement reference, but the installation error and roller deformation of the wide belt conveyor can easily cause the laser axis to deviate. The existing patent has no cooperative mechanism for adjusting the elevation angle and the horizontal angle, and only relies on fixed installation, which cannot calibrate the alignment relationship between the laser and the axis, resulting in inconsistent cross-sectional measurement references at different positions of the wide belt. The load changes and roller vibrations during the operation of the wide belt can cause the belt to shift horizontally or tilt at an angle, and there is no real-time dynamic adjustment function. There is no elevation compensation mechanism to correct the deviation of the laser incidence angle caused by the belt tilt, and there is no horizontal angle fine adjustment function to respond to the horizontal shift, which cannot ensure that the face laser always covers the target area during measurement. Therefore, it is necessary to provide an adjustable mobile wide belt thickness measurement system and structure. SUMMARY

[0003] The purpose of the present application is to provide an adjustable mobile wide belt thickness measurement system and structure. To solve the above-mentioned problems of the prior art, the present application realizes the following technical solutions: In a first aspect, the present application provides an adjustable mobile wide belt thickness measurement structure, which specifically includes the following: Fixed block: high-strength bolts are used to fasten the fixed block to the conveyor frame pre-set interface on both sides of the roller, the bolts are pre-tightened according to the pre-set torque, and the torque wrench is controlled to avoid deformation of the frame. The top of the fixed block is reserved for the installation of a cross-roller bearing mounting groove, two positioning pins are embedded in the groove, the spacing error meets the pre-set spacing error range, and the coaxiality of the bearing inner ring and the fixed block is ensured within the pre-set axial error range; Adjusting mechanism: the horizontal angle adjusting mechanism is rigidly welded with the outer ring of the cross-roller bearing, and the torque threshold of the knob is set to 5 newton meters to prevent excessive locking from causing bearing jamming; the elevation angle adjusting support rod is vertically welded on the top of the horizontal mechanism, the top of the support rod is hinged to the bottom of the sliding table base through a fish-eye bearing, and an elevation locking mechanism with torque feedback is installed on the side of the sliding table base; Measurement module: the linear module is fixed to the sliding table base through four bolts, the module slider is connected with the measurement device, the integrated surface laser emitting end, receiving end and dual-axis inclination sensor are rigidly connected through flanges, one end of the drag chain is fixed to the drag chain frame of the sliding table base, and the other end is connected with the cable interface of the measurement device to ensure that the cable is not tangled when the module moves.

[0004] In a second aspect, the embodiment of the present application provides a movable adjustable wide belt thickness measuring system, which specifically includes the following modules: Measurement calibration module: combining mechanical positioning pre-tightening, two-way vector fitting calibration and multi-source noise suppression technology, the roller axis and the laser surface vector are fitted through the cross-roller bearing positioning pin hole and the least squares method, and the bolt pre-tightening torque control and the sliding window filtering are combined to shorten the calibration time of the reference data; Adjusting and compensating module: designing gray scale mutation edge detection, stroke adaptive redundancy and runout trend prediction mechanism, dynamically identifying the belt edge through laser gray scale difference, and pre-setting stroke redundancy to adapt to belt runout; combining runout trend prediction based on historical data to adjust the starting position of the module in advance; Control correction module: based on the adjustment of the starting position of the module, speed synchronization control, dynamic inclination compensation and environmental light adaptive correction are performed, the belt speed, laser sampling frequency and module moving speed are matched; combining the real-time correction of the vertical distance by the dual-axis inclination sensor; combining the correction of the environmental light coefficient by narrowband filtering; Analysis and calculation module: an analysis model for wear pattern analysis is constructed, full-width thickness data is stored in a matrix to obtain complete cross-sectional thickness; combining gray scale threshold identification of steel wire and introducing corrosion coefficient correction safety distance, combining cross-sectional area and wear gradient calculation, realizing four-dimensional parameter output of thickness, safety distance, wear pattern and corrosion degree; Adjustment optimization module: design the mechanism of double-angle linkage adjustment driven by thickness deviation, adaptive correction of stroke and feedback of environmental parameters, adjust the elevation angle and horizontal angle by synchronous driving of thickness deviation, solve the accumulation of laser alignment deviation and dynamic measurement error, and trigger the recalibration of environmental parameters; combine with real-time correction of module stroke by belt width.

