Method and system for controlling installation deviation of belt conveyor intermediate frame based on laser release

Abstract

The present application belongs to the technical field of industrial automation and mechanical installation, and relates to a belt conveyor intermediate frame installation deviation control method and system based on laser laying-out. The control system comprises: a laser emitting module installed at the head and tail of the belt conveyor installation path, used to establish longitudinal and transverse laser reference lines to form a two-dimensional installation reference plane; a laser receiving and sensing module installed at the center point of each intermediate frame, used to obtain pose deviation information of the intermediate frame relative to the two-dimensional laser reference plane; a central control and processing module used to compare the pose deviation information with a preset threshold to generate corresponding adjustment instructions; and an automatic adjustment module installed at four support points of each intermediate frame, used to drive the intermediate frame to move in a three-dimensional space based on the adjustment instructions to eliminate the deviation in the installation process.

Description

Technical Field

[0001] This invention belongs to the field of industrial automation and mechanical installation technology, and particularly relates to a method and system for controlling the installation deviation of the intermediate frame of a belt conveyor based on laser line laying. Background Technology

[0002] Belt conveyors are key equipment used for the continuous transport of materials in industries such as ports, mines, power plants, and building materials. Their installation accuracy, especially the straightness and levelness of the intermediate frame, directly affects the belt's operating efficiency, service life, and safety. Significant lateral and longitudinal deviations in the intermediate frame installation can lead to belt misalignment, accelerated wear, material spillage, and increased energy consumption; in severe cases, it may even cause equipment shutdowns and other production accidents.

[0003] The current installation method has the following shortcomings:

[0004] Large subjective error: The establishment of baselines, instrument readings and the range of manual adjustments are highly dependent on human judgment, and there are significant differences between different operators, making it difficult to ensure consistency and accuracy;

[0005] Low efficiency and long construction period: The measurement, adjustment and re-measurement process is cumbersome and requires the cooperation of many people. Especially in the long-distance (several kilometers) installation process, the frequent transfer and re-establishment of benchmarks greatly slows down the construction progress.

[0006] High overall costs: The lengthy construction period and large manpower investment result in high installation costs;

[0007] Poor environmental adaptability: Under the influence of complex terrain (such as undulations, turns or obstacles) or external environment (such as wind and vibration), the steel wire reference line is prone to swaying or sagging, making it difficult to maintain a high-precision reference and affecting the installation quality.

[0008] The prior art publication CN 111591673 A discloses an "installation method for long-distance belt conveyors," which ensures installation accuracy by strictly controlling the installation tolerances of the support foundation, the support itself, and the rollers (e.g., axial deviation not exceeding 2-5mm). However, this prior art is still a static, phased tolerance control method, overly reliant on the accuracy of initial measurements and manual adjustments, lacking real-time dynamic detection and calibration of components during installation, resulting in low automation and failure to fundamentally improve adjustment efficiency.

[0009] The prior art publication CN 116767787 A discloses an "automatic belt conveyor correction method", which uses sensors to detect belt deviation and uses a control system to adjust the frame or rollers for correction. It mainly focuses on maintenance and correction issues during equipment operation, rather than precise positioning during the installation stage. Therefore, it cannot solve the problem of spatial orientation calibration during intermediate frame installation. Moreover, its sensor layout and control logic are designed for belts in operation and cannot meet the precision control requirements during the installation stage.

[0010] In summary, existing technologies suffer from insufficient precision, low efficiency, reliance on manual labor, and poor environmental adaptability. There is an urgent need for a method to control the installation precision of intermediate frames that can be implemented during the installation phase, has a high degree of automation, and can provide real-time feedback and dynamic adjustment, in order to fundamentally solve these problems. Summary of the Invention

[0011] This invention addresses the problems of low efficiency, poor environmental adaptability, and high cost in the installation of intermediate frames for belt conveyors in existing technologies. It provides a method and system for controlling installation deviations of intermediate frames for belt conveyors based on laser line laying. This method enables high-precision spatial orientation calibration and automated adjustment during the installation stage, fundamentally improving the straightness and levelness of the intermediate frame installation, ensuring the stability and safety of belt operation, and providing technical support for the efficient construction and reliable operation of long-distance conveyors.

