Adjustable mobile wide belt thickness measuring system and structure

Abstract

The present application relates to the technical field of belt thickness measurement, and discloses an adjustable mobile wide belt thickness measurement system and structure, which comprises the following steps: positioning through a cross-roller bearing positioning pin hole, fitting a roller axis with a laser surface vector, adding a bolt pre-tightening torque control and a sliding window filtering; dynamically identifying the belt edge through a laser gray difference value, presetting a stroke redundancy to adapt to belt deviation, combining historical data to predict the deviation trend, performing self-adaptive correction, real-time correction of the vertical distance, constructing a wear pattern analysis model to obtain the complete cross-sectional thickness, combining the gray threshold value to identify the steel wire and introducing a corrosion coefficient to correct the safety distance, adding cross-sectional area and wear gradient calculation to solve the problem of no overall wear evaluation, synchronously driving the elevation angle and horizontal angle adjustment through the thickness deviation to solve the laser alignment deviation accumulation and dynamic measurement error, triggering the environmental parameter re-calibration to solve the deviation caused by environmental interference, and real-time correction of the module stroke combined with the belt width.

Description

Technical Field

[0001] This invention relates to the field of belt thickness measurement technology, specifically to an adjustable and movable wide belt thickness measurement system and structure. Background Technology

[0002] The current technical background of belt thickness measurement is characterized by strong reliance on manual labor, significant defects in traditional solutions, and a lack of adaptability to wide belts. In industries such as mining and ports, the thickness measurement of wide belts has long relied on manual inspections during shutdowns, which requires interrupting production. Visual inspection of belt damage can only identify obvious cracks and measure the specific thickness. Furthermore, walking inspections of ultra-wide / long-distance belts are time-consuming and laborious, and potential wear risks are difficult to identify, resulting in poor reliability.

[0003] In existing technologies, thickness is calculated by using distance sensors located above and below the conveyor belt. However, bending, tilting, and fluctuations during belt operation can cause the measured data to be greater than the actual value. Laser detection requires line laser sensors on both the upper and lower sides of the belt, resulting in sensor redundancy and waste. Furthermore, it cannot locate the position of the steel wires in the steel wire lining of the belt, making it difficult to measure the actual safe distance between the worn surface and the steel wires. Existing technologies can only achieve single-point / local line measurement, lacking surface laser technology to obtain the complete cross-sectional shape of the roller and belt. Additionally, the absence of a linear module along the roller axis prevents coverage of the edge areas of ultra-wide belts, leading to measurement blind spots and an inability to reflect overall wear uniformity. The core prerequisite for surface laser measurement is surface laser technology. Precise alignment with the roller axis ensures accurate cross-sectional measurement reference. However, wide belt conveyors are prone to laser axis misalignment due to installation errors and roller deformation. Existing patents lack a coordinated mechanism for elevation and horizontal angle adjustment, relying solely on fixed installation, which fails to calibrate the alignment between the laser and the axis, resulting in inconsistent cross-sectional measurement references at different positions on the wide belt. During operation, load changes and roller vibrations can cause lateral belt shift or tilting, and there is no real-time dynamic adjustment function: neither an elevation compensation mechanism to correct laser incident angle deviation caused by belt tilting nor a horizontal angle fine-tuning function to address lateral shift, making it impossible to guarantee that the laser always covers the target area during measurement.

[0004] Therefore, there is a need to provide an adjustable, movable wide belt thickness measurement system and structure. Summary of the Invention

[0005] The purpose of this invention is to provide an adjustable, movable wide belt thickness measurement system and structure. To solve the above-mentioned problems in the prior art, this invention achieves this through the following technical solution:

[0006] In a first aspect, the adjustable movable wide belt thickness measuring structure provided by the embodiments of the present invention specifically includes the following:

[0007] 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 to avoid deformation of the frame. 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.

[0008] 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 base through a fisheye bearing. An elevation angle locking mechanism with torque feedback is installed on the side of the slide base.