[0005] In a third aspect, the application provides a method for adjusting and moving a wide belt thickness measurement, which specifically includes the following steps: Step one: combine mechanical positioning pre-tightening, two-way vector fitting calibration and multi-source noise suppression technology, position the cross roller bearing pin hole, fit the roller axis and laser surface vector by least square method, combine with bolt pre-tightening torque control and sliding window filtering, shorten the calibration time of reference data; Step two: design gray scale mutation edge detection, adaptive redundancy of stroke and runout trend prediction mechanism, dynamically identify the belt edge by laser gray scale difference, and preset the stroke redundancy to adapt to the belt runout; combine with the runout trend prediction of historical data to adjust the starting position of the module in advance; Step three: based on the starting position of the adjustment module, perform speed synchronization control, dynamic inclination compensation and environmental light adaptive correction, match the belt speed with the laser sampling frequency and the module moving speed; combine with the real-time correction of vertical distance by double-axis inclination sensor; combine with narrowband filtering to correct the environmental light coefficient; Step four: build an analysis model for wear pattern analysis, store full-width thickness data in matrix form to obtain complete cross-section thickness; combine with gray threshold value identification of steel wire and introduction of corrosion coefficient correction safety distance, combine with cross-sectional area and wear gradient calculation to realize four-dimensional parameter output of thickness, safety distance, wear pattern and corrosion degree; Step five: design the mechanism of double-angle linkage adjustment driven by thickness deviation, adaptive correction of stroke and feedback of environmental parameters, adjust the elevation angle and horizontal angle by synchronous driving of thickness deviation, solve the accumulation of laser alignment deviation and dynamic measurement error, and trigger the recalibration of environmental parameters; combine with real-time correction of module stroke by belt width.

[0006] The application has the following advantages: 1. Fusion mechanical positioning pre-tightening, two-way vector fitting calibration and multi-source noise suppression technology, through cross roller bearing positioning pin hole, least square method fitting roller axis and laser surface vector, new bolt pre-tightening torque control and sliding window filtering, shorten the calibration time, improve the data purity; Design gray mutation edge detection, travel adaptive redundancy and runout trend prediction mechanism, dynamically identify the belt edge through the laser gray difference, preset the travel redundancy to adapt to the belt runout; Add runout trend prediction based on historical data, adjust the module starting position in advance; Speed synchronization control, dynamic inclination compensation and ambient light adaptive correction, through the linkage matching of belt speed, laser sampling frequency and module moving speed, solve the data fault caused by the asynchronous measurement and movement; Combined with the real-time correction of vertical distance by double-axis inclination sensor, reduce the error caused by belt inclination; Add narrowband filtering and ambient light coefficient correction to solve the problem of ambient light interference with laser reception; 2. Construct the analysis model of full cross-section thickness matrix, gray mutation steel wire positioning corrosion coefficient correction and wear pattern analysis, store full-width thickness data in matrix form to obtain complete cross-section thickness; Combined with gray threshold value recognition of steel wire and introduction of corrosion coefficient correction safety distance, solve the problem of steel wire positioning loss and corrosion leading to inaccurate safety evaluation; Add cross-sectional area and wear gradient calculation to solve the problem of single thickness parameter without overall wear evaluation, realize four-dimensional parameter output of thickness, safety distance, wear pattern and corrosion degree; Design thickness deviation driven double-angle linkage adjustment, travel adaptive correction and environmental parameter feedback mechanism, adjust the elevation angle and horizontal angle by synchronously driving the thickness deviation, solve the problem of laser alignment deviation accumulation and dynamic measurement error, and trigger the environmental parameter re-calibration to solve the deviation caused by environmental interference; Combined with real-time correction of module travel by belt width. BRIEF DESCRIPTION OF DRAWINGS

[0007] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following will briefly introduce the drawings needed to be used in the embodiment description. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor.

[0008] Figure 1 is a step flow chart of an adjustable mobile wide belt thickness measuring system and structure provided by embodiment 1 of the present application; Figure 2 is a structural schematic diagram of an adjustable mobile wide belt thickness measuring system and structure provided by embodiment 2 of the present application. DETAILED DESCRIPTION

[0009] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. 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 embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0010] Example 1: An adjustable movable wide belt thickness measuring structure provided in this embodiment of the invention specifically includes the following: Fixed blocks: High-strength bolts are used to fasten the fixed blocks to the preset interfaces of the conveyor frame on both sides of the roller. The bolts are pre-tightened according to the preset torque and controlled by a torque wrench to prevent the frame from deforming. The top of the fixed block has a reserved groove for the installation of cross roller bearings. Two positioning pins are embedded in the groove. The spacing error meets the preset spacing error range to ensure that the coaxiality of the bearing inner ring and the fixed block is within the preset axiality error. Adjustment mechanism: The horizontal angle adjustment mechanism is rigidly welded to the outer ring of the crossed roller bearing. The knob torque threshold is set to 5 Nm to prevent excessive tightening from causing the bearing to jam. The elevation angle adjustment support rod is vertically welded to the top of the horizontal mechanism. The top of the support rod is hinged to the bottom of the slide table through a fisheye bearing. An elevation angle locking mechanism with torque feedback is installed on the side of the slide table. Measurement Module: The linear module is fixed to the slide base with 4 bolts. The module slider and the measuring device, the integrated surface laser emitter, receiver and dual-axis tilt sensor are rigidly connected by a flange. One end of the cable chain is fixed to the cable chain frame of the slide base, and the other end is connected to the cable interface of the measuring device to ensure that the cable does not get tangled when the module moves.