[0012] To achieve the above objectives, a first aspect of the present invention provides a belt conveyor intermediate frame installation deviation control system based on laser-based wire feeding, comprising:

[0013] The laser emitting module is installed at both ends of the installation path of the belt conveyor to establish longitudinal and transverse laser reference lines, forming a two-dimensional installation reference plane;

[0014] A laser receiving and sensing module is installed at the center point of each intermediate frame to acquire the pose deviation information of the intermediate frame relative to the two-dimensional laser reference plane. Specifically: in the longitudinal direction, the module receives the light spot signal formed by the longitudinal laser reference line in the photosensitive area and performs position analysis to calculate the longitudinal deviation of the intermediate frame; in the lateral direction, the module visually perceives the projection position formed by the lateral laser reference line within the field of view and calculates the lateral deviation data of the intermediate frame based on the offset of the projection position relative to the lateral reference feature.

[0015] The central control and processing module is used to compare the pose deviation information with the preset threshold and generate corresponding adjustment instructions.

[0016] An automatic adjustment module is installed at four support points of each intermediate frame. It is used to drive the intermediate frame to move in three-dimensional space based on adjustment commands to eliminate deviations during the installation process.

[0017] In some embodiments, the automatic adjustment module includes a motor, a servo driver, and an encoder feedback device, wherein: the servo driver receives adjustment commands from the central control and processing module, and converts the adjustment commands into motor driving torque through pulse distribution and current control, driving the motor to perform forward, reverse, or holding operations; the encoder feedback device detects the angular position of the motor shaft in real time.

[0018] In a second aspect, the present invention provides a method for controlling the installation deviation of the intermediate frame of a belt conveyor based on laser line marking, used in the belt conveyor intermediate frame installation deviation control system described in the first aspect of the present invention, comprising the following steps:

[0019] A laser emitting module is set up on the installation path of the belt conveyor. The laser emitting module generates a horizontal laser reference line and a vertical laser reference line to form a two-dimensional laser reference surface covering the entire installation path.

[0020] Hoist the intermediate frame to the designed position so that the laser receiving and sensing module on the intermediate frame is within the effective sensing range of the two-dimensional laser reference plane;

[0021] The laser receiving and sensing module detects the deviation of the intermediate frame relative to the horizontal and vertical laser reference lines in real time, obtains deviation data including the horizontal and vertical deviation values, and uploads it to the central control and processing module.

[0022] The central control and processing module compares the lateral deviation value and the longitudinal deviation value with their respective preset allowable deviation thresholds;

[0023] When the lateral and / or longitudinal deviation exceeds the allowable deviation threshold, the adjustment direction and number of adjustment steps are determined, and an adjustment command is sent to the automatic adjustment module at the corresponding position.

[0024] The automatic adjustment module adjusts the position of the intermediate frame according to the adjustment instructions until the lateral deviation value and / or longitudinal deviation value are both less than or equal to the allowable deviation threshold.

[0025] In some embodiments, the method of setting a laser emitting module on the belt conveyor installation path includes:

[0026] A laser emitting module is installed at the beginning and end of the installation path of the belt conveyor;

[0027] The mounting base for each laser emitting module is leveled and calibrated to ensure that the horizontal deviation of the mounting base is within the set horizontal deviation range;

[0028] Measure and adjust the three-dimensional coordinates of each laser emitting module so that its deviation from the design centerline is within the set range;

[0029] The straightness of the laser beam of each laser emitting module is checked at multiple distance points to ensure that the drift of the laser beam is within a set drift range within a set distance range.

[0030] In some embodiments, the formation of the two-dimensional laser reference surface includes:

[0031] The laser beam generated by the first laser emitting module is projected perpendicular to the axis of the belt conveyor installation path, forming a transverse positioning reference line at the transverse installation position of the intermediate frame.