[0009] Measuring linear module: The linear module is fixed to the slide base with 4 bolts. The linear module slider and measuring device, integrated with the surface laser emitter, receiver and dual-axis tilt sensor are rigidly connected by flange. One end of the drag chain is fixed to the drag 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 linear module moves.

[0010] Secondly, the adjustable movable wide belt thickness measurement system provided in this embodiment of the invention specifically includes the following modules:

[0011] Measurement and calibration module: Collects roller reference data and locking torque value for calibration and verification, completes horizontal and vertical angle calibration and preload torque verification, eliminates abnormal vectors through dual vector fitting, uses box plot method and sliding window filtering to complete multi-order noise suppression, verifies preload torque and executes abnormal alarm;

[0012] Adjustment and compensation module: Combines the reference data to start the straight module, identifies the belt edge coordinates through gray-scale change and calculates the final actual belt width, sets the straight module stroke, combines historical data to predict and pre-compensate the deviation trend, verifies the positioning error and corrects the parallelism of the straight module, and adjusts the starting position of the straight module in advance.

[0013] Control and correction module: Based on adjusting the starting position of the linear module, the real-time speed of the belt is obtained. The belt speed, laser sampling frequency and linear module movement speed are linked and matched to adjust the gray value and vertical distance, remove abnormal frames of belt gray value fluctuation and perform interpolation to complete the data.

[0014] Analysis and calculation module: Combining grayscale values ​​and vertical distance, it collects the distance on the roller surface to establish a benchmark database, calculates and stores the full cross-section thickness matrix, identifies the steel wire area based on the grayscale threshold and corrects the safety distance, analyzes and calculates the wear unevenness of the belt, solves the cross-sectional area of ​​the belt, and forms four-dimensional evaluation parameters to evaluate the overall wear degree of the belt.

[0015] Adjustment and optimization module: Calculates thickness and width deviations using the full cross-section thickness matrix, adjusts elevation and horizontal angles in conjunction, dynamically corrects the travel and movement speed of the linear module, collects thickness data after adjustment to verify the effect, updates the initial startup value, and triggers an alarm when an anomaly occurs.

[0016] Thirdly, the adjustable movable wide belt thickness measurement method provided by the embodiments of the present invention specifically includes the following steps:

[0017] 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.

[0018] 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 starting position of the straight module in advance.

[0019] Step 3: Based on adjusting the starting position of the linear 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 linear module movement speed; real-time correction of vertical distance is combined with dual-axis tilt sensors; and ambient light coefficient is corrected using narrowband filtering.

[0020] 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.

[0021] 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 the belt width, the linear module stroke is corrected in real time.

[0022] The beneficial effects of this invention are:

[0023] 1. Integrating mechanical positioning pre-tightening, dual-vector fitting calibration, and multi-source noise suppression technologies, this system uses cross roller bearing positioning pin holes and least squares method to fit the roller axis and laser surface vector. New features include bolt pre-tightening torque control and sliding window filtering, shortening calibration time and improving data purity. A grayscale abrupt change edge detection, adaptive stroke redundancy, and belt misalignment prediction mechanism are designed. The system dynamically identifies belt edges using laser grayscale differences and pre-sets stroke redundancy to adapt to belt misalignment. A new feature is added: belt misalignment trend prediction based on historical data, allowing for advance adjustment of the linear module's starting position. Speed ​​synchronization control, dynamic tilt compensation, and ambient light adaptive correction are implemented. By linking belt speed with laser sampling frequency and linear module movement speed, data gaps caused by asynchronous measurement and movement are resolved. Real-time vertical distance correction using dual-axis tilt sensors reduces errors caused by belt tilt. Narrowband filtering and ambient light coefficient correction are added to address ambient light interference with laser reception.