[0011] Example 2: As Figure 1 As shown in the figure, an adjustable movable wide belt thickness measurement system provided by an embodiment of the present invention specifically includes the following modules: Measurement and calibration module: Integrating mechanical positioning preload, dual-vector fitting calibration and multi-source noise suppression technology, it uses cross roller bearing positioning pin holes, least squares fitting of roller axis and laser surface vector, combined with bolt preload torque control and sliding window filtering to shorten calibration time and improve data purity; In a specific embodiment, reference data is collected. The laser emitting end of the starting surface covers the entire axial length of the roller, and the receiving end collects the coordinates of the light spots on both ends of the roller. and Simultaneously, the initial distance from the measuring device to the roller surface is recorded by the distance sensor built into the receiver. ; Horizontal angle calibration, based on data acquisition and Calculate the horizontal vector of the roller axis Simultaneously acquire the coordinates of the laser spot corresponding to the laser surface on the end face of the roller. and Calculate the horizontal vector of the laser surface Rotate the horizontal angle adjustment mechanism to monitor the angle deviation in real time until the deviation meets the preset angle deviation range, then tighten the knob. The specific method for calculating the angular deviation is as follows: Obtain the horizontal vector of the roller axis Horizontal vector of laser surface Through the formula: Analysis yielded angular deviation ,in, The horizontal vector magnitude of the roller axis. The horizontal vector magnitude of the laser surface; Elevation angle calibration, collecting the coordinates of the light spot on the middle surface of the roller. The height of the slide table is finely adjusted by the ball screw of the elevation adjustment support rod so that the laser surface completely covers the roller generatrix. The elevation angle deviation is calculated until the deviation meets the preset elevation angle deviation range, and then the elevation angle locking mechanism is locked. The specific method for calculating the elevation angle deviation is as follows: The coordinates of the light spot on the middle surface of the roller are obtained using the formula: Analysis yielded elevation angle deviation ; The laser receiver acquires the three-dimensional coordinates (x, y, z) and grayscale value of the laser spot, and synchronously outputs the initial distance from the device to the roller surface. ; A torque sensor, integrated into the horizontal / elevation locking mechanism, collects the locking torque value in real time to ensure that it meets the set locking torque threshold. Two-vector fitting was used to obtain the coordinates of the light spots on both ends of the roller using the least squares method. and Linear regression was performed to obtain the equation for the roller axis. The vectors are compared in real time with the laser surface vectors to eliminate abnormal vectors that exceed the preset axiality error range; Multi-order noise suppression involves removing outliers caused by vibration using box plots, and smoothing the remaining data using a 5-point sliding window filter. The formula is as follows: Reduce the impact of high-frequency vibration and noise; Preload torque verification: If the torque sensor value deviates from the set threshold by ±10%, an audible and visual alarm will be triggered, prompting the user to readjust the bolts / knobs to avoid calibration deviations caused by mechanical stress. Adjustment and compensation module: Designed grayscale abrupt change edge detection, travel adaptive redundancy and belt deviation trend prediction mechanism. It dynamically identifies belt edges through laser grayscale difference, presets travel redundancy to adapt to belt deviation; and combines historical data to predict belt deviation trend to adjust the module's starting position in advance. In a specific embodiment, the linear module is activated, driving the measuring device to move along the roller axis. The laser receiver collects the grayscale value of the belt surface. When the grayscale value changes abruptly from the background grayscale to the belt grayscale, it is marked as the belt edge coordinate. Continue moving until the grayscale value abruptly changes from the belt grayscale back to the background grayscale, then mark it as... Calculate the actual width of the belt ; Repeat the measurement three times and take the average value as the final actual width of the belt. Eliminate edge misjudgment caused by impurities on the belt surface; The stroke setting is based on the final actual width of the belt, which determines the stroke of the linear module. Each side has a 100mm redundancy to accommodate ±100mm belt misalignment during operation and to set the initial moving speed of the module. To pre-compensate for belt misalignment, historical operating data of the conveyor was retrieved, and the belt misalignment trend coefficient was calculated using linear regression. If the trend coefficient deviates If the deviation exceeds the preset deviation trend threshold, the module's starting position will be shifted in the deviation direction. To avoid missing edges during measurement; Start the module without load along the linear module travel. The slider moves back and forth three times, and the module encoder records the endpoint position of each movement to calculate the positioning error. ,in, The actual endpoint coordinates, To set the endpoint coordinates, if the positioning error... If the error exceeds the preset positioning range, the parallelism of the module will be corrected by adjusting the bolts at the bottom of the slide base. Simultaneously check the cable chain's extension and retraction status. If jamming occurs, adjust the position of the cable chain frame to ensure smooth movement. The laser receiver collects grayscale values ​​and edge coordinates. The module encoder outputs slider position data in real time; the conveyor control system acquires belt misalignment data for nearly M hours. Edge recognition is optimized by using an adaptive grayscale threshold algorithm, which adjusts the grayscale difference threshold according to the real-time ambient light intensity to avoid edge misjudgment caused by ambient light interference. Deviation trend prediction, based on historical deviation data Perform linear regression and fit the equation. Obtain the belt offset position at time t ,in n is the number of data points. As the initial offset position, the deviation trend coefficient is used. Determine the direction and speed of deviation; Positioning error statistics: Calculate the average positioning error of three unloaded movements. and the standard deviation of positioning error If the standard deviation of the positioning error If the error exceeds the preset standard deviation threshold, a prompt will be made to lubricate the module guide rail. Control and correction module: Based on speed synchronization control, dynamic tilt compensation and ambient light adaptive correction, it solves the data gap caused by the asynchrony between measurement and movement by linking and matching belt speed with laser sampling frequency and module moving speed; combined with dual-axis tilt sensor to correct vertical distance in real time, reducing the error caused by belt tilt; combined with narrowband filtering to correct ambient light coefficient, solving the problem of ambient light interfering with laser reception. In a specific embodiment, the real-time speed of the conveyor belt is read by the conveyor PLC. If the PLC data is interrupted, the speed will be automatically switched to the laser Doppler velocimetry module built into the measuring device. The sampling frequency is matched with the module speed, and the sampling point interval in the belt running direction is set. Laser sampling frequency Ensure there are no data gaps in the running direction; set the interval for axial sampling points on the roller. linear module moving speed To ensure uniform axial sampling; The module slider starts from the pre-compensated starting position, at the module's initial moving speed. The cable chain moves synchronously up and down along the roller axis; the surface laser emitter continuously emits a laser surface, and the receiver collects data for each frame at frequency f. Each frame of data includes: axial direction... Three-dimensional coordinates of each sampling point And i = 1, 2, ..., m, where i is the sampling point index, the X-axis is the roller axis, the Y-axis is the belt