[0032] The laser beam generated by the second laser emitting module is projected parallel to the design centerline of the belt conveyor installation path, forming a longitudinal positioning reference line that runs through the entire installation path;

[0033] The horizontal laser reference line and the vertical laser reference line intersect perpendicularly in space to form a two-dimensional laser reference plane. The horizontal reference line is used to determine the deviation of the intermediate frame in the left and right directions. The deviation is obtained based on the change in the projection position of the horizontal laser reference line within the field of view of the laser receiving and sensing module. The vertical reference line is used to determine the deviation of the intermediate frame in the front and back directions. The deviation is obtained based on the illumination measurement results of the laser receiving unit by the vertical laser reference line.

[0034] In some embodiments, the longitudinal deviation value is the distance between the center position of the spot formed by the longitudinal laser reference line within the photosensitive area of ​​the longitudinal laser receiving unit and the center of the longitudinal reference; the longitudinal deviation value is the distance between the center position of the spot formed by the longitudinal laser reference line within the photosensitive area of ​​the longitudinal laser receiving unit and the center of the longitudinal reference.

[0035] In some embodiments, determining the adjustment direction includes: judging whether the intermediate frame is adjusted to the left or right based on the sign of the lateral deviation value; judging whether the intermediate frame is adjusted towards the head or tail of the belt conveyor based on the sign of the longitudinal deviation value; the formula for calculating the number of adjustment steps is: number of adjustment steps = (actual deviation value × reduction ratio × subdivision coefficient) / (lead × margin coefficient).

[0036] In some embodiments, during the adjustment of the position of the intermediate frame, if the deviation value of a single intermediate frame still does not reach the allowable threshold range after a preset number of cyclic adjustments, the adjustment is stopped and an alarm is issued; if the total adjustment time of a single intermediate frame exceeds a preset time, the adjustment is stopped and an alarm is issued.

[0037] In some embodiments, the belt conveyor intermediate frame installation deviation control method further includes:

[0038] When both the lateral and longitudinal deviation values ​​meet the requirements, stop the adjustment and complete the installation and positioning of the current intermediate frame;

[0039] During the adjustment process, the installation status and deviation data of the intermediate frame are displayed in real time, and the final qualified data is automatically recorded after positioning is completed.

[0040] Once all intermediate frames along the entire belt conveyor installation path have been installed and positioned, an installation calibration report containing all key data will be automatically generated.

[0041] In some embodiments, the method for stopping the adjustment action includes:

[0042] The central control and processing module sends a deceleration command to the automatic execution and adjustment module, which controls the motor to gradually reduce its speed according to a predetermined deceleration curve.

[0043] When the motor speed drops below the preset safety threshold, the motor drive current is cut off, and the motor stops running;

[0044] After the motor stops, the position of the support feet is locked by an electromagnetic brake or mechanical locking mechanism to ensure that the position of the intermediate frame remains stable.

[0045] After locking, multiple deviation checks are performed to confirm that the intermediate frame position is stable and the deviation value consistently meets the design requirements.

[0046] Once the deviation detection is passed, an installation completion notification will be issued, and subsequent fixing operations will continue.

[0047] Compared with the prior art, the advantages and positive effects of the present invention are as follows:

[0048] (1) Significantly improved accuracy: By adopting a high-precision laser reference combined with real-time feedback control, the installation accuracy of the intermediate frame is improved from the traditional centimeter level to the millimeter level, completely eliminating the subjective error caused by manual reading and manual adjustment, and ensuring the long-term stable operation of the conveyor;

[0049] (2) Installation efficiency is greatly improved: by replacing the tedious manual multiple measurements and repeated adjustments with automated control, the adjustment time at a single point is significantly shortened, the manpower input and overall construction period are reduced, thereby effectively reducing the overall installation cost;

[0050] (3) Strong environmental adaptability: Based on laser reference technology without physical medium, it overcomes the problem that steel wire reference lines are easily affected by wind, vibration and terrain undulation. It can maintain a uniform and stable high-precision reference under long distance and complex working conditions, effectively suppressing error accumulation.