[0024] 2. An analytical model was constructed to construct a full-section thickness matrix, correct the corrosion coefficient for steel wire positioning based on grayscale abrupt changes, and analyze wear morphology. Full-width thickness data was stored in a matrix to obtain the complete cross-sectional thickness. Steel wire identification was combined with grayscale thresholding, and a corrosion coefficient was introduced to correct the safety distance, resolving issues such as inaccurate safety assessments due to missing steel wire positioning and corrosion. The calculation of cross-sectional area and wear gradient was added to address the lack of overall wear assessment with only a single thickness parameter, achieving four-dimensional parameter output: thickness, safety distance, wear morphology, and corrosion degree. A mechanism was designed for thickness deviation-driven dual-angle linkage adjustment, adaptive stroke correction, and environmental parameter feedback. Thickness deviation synchronously drives the adjustment of elevation and horizontal angles, resolving laser alignment deviation accumulation and dynamic measurement errors, and triggering environmental parameter recalibration to address deviations caused by environmental interference. The linear module stroke was corrected in real-time based on belt width. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a flowchart illustrating the steps of an adjustable movable wide belt thickness measurement system and structure provided in Embodiment 1 of the present invention.

[0027] Figure 2 This is a schematic diagram of an adjustable movable wide belt thickness measurement system and structure provided in Embodiment 2 of the present invention. Detailed Implementation

[0028] 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.

[0029] Example 1: An adjustable movable wide belt thickness measuring structure provided in this embodiment of the invention specifically includes the following:

[0030] 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 to avoid deformation of the frame. 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.

[0031] 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 base through a fisheye bearing. An elevation angle locking mechanism with torque feedback is installed on the side of the slide base.

[0032] Measuring linear module: The linear module is fixed to the slide base with 4 bolts. The linear module slider and measuring device, integrated with the surface laser emitter, receiver and dual-axis tilt sensor are rigidly connected by flange. One end of the drag chain is fixed to the drag 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 linear module moves.

[0033] 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:

[0034] 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;

[0035] 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. ;

[0036] 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.

[0037] The specific method for calculating the angular deviation is as follows:

[0038] Obtain the horizontal vector of the roller axis Horizontal vector of laser surface Through the formula:

[0039]

[0040] Analysis yielded angular deviation ,in, The horizontal vector length of the roller axis. The horizontal vector magnitude of the laser surface;

[0041] Elevation angle calibration, collecting the coordinates of the light spot on the middle surface of the roller. The height of the slide block is finely adjusted by the ball screw of the elevation adjustment support rod to ensure that the laser surface completely covers the roller generatrix. The positional relationship of the three points is observed in the host computer, and the elevation angle is finely adjusted to correct the elevation angle deviation until it is achieved. and , Collinear, locking elevation angle locking mechanism;

[0042] 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. ;

[0043] 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.

[0044] 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 of 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;

[0045] Multi-order noise suppression involves removing outliers caused by vibrations 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;

[0046] 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.

[0047] Adjustment and compensation module: Designed grayscale abrupt change edge detection, stroke adaptive redundancy and belt deviation trend prediction mechanism. Dynamically identify belt edge through laser grayscale difference, preset stroke redundancy to adapt to belt deviation; combine historical data to predict belt deviation trend and adjust the starting position of straight module in advance.

[0048] 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 ;

[0049] 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;

[0050] 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 margin to accommodate ±100mm belt misalignment during operation and to set the initial moving speed of the linear module.

[0051] 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 starting position of the straight line module will be shifted in the deviation direction. To avoid missing edges during measurement;

[0052] Start the linear module under no-load along the linear module stroke The slider moves back and forth three times, and the linear 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 linear module is corrected by adjusting the bolts at the bottom of the slide base.

[0053] Simultaneously check the cable chain's extension and retraction status. If any jamming occurs, adjust the position of the cable chain frame to ensure smooth movement.

[0054] The laser receiver collects grayscale values ​​and edge coordinates. The linear encoder module outputs slider position data in real time; the conveyor control system acquires belt misalignment data for nearly M hours.

[0055] 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.

[0056] 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;

[0057] 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, it indicates the need for lubrication of the linear module guide rail.

[0058] 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 linear 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.

[0059] 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.

[0060] The sampling frequency is matched with the speed of the linear module, 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;

[0061] The linear module slider starts from the pre-compensated starting position, with the linear 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;

[0062] 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;

[0063] 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;

[0064] 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.