running direction, and the Z-axis is the vertical direction; Obtain the grayscale value of each sampling point The real-time tilt angle of the belt is collected by a dual-axis tilt sensor. That is, the tilt angle along the roller axis; A narrowband filter is installed at the laser receiver to filter out stray light of other wavelengths in the environment. The real-time light intensity I is collected by an ambient light sensor. If the real-time light intensity exceeds a preset light intensity threshold, the grayscale value is corrected using the formula: Analysis yields corrected grayscale values ,in, This is the light intensity correction coefficient, with a preset value of 0.01, to ensure a stable grayscale difference between the steel wire and the rubber area; Based on the timestamp of the laser receiver, linear interpolation is performed on the tilt angle, ambient light, and speed data to ensure that each frame of laser data corresponds to a unique real-time tilt angle, real-time light intensity, and real-time belt speed, thus avoiding compensation deviations caused by time differences. Belt tilt will cause vertical distance Too large; adjust vertical distance based on real-time tilt angle. Also consider the effect of ambient light on vertical distance The influence of acquisition accuracy, introducing the ambient light coefficient. By correcting the formula: Analysis yields corrected vertical distance ,in, This represents the real-time tilt angle of the belt; Linear interpolation is used to correct the coordinates of the belt running direction. To ensure that the sampling points at different axial positions are evenly spaced along the running direction, the formula is: The alignment coordinates of the running direction were obtained through analysis. ,in, Let i be the timestamp of the i-th sampling point. This is the start timestamp; Calculate the standard deviation of grayscale values ​​for each frame of data. ,like If the value is greater than 50, it indicates that the grayscale fluctuation within the frame is too large. In this case, the corresponding frame data will be removed and the data will be completed by interpolation between the preceding and following frames to ensure data continuity. Analysis and Calculation Module: Constructs an analytical model for full-section thickness matrix, gray-scale abrupt steel wire positioning corrosion coefficient correction, and wear morphology analysis. It obtains complete cross-sectional thickness by storing full-width thickness data in a matrix. It identifies steel wires by combining gray-scale thresholds and introduces a corrosion coefficient to correct the safety distance, solving the problems of inaccurate safety assessments caused by missing steel wire positioning and corrosion. It adds calculations for cross-sectional area and wear gradient to solve the problem of lacking overall wear assessment with only a single thickness parameter, achieving four-dimensional parameter output of thickness, safety distance, wear morphology, and corrosion degree. In a specific embodiment, with the belt not covering the rollers, the conveyor is unloaded, and the linear module is started along the linear module's travel path. The laser receiver moves and collects vertical distance data from the roller surface. And i=1,2,...,m, where m is the number of collection points. Repeated collections are taken and the average value is stored as a benchmark database. Construct the full cross-section thickness matrix based on the corrected vertical distance. Calculate the belt thickness at each sampling point. To avoid the influence of positive and negative signs, correct the vertical distance. This refers to the distance between the belt surface and the vertical distance data. The distance between the roller surfaces is the absolute value of the difference, which represents the thickness. Along the direction of linear module movement, each time it moves 1 Repeat the thickness calculation to obtain the full-width thickness matrix H, with dimensions m×n, and , The total number of samples for the full-width measurement, matrix elements The belt thickness represents the j-th axial position and the i-th running direction position; Steel wire area recognition, setting grayscale threshold Iterate through the grayscale curve of each frame of data, when the grayscale value When the value is ≥250, it is determined to be a steel wire area, and the corresponding corrected vertical distance is... That is, the vertical distance from the surface of the steel wire. ; Calculate the corrected wire safety distance This reflects the actual safe thickness from the belt surface to the steel wire. If corrosion reduces the strength of the steel wire, the safe distance threshold will be reduced. Calculate the wear non-uniformity and extract the thickness curve for each axial position j. Cubic spline interpolation was used to fit the curve to ensure smoothness, and the maximum thickness at that location was calculated. Minimum thickness Average thickness, wear unevenness ; For the fitted thickness curve The cross-sectional area of ​​the belt at this axial position is calculated using the trapezoidal integral method. ,in, The overall wear level is assessed by using the ratio of the belt cross-sectional area to the designed cross-sectional area as the integral step size. Adjustment and optimization module: Design a mechanism for dual-angle linkage adjustment driven by thickness deviation, adaptive stroke correction and environmental parameter feedback. By synchronously driving the elevation angle and horizontal angle adjustment through thickness deviation, it solves the problem of laser alignment deviation accumulation and dynamic measurement error, and triggers environmental parameter recalibration to solve the deviation caused by environmental interference; combined with real-time correction of the module stroke by belt width; In a specific embodiment, the overall average value of the thickness matrix H is calculated. With belt design thickness By comparison, the thickness deviation was obtained. ; If thickness deviation If the thickness deviation exceeds the preset threshold, it is determined that there is an alignment deviation or environmental interference in the measurement system, and dynamic adjustment is initiated; if the thickness deviation... If the thickness deviation is less than or equal to the preset thickness deviation threshold, maintain the current parameters and continue the measurement; Based on thickness deviation Calculate the elevation adjustment amount , The thickness bias influence coefficient was calibrated experimentally; the ball screw of the elevation angle adjustment support rod was adjusted according to the elevation angle. Automatic fine-tuning is performed, and three sets of thickness data are collected after adjustment. If there is a thickness deviation... If the thickness deviation exceeds the preset threshold, the ambient light sensor and distance sensor will be automatically recalibrated to eliminate deviations caused by environmental interference. The adjustment will be repeated up to 3 times to avoid over-adjustment. The horizontal angle adjustment amount is calculated synchronously, and the crossed roller bearing is rotated to adjust according to the horizontal angle adjustment amount. During the adjustment process, the dial value is read in real time to ensure that the angle deviation is less than or equal to the preset angle deviation threshold. After adjustment, the knob is locked. During the dynamic measurement process, the belt edge coordinates are reacquired every 10 seconds. and Calculate real-time width ; Calculate width deviation If the width deviation If the width deviation exceeds the set threshold, the linear module travel is recalculated and updated. Based on the updated linear module stroke Recalculate f and adjust the calculation to update the linear module's movement speed. ; After the current measurement cycle ends, the module automatically switches to updating the linear module stroke. No downtime is required, ensuring continuous measurement. After adjustment, collect 100 frames of thickness data and calculate the new overall update average. thickness update deviation If the thickness update deviation If the thickness deviation is less than or equal to the preset thickness deviation threshold, the adjustment is successful; if the thickness update deviation is... If the thickness deviation exceeds the preset threshold, an audible and visual alarm will be triggered, prompting manual inspection. The adjusted elevation angle, horizontal angle, stroke, and speed parameters are stored in the system memory as initial parameters for the next startup, reducing the time spent on repeated adjustments.