[0051] (4) Full-process digital management: The installation process supports real-time status monitoring and automatic data recording, and can generate traceable quality documents to realize the digitalization and transparency of installation quality, providing data support for subsequent maintenance and operation optimization. Attached Figure Description

[0052] Figure 1 This is a structural block diagram of the belt conveyor intermediate frame installation deviation control system based on laser wire laying, as described in the first aspect embodiment of the present invention.

[0053] Figure 2 This is a flowchart of the method for controlling the installation deviation of the intermediate frame of a belt conveyor based on laser wire laying, as described in the second aspect of the present invention.

[0054] Figure 3 This is a structural block diagram of the belt conveyor intermediate frame installation deviation control system based on laser wire laying, as described in the third aspect embodiment of the present invention.

[0055] Figure 4 This is a flowchart of the method for controlling the installation deviation of the intermediate frame of a belt conveyor based on laser wire laying, as described in the fourth aspect of the present invention. Detailed Implementation

[0056] The present invention will now be described in detail through exemplary embodiments. However, it should be understood that, without further description, elements, structures, and features in one embodiment may be advantageously incorporated into other embodiments.

[0057] During long-distance installation of belt conveyors, the large number of intermediate frames and the complex construction environment easily lead to deviations in the lateral and longitudinal directions, making it difficult to guarantee the installation accuracy of the entire conveyor line. However, existing installation methods heavily rely on manual measurement and adjustment when dealing with intermediate frame installation accuracy issues, making it difficult to achieve real-time detection and dynamic correction of deviations. This results in low installation accuracy, low efficiency, and significant error accumulation. This invention provides a belt conveyor intermediate frame installation deviation control method and system based on laser-based line marking. By establishing a two-dimensional installation reference plane and calculating the lateral and longitudinal deviations of the intermediate frame relative to the laser reference line in real time, dynamic adjustments are executed according to a preset process to achieve precise restoration of the intermediate frame's spatial position, significantly improving the accuracy and consistency of intermediate frame installation.

[0058] In a broad embodiment of the present invention, the belt conveyor intermediate frame installation deviation control system based on laser line laying includes: a laser emitting module, installed at both ends of the belt conveyor installation path, used to establish longitudinal and transverse laser reference lines to form a two-dimensional installation reference plane;

[0059] A laser receiving and sensing module is installed at the center point of each intermediate frame to acquire the pose deviation information of the intermediate frame relative to the two-dimensional laser reference plane. Specifically: in the longitudinal direction, the module receives the light spot signal formed by the longitudinal laser reference line in the photosensitive area and performs position analysis to calculate the longitudinal deviation of the intermediate frame; in the lateral direction, the module visually perceives the projection position formed by the lateral laser reference line within the field of view and calculates the lateral deviation data of the intermediate frame based on the offset of the projection position relative to the lateral reference feature.

[0060] The central control and processing module is used to compare the pose deviation information with the preset threshold and generate corresponding adjustment instructions.

[0061] An automatic adjustment module is installed at four support points of each intermediate frame. It is used to drive the intermediate frame to move in three-dimensional space based on adjustment commands to eliminate deviations during the installation process.

[0062] In some embodiments, the automatic adjustment module includes a motor, a servo driver, and an encoder feedback device, wherein: the servo driver receives adjustment commands from the central control and processing module, and converts the adjustment commands into motor driving torque through pulse distribution and current control, driving the motor to perform forward, reverse, or holding operations; the encoder feedback device detects the angular position of the motor shaft in real time.

[0063] The present invention also aims to provide a method for controlling the installation deviation of the intermediate frame of a belt conveyor based on laser line laying, which is used in the aforementioned belt conveyor intermediate frame installation deviation control system, and includes the following steps:

[0064] A laser emitting module is set up on the installation path of the belt conveyor. The laser emitting module generates a horizontal laser reference line and a vertical laser reference line to form a two-dimensional laser reference surface covering the entire installation path.