[0065] 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 is the real-time tilt angle of the belt;

[0066] 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 in the running direction, the original coordinates are... Add the acquisition time of the i-th sampling point With start time The alignment coordinates of the belt in the running direction are obtained by measuring the displacement distance of the belt within the interval. ;

[0067] 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.

[0068] 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.

[0069] 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 baseline database.

[0070] 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. The data represents the distance between the belt surface and the vertical distance. The distance between the roller surfaces is the absolute value of the difference, which represents the thickness.

[0071] Along the direction of linear module movement, each movement is 1 unit Repeated thickness calculations yield the full-width cross-sectional thickness matrix H, with dimensions m×n, where n is the total number of samples taken for the full-width measurement. Matrix elements... The belt thickness represents the j-th axial position and the i-th running direction position;

[0072] 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. ;

[0073] 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.

[0074] 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 ;

[0075] 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.

[0076] 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 belt width, it corrects the linear module stroke in real time.

[0077] In a specific embodiment, the overall average value of the full cross-section thickness matrix H is calculated. With belt design thickness By comparison, the thickness deviation was obtained. ;

[0078] 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;

[0079] 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.

[0080] 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.

[0081] During the dynamic measurement process, the belt edge coordinates are reacquired every 10 seconds. and Calculate real-time width ;

[0082] 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. ;

[0083] After the current measurement cycle ends, the linear module automatically switches to updating the linear module stroke. No downtime is required, ensuring continuous measurement.

[0084] 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.

[0085] 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.

[0086] 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:

[0087] 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.

[0088] 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 starting position of the straight module in advance.

[0089] Step 3: Based on adjusting the starting position of the linear 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 linear module movement speed; real-time correction of vertical distance is combined with dual-axis tilt sensors; and ambient light coefficient is corrected using narrowband filtering.

[0090] 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.

[0091] 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 the belt width, the linear module stroke is corrected in real time.

[0092] 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 modules: 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. The coordinates of the light spots on both ends of the roller are collected. At the same time, the initial distance from the measuring device to the roller surface is recorded by the distance sensor built into the receiver. Horizontal angle calibration and elevation angle calibration are performed. The horizontal angle and elevation angle locking mechanism are locked according to the torque sensor. The coordinates of the light spots on both ends of the roller are fitted to obtain the roller axis equation. The equation is compared with the laser surface vector in real time. Abnormal vectors that exceed the preset axis error range are eliminated. The box plot method and sliding window filtering are used to complete multi-order noise suppression. Adjustment and compensation module: Design a gray-scale abrupt change edge detection, travel adaptive redundancy and belt deviation trend prediction mechanism. Dynamically identify belt edges through laser gray-scale difference, identify belt edge coordinates through gray-scale abrupt changes and calculate the final actual belt width, set the straight module travel, preset travel redundancy to adapt to belt deviation; combine historical data to predict belt deviation trends and adjust the starting position of the straight module in advance. Control and correction module: acquires the real-time speed of the belt, links and matches the belt speed, laser sampling frequency and linear module movement speed, combines the real-time tilt angle collected by the dual-axis tilt sensor to correct the vertical distance in real time, and combines narrowband filtering to correct 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 linear module stroke in real time. The thickness and width deviations are calculated using the full-section thickness matrix, and the elevation and horizontal angles are adjusted accordingly. The travel and speed of the linear module are dynamically corrected, and environmental parameters are automatically recalibrated.

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 linear 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 starting position of the straight line module will be shifted in the deviation direction. Start the linear module under no-load along the linear module travel distance The slider moves back and forth three times, and the linear 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 linear module is 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 linear encoder outputs slider position data in real time; the conveyor control system acquires nearly M hours of belt misalignment data.

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 linear 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 speed of the linear module, 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 linear module slider starts from the pre-compensated starting position, with the linear 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 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. The data represents the distance between the belt surface and the vertical distance. 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 the full-width cross-sectional thickness matrix H, with dimensions m×n. The 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 the linear module travel is as follows: Calculate the overall average value of the thickness matrix H of the entire cross section. 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 linear 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 Linear Module: The linear module is fixed to the slide base with 4 bolts. The linear 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 drag chain is fixed to the drag 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 linear module moves.

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