[0012] Example 3: As Figure 2 As shown in the figure, an adjustable movable wide belt thickness measurement method provided by an embodiment of the present invention specifically includes the following steps: Step 1: Integrating mechanical positioning preload, dual-vector fitting calibration, and multi-source noise suppression technologies, the calibration time for reference data is shortened by using the positioning pin holes of the cross roller bearing, fitting the roller axis with the laser surface vector using the least squares method, and combining bolt preload torque control and sliding window filtering. Step 2: Design a grayscale abrupt change edge detection, travel adaptive redundancy, and belt misalignment trend prediction mechanism. Dynamically identify belt edges through laser grayscale difference, preset travel redundancy to adapt to belt misalignment; combine historical data to predict belt misalignment trends and adjust the module's starting position in advance. Step 3: Based on adjusting the initial position of the module, speed synchronization control, dynamic tilt compensation, and ambient light adaptive correction are performed. This is achieved through the linkage and matching of belt speed, laser sampling frequency, and module moving speed; real-time correction of vertical distance is combined with dual-axis tilt sensors; and the ambient light coefficient is corrected using narrowband filtering. Step 4: Construct an analytical model for wear morphology analysis. By storing the full width thickness data in a matrix, the complete cross-sectional thickness is obtained. The steel wire is identified by combining grayscale threshold and the corrosion coefficient is introduced to correct the safety distance. The cross-sectional area and wear gradient are combined to calculate and output four-dimensional parameters: thickness, safety distance, wear morphology, and corrosion degree. Step 5: Design a mechanism for dual-angle linkage adjustment driven by thickness deviation, adaptive stroke correction, and environmental parameter feedback. By synchronously driving the elevation and horizontal angle adjustments through thickness deviation, the mechanism solves the problems of laser alignment deviation accumulation and dynamic measurement error, and triggers environmental parameter recalibration. Combined with real-time correction of the module stroke by belt width.