[0065] Hoist the intermediate frame to the designed position so that the laser receiving and sensing module on the intermediate frame is within the effective sensing range of the two-dimensional laser reference plane;

[0066] The laser receiving and sensing module detects the deviation of the intermediate frame relative to the horizontal and vertical laser reference lines in real time, obtains deviation data including the horizontal and vertical deviation values, and uploads it to the central control and processing module.

[0067] The central control and processing module compares the lateral deviation value and the longitudinal deviation value with their respective preset allowable deviation thresholds;

[0068] When the lateral and / or longitudinal deviation exceeds the allowable deviation threshold, the adjustment direction and number of adjustment steps are determined, and an adjustment command is sent to the automatic adjustment module at the corresponding position.

[0069] The automatic adjustment module adjusts the position of the intermediate frame according to the adjustment instructions until the lateral deviation value and / or longitudinal deviation value are both less than or equal to the allowable deviation threshold.

[0070] In some embodiments, the method of setting a laser emitting module on the belt conveyor installation path includes:

[0071] A laser emitting module is installed at the beginning and end of the installation path of the belt conveyor;

[0072] The mounting base for each laser emitting module is leveled and calibrated to ensure that the horizontal deviation of the mounting base is within the set horizontal deviation range;

[0073] Measure and adjust the three-dimensional coordinates of each laser emitting module so that its deviation from the design centerline is within the set range;

[0074] The straightness of the laser beam of each laser emitting module is checked at multiple distance points to ensure that the drift of the laser beam is within a set drift range within a set distance range.

[0075] In some embodiments, the formation of the two-dimensional laser reference surface includes:

[0076] The laser beam generated by the first laser emitting module is projected perpendicular to the axis of the belt conveyor installation path, forming a transverse positioning reference line at the transverse installation position of the intermediate frame.

[0077] The laser beam generated by the second laser emitting module is projected parallel to the design centerline of the belt conveyor installation path, forming a longitudinal positioning reference line that runs through the entire installation path;

[0078] The horizontal laser reference line and the vertical laser reference line intersect perpendicularly in space to form a two-dimensional laser reference plane. The horizontal reference line is used to determine the deviation of the intermediate frame in the left and right directions. The deviation is obtained based on the change in the projection position of the horizontal laser reference line within the field of view of the laser receiving and sensing module. The vertical reference line is used to determine the deviation of the intermediate frame in the front and back directions. The deviation is obtained based on the illumination measurement results of the laser receiving unit by the vertical laser reference line.

[0079] In some embodiments, the longitudinal deviation value is the distance between the center position of the spot formed by the longitudinal laser reference line within the photosensitive area of ​​the longitudinal laser receiving unit and the center of the longitudinal reference; the longitudinal deviation value is the distance between the center position of the spot formed by the longitudinal laser reference line within the photosensitive area of ​​the longitudinal laser receiving unit and the center of the longitudinal reference.

[0080] In some embodiments, determining the adjustment direction includes: judging whether the intermediate frame is adjusted to the left or right based on the sign of the lateral deviation value; judging whether the intermediate frame is adjusted towards the head or tail of the belt conveyor based on the sign of the longitudinal deviation value; the formula for calculating the number of adjustment steps is: number of adjustment steps = (actual deviation value × reduction ratio × subdivision coefficient) / (lead × margin coefficient).

[0081] In some embodiments, during the adjustment of the position of the intermediate frame, if the deviation value of a single intermediate frame still does not reach the allowable threshold range after a preset number of cyclic adjustments, the adjustment is stopped and an alarm is issued; if the total adjustment time of a single intermediate frame exceeds a preset time, the adjustment is stopped and an alarm is issued.

[0082] In some embodiments, the belt conveyor intermediate frame installation deviation control method further includes:

[0083] When both the lateral and longitudinal deviation values ​​meet the requirements, stop the adjustment and complete the installation and positioning of the current intermediate frame;

[0084] During the adjustment process, the installation status and deviation data of the intermediate frame are displayed in real time, and the final qualified data is automatically recorded after positioning is completed.

[0085] Once all intermediate frames along the entire belt conveyor installation path have been installed and positioned, an installation calibration report containing all key data will be automatically generated.

[0086] In some embodiments, the method for stopping the adjustment action includes:

[0087] The central control and processing module sends a deceleration command to the automatic execution and adjustment module, which controls the motor to gradually reduce its speed according to a predetermined deceleration curve.

[0088] When the motor speed drops below the preset safety threshold, the motor drive current is cut off, and the motor stops running;

[0089] After the motor stops, the position of the support feet is locked by an electromagnetic brake or mechanical locking mechanism to ensure that the position of the intermediate frame remains stable.

[0090] After locking, multiple deviation checks are performed to confirm that the intermediate frame position is stable and the deviation value consistently meets the design requirements.

[0091] Once the deviation detection is passed, an installation completion notification will be issued, and subsequent fixing operations will continue.

[0092] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0093] See Figure 1 According to a first aspect of the present invention, a belt conveyor intermediate frame installation deviation control system based on laser-based wire laying is provided, comprising:

[0094] The laser emitting module is installed at both ends of the installation path of the belt conveyor to establish longitudinal and transverse laser reference lines, forming a two-dimensional installation reference plane;

[0095] A laser receiving and sensing module is installed at the center point of each intermediate frame to acquire the pose deviation information of the intermediate frame relative to the two-dimensional laser reference plane. Specifically: in the longitudinal direction, the module receives the light spot signal formed by the longitudinal laser reference line in the photosensitive area and performs position analysis to calculate the longitudinal deviation of the intermediate frame; in the lateral direction, the module visually perceives the projection position formed by the lateral laser reference line within the field of view and calculates the lateral deviation data of the intermediate frame based on the offset of the projection position relative to the lateral reference feature.

[0096] The central control and processing module is used to compare the pose deviation information with the preset threshold and generate corresponding adjustment instructions.

[0097] An automatic adjustment module is installed at four support points of each intermediate frame. It is used to drive the intermediate frame to move in three-dimensional space based on adjustment commands to eliminate deviations during the installation process.

[0098] Specifically, the automatic adjustment module includes a motor, a servo driver, an encoder feedback device, and a mechanical transmission device. The motor is a hybrid stepper motor with a repeatability of no less than 0.02 mm and a response time of no more than 20 milliseconds. The servo driver receives digital control signals from the central control and processing module, converting the commands into motor drive torque through pulse distribution and current control, driving the motor to perform forward, reverse, or holding operations. The encoder feedback device detects the angular position of the motor shaft in real time. The mechanical transmission device uses a worm gear reducer to ensure that the position of the intermediate frame remains unchanged when power is off.

[0099] Specifically, the laser receiving and sensing module includes at least a module housing, a longitudinal laser receiving unit, a lateral visual sensing unit, an internal reference structure, and a signal processing unit. The module housing is used for stable installation and relative positioning with the intermediate frame; the longitudinal laser receiving unit receives the light spot signal formed by the longitudinal laser reference line within the photosensitive area; the lateral visual sensing unit acquires the projected image formed by the lateral laser reference line within the field of view; the internal reference structure provides the longitudinal reference center and lateral reference features; and the signal processing unit analyzes the longitudinal laser signal and the lateral visual signal and outputs the corresponding deviation data.

[0100] The laser receiving and sensing module is a composite deviation sensing module. It uses different sensing methods to acquire longitudinal and lateral deviations that exist during the installation of the intermediate frame, so as to meet the measurement needs of the belt conveyor intermediate frame in long-distance and high-precision installation scenarios.