[0013] The above provides a detailed description of one embodiment of the present invention, but the content described is only a preferred embodiment of the present invention and should not be considered as limiting the scope of the present invention. The above formulas are all dimensionless numerical calculations, and the formulas are derived from software simulations based on a large amount of collected data to obtain the most recent real-world situation. The preset parameters in the formulas are set by those skilled in the art based on actual conditions and historical experience, and can be adjusted according to actual conditions. The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. All equivalent changes and improvements made in accordance with the scope of the present invention should still fall within the patent coverage of the present invention.

Claims

1. An adjustable movable wide belt thickness measurement system, characterized in that, Includes the following steps: Measurement and calibration module: It integrates mechanical positioning preload, dual-vector fitting calibration and multi-source noise suppression technology. It uses the positioning pin hole of the cross roller bearing, the least squares method to fit the roller axis and the laser surface vector, and combines bolt preload torque control and sliding window filtering to shorten the calibration time of the reference data. Adjustment and compensation module: Designed grayscale abrupt change edge detection, travel adaptive redundancy and belt deviation trend prediction mechanism. It dynamically identifies belt edges through laser grayscale difference, presets travel redundancy to adapt to belt deviation; and combines historical data to predict belt deviation trend to adjust the module's starting position in advance. Control and correction module: Based on adjusting the starting position of the module, it performs speed synchronization control, dynamic tilt compensation, and ambient light adaptive correction. This is achieved through the linkage and matching of belt speed, laser sampling frequency, and module movement speed; combined with dual-axis tilt sensors, it corrects the vertical distance in real time; and combined with narrowband filtering, it corrects the ambient light coefficient. Analysis and Calculation Module: Constructs a wear morphology analysis model, obtains the complete cross-sectional thickness by storing full-width thickness data in a matrix, identifies steel wires by combining grayscale thresholds and introduces a corrosion coefficient to correct the safety distance, and calculates the cross-sectional area and wear gradient to achieve four-dimensional parameter output of thickness, safety distance, wear morphology and corrosion degree; Adjustment and optimization module: Design a mechanism for dual-angle linkage adjustment driven by thickness deviation, adaptive stroke correction and environmental parameter feedback. By synchronously driving the elevation angle and horizontal angle adjustment through thickness deviation, it solves the problem of laser alignment deviation accumulation and dynamic measurement error, and triggers environmental parameter recalibration. Combined with belt width, it corrects the module stroke in real time.

2. The adjustable movable wide belt thickness measuring system according to claim 1, characterized in that, The method for controlling the bolt preload torque is as follows: Horizontal angle calibration, combined with the collected data and Calculate the horizontal vector of the roller axis and the horizontal vector of the laser surface; rotate the horizontal angle adjustment mechanism, monitor the angle deviation in real time, and lock the knob until the deviation meets the preset angle deviation range. Elevation calibration involves collecting the coordinates of the light spot on the middle surface of the roller, fine-tuning the height of the slide table by adjusting the ball screw of the elevation adjustment support rod to ensure that the laser surface completely covers the roller generatrix, calculating the elevation deviation until the deviation meets the preset elevation deviation range, and locking the elevation locking mechanism. The laser receiver acquires the three-dimensional coordinates (x, y, z) and grayscale value of the light spot, and synchronously outputs the initial distance from the device to the roller surface; A torque sensor, integrated into the horizontal / elevation locking mechanism, collects the locking torque value in real time to ensure that it meets the set locking torque threshold. Two-vector fitting is used to perform linear regression on the coordinates of the light spots on both ends of the roller using the least squares method to obtain the roller axis equation. This equation is then compared in real time with the laser surface vector to remove abnormal vectors that exceed the preset axis error range. Preload torque verification: If the torque sensor value deviates from the set threshold by ±10%, an audible and visual alarm is triggered, prompting the user to readjust the bolts / knobs to avoid calibration deviations caused by mechanical stress.

3. The adjustable movable wide belt thickness measuring system according to claim 1, characterized in that, The method for detecting grayscale abrupt edge changes is as follows: The linear module is activated, causing the measuring device to move axially along the roller. The laser receiver collects the grayscale value of the belt surface. When the grayscale value abruptly changes from the background grayscale to the belt grayscale, it is marked as the belt edge coordinate. Continue moving until the grayscale value abruptly changes from the belt grayscale back to the background grayscale, then mark it as... Calculate the actual width of the belt ; Repeat the measurement three times and take the average value as the final actual width of the belt. Eliminate edge misjudgment caused by impurities on the belt surface.

4. The adjustable movable wide belt thickness measuring system according to claim 1, characterized in that, The method for adaptive redundancy of the travel route is as follows: Stroke setting: Set the stroke of the linear module based on the final actual width of the belt, and set the initial moving speed of the module; To pre-compensate for belt misalignment, historical operating data of the conveyor was retrieved, and the belt misalignment trend coefficient was calculated using linear regression. If the trend coefficient deviates If the deviation exceeds the preset deviation trend threshold, the module's starting position will be shifted in the deviation direction. Start the module without load along the linear module travel. The slider moves back and forth three times, and the module encoder records the endpoint position of each movement to calculate the positioning error. ,in, The actual endpoint coordinates, To set the endpoint coordinates, if the positioning error... If the error exceeds the preset positioning range, the parallelism of the module will be corrected by adjusting the bolts at the bottom of the slide base. Simultaneously check the cable chain's extension and retraction status. If jamming occurs, adjust the position of the cable chain frame to ensure smooth movement. The laser receiver collects grayscale values ​​and edge coordinates. The module encoder outputs slider position data in real time; the conveyor control system acquires belt misalignment data for nearly M hours.

5. The adjustable movable wide belt thickness measuring system according to claim 1, characterized in that, The method for predicting the deviation trend is as follows: Deviation trend prediction, based on historical deviation data Perform linear regression and fit the equation. ,in n is the number of data points. As the initial offset position, the deviation trend coefficient is used. Determine the direction and speed of deviation; Positioning error statistics: Calculate the average positioning error of three unloaded movements. and the standard deviation of positioning error If the standard deviation of the positioning error If the error exceeds the preset standard deviation threshold, a prompt will be made to lubricate the module guide rail.

6. The adjustable movable wide belt thickness measuring system according to claim 1, characterized in that, The method for correcting the ambient light coefficient is as follows: The sampling frequency is matched with the module speed, and the sampling point interval in the belt running direction is set. Laser sampling frequency Ensure there are no data gaps in the running direction; set the interval for axial sampling points on the roller. linear module moving speed ; The module slider starts from the pre-compensated starting position, at the module's initial moving speed. The roller moves along the axial direction, and the cable chain is simultaneously extended and retracted; the surface laser emitting end continuously emits a laser surface, and the receiving end collects data for each frame at frequency f. A narrowband filter is installed at the laser receiver to filter out stray light of other wavelengths in the environment. The real-time light intensity I is collected by the ambient light sensor. If the real-time light intensity is greater than the preset light intensity threshold, the gray value is corrected. Based on the timestamp of the laser receiver, linear interpolation is performed on the tilt angle, ambient light, and velocity data; Belt tilt will cause vertical distance Too large; adjust vertical distance based on real-time tilt angle. By introducing the ambient light coefficient, the corrected vertical distance is obtained through analysis using a correction formula. ; Linear interpolation is used to correct the coordinates of the belt running direction. The alignment coordinates of the running direction were obtained through analysis. ; Calculate the standard deviation of grayscale values ​​for each frame of data. ,like If the value is greater than 50, it indicates that the grayscale fluctuation within the frame is too large. In this case, the corresponding frame data will be removed and the data will be supplemented by interpolation between the preceding and following frames.

7. The adjustable movable wide belt thickness measuring system according to claim 1, characterized in that, The method for correcting the safety distance is as follows: Construct the full cross-section thickness matrix based on the corrected vertical distance. Calculate the belt thickness at each sampling point. To avoid the influence of positive and negative signs, correct the vertical distance. This refers to the distance between the belt surface and the vertical distance data. The distance between the roller surfaces is the absolute value of the difference, which represents the thickness. Along the direction of linear module movement, the thickness calculation is repeated every time the module moves one sampling point, resulting in a full-width thickness matrix H with dimensions m×n. , The total number of samples for the full-width measurement, matrix elements The belt thickness represents the j-th axial position and the i-th running direction position; Steel wire area recognition, setting grayscale threshold Iterate through the grayscale curve of each frame of data, when the grayscale value When the value is ≥250, it is determined to be a steel wire area, and the corresponding corrected vertical distance is... That is, the vertical distance from the surface of the steel wire. ; Calculate the corrected wire safety distance This reflects the actual safe thickness from the belt surface to the steel wire. If corrosion reduces the strength of the steel wire, the safe distance threshold will be reduced.

8. The adjustable movable wide belt thickness measuring system according to claim 1, characterized in that, The method for constructing the wear morphology analysis model is as follows: Calculate the corrected wire safety distance This reflects the actual safe thickness from the belt surface to the steel wire. If corrosion reduces the strength of the steel wire, the safe distance threshold will be reduced. Calculate the wear non-uniformity and extract the thickness curve for each axial position j. Cubic spline interpolation was used to fit the curve to ensure smoothness, and the maximum thickness at that location was calculated. Minimum thickness Average thickness, wear unevenness ; For the fitted thickness curve The cross-sectional area of ​​the belt at this axial position is calculated using the trapezoidal integral method. ,in, The overall wear level is assessed by using the ratio of the belt cross-sectional area to the designed cross-sectional area as the integral step size.

9. An adjustable movable wide belt thickness measuring system according to claim 1, characterized in that, The method for real-time correction of module travel is as follows: Calculate the overall average value of the thickness matrix H With belt design thickness By comparison, the thickness deviation was obtained. ; If thickness deviation If the thickness deviation exceeds the preset threshold, it is determined that there is an alignment deviation or environmental interference in the measurement system, and dynamic adjustment is initiated; if the thickness deviation... If the thickness deviation is less than or equal to the preset thickness deviation threshold, maintain the current parameters and continue the measurement; Based on thickness deviation Calculate the elevation adjustment amount The ball screw of the elevation angle adjustment support rod is adjusted according to the elevation angle. Automatic fine-tuning is performed, and three sets of thickness data are collected after adjustment. If there is a thickness deviation... If the deviation exceeds the preset thickness threshold, the ambient light sensor and distance sensor will be automatically recalibrated to eliminate deviations caused by environmental interference and the adjustment will be repeated. The horizontal angle adjustment amount is calculated synchronously, and the crossed roller bearing is rotated to adjust according to the horizontal angle adjustment amount. During the adjustment process, the dial value is read in real time to ensure that the angle deviation is less than or equal to the preset angle deviation threshold. After adjustment, the knob is locked. During the dynamic measurement process, the belt edge coordinates are reacquired every 10 seconds. and Calculate real-time width ; Calculate width deviation If the width deviation is greater than the set width deviation threshold, then the linear module stroke is calculated and updated. Based on the updated linear module stroke Recalculate the laser sampling frequency f and simultaneously adjust the calculation to update the linear module's moving speed. ; After the current measurement cycle ends, the module automatically switches to update the linear module stroke. After adjustment, collect 100 frames of thickness data, calculate the new overall update average and thickness update deviation. If the thickness update deviation is less than or equal to the preset thickness deviation threshold, the adjustment is successful; if the thickness update deviation is greater than the preset thickness deviation threshold, an audible and visual alarm is triggered, prompting manual inspection.

10. An adjustable movable wide belt thickness measuring structure, the thickness measuring structure being used to perform the thickness measuring system according to any one of claims 1-9, characterized in that, include: Fixed block: The fixed block is fastened to the preset interface of the conveyor frame on both sides of the roller with high-strength bolts. The bolts are pre-tightened according to the preset torque and controlled by a torque wrench. The top of the fixed block is reserved with a cross roller bearing mounting groove. Two positioning pins are embedded in the groove. The spacing error meets the preset spacing error range to ensure that the coaxiality of the bearing inner ring and the fixed block is within the preset axiality error. Adjustment mechanism: The horizontal angle adjustment mechanism is rigidly welded to the outer ring of the crossed roller bearing, and the knob torque threshold is set to 5 Nm; the elevation angle adjustment support rod is vertically welded to the top of the horizontal mechanism, and the top of the support rod is hinged to the bottom of the slide table through a fisheye bearing. An elevation angle locking mechanism with torque feedback is installed on the side of the slide table. Measurement Module: The linear module is fixed to the slide base with 4 bolts. The module slider and the measuring device, the integrated surface laser emitter, receiver and dual-axis tilt sensor are rigidly connected by a flange. One end of the cable chain is fixed to the cable chain frame of the slide base, and the other end is connected to the cable interface of the measuring device to ensure that the cable does not get tangled when the module moves.

Images