[0101] In the longitudinal direction, the longitudinal laser receiving unit receives the spot signal formed by the longitudinal laser reference line within its photosensitive area. By analyzing the positional offset of the spot signal relative to the longitudinal reference center inside the module, the longitudinal deviation of the intermediate frame in the belt conveyor installation path direction is calculated. This longitudinal deviation is obtained based on the optical signal formed by laser irradiation; the measurement principle is clear, and the stability is high, making it suitable as the primary criterion for determining longitudinal positioning accuracy.

[0102] In the lateral direction, the lateral visual perception unit acquires the projected image of the lateral laser reference line within the module's field of view. By identifying the changes in the projected position relative to a preset lateral reference feature inside the module, the lateral deviation of the intermediate frame in the left-right direction is analyzed. The acquisition of the lateral deviation does not depend on the geometric intersection or direct illumination relationship between the lateral laser reference line and the intermediate frame or the laser receiver and sensing module; it only requires that the lateral laser reference line be within the visible range of the visual perception unit. This effectively avoids the problem of traditional laser measurement methods easily failing when the laser beam is parallel to the object being measured.

[0103] The laser receiving and sensing module digitizes the acquired longitudinal and lateral deviation values ​​and transmits them in real time to the central control and processing module, serving as input for the automatic adjustment module to perform closed-loop control. By combining longitudinal laser illumination measurement with lateral visual projection sensing, the synchronous acquisition of the intermediate frame's longitudinal and lateral deviations is achieved within the same module, significantly improving the applicability, measurement robustness, and overall control accuracy of the intermediate frame installation and positioning.

[0104] It should be noted that in this embodiment, each intermediate frame is configured with four support points, and each support point is configured with an independent automatic adjustment module. Through the coordinated control of the central control and processing module, synchronous or differentiated adjustment of multiple support points can be achieved, thereby correcting the positioning deviation of the intermediate frame.

[0105] It should be noted that the "design centerline of the belt conveyor installation path" mentioned in this application refers to the theoretical installation centerline of the belt conveyor. The axis of each intermediate frame should be aligned with the design centerline, and the degree of alignment is the installation accuracy that needs to be controlled.

[0106] The aforementioned laser-based conveyor intermediate frame installation deviation control system of this invention achieves dynamic correction of the intermediate frame's longitudinal and transverse deviations through a deviation detection mechanism combining laser reference plane establishment, longitudinal laser irradiation measurement, and transverse visual projection perception, along with closed-loop motor control. This improves installation accuracy from centimeter-level to millimeter-level, completely eliminating subjective errors from manual measurement. Automated control replaces cumbersome manual operations, significantly shortening adjustment time and reducing construction costs. The laser reference, based on a non-physical medium, overcomes the problem of traditional steel wire references being susceptible to wind and vibration, maintaining a high-precision, unified reference even under long-distance and complex working conditions.

[0107] See Figure 2 A second aspect of the present invention provides a method for controlling the installation deviation of the intermediate frame of a belt conveyor based on laser line marking, applied to the belt conveyor intermediate frame installation deviation control system described in the first aspect of the present invention, comprising the following steps:

[0108] Step S1: Set up a laser emitting module on the installation path of the belt conveyor. The laser emitting module generates a transverse laser reference line and a longitudinal laser reference line to form a two-dimensional laser reference surface covering the entire installation path.

[0109] Specifically, the laser emitting module is set up as follows: a laser emitting module is set up at the starting and ending positions of the belt conveyor installation path; the mounting base of each laser emitting module is leveled and calibrated to ensure that the deviation of the base level is controlled within 0.2mm / m; the three-dimensional coordinates of the laser emitter are measured to ensure that the deviation between it and the design centerline of the belt conveyor installation path does not exceed ±2mm; using a calibration target plate, the straightness of the laser beam of each laser emitting module is checked at multiple distance points to ensure that the drift does not exceed ±1mm within a distance of 100 meters.

[0110] Specifically, the method for forming a two-dimensional laser reference surface is as follows:

[0111] The laser beam generated by the first laser emitting module is projected perpendicular to the axis of the belt conveyor installation path, forming a transverse positioning reference line at the transverse installation position of the intermediate frame.

[0112] The laser beam generated by the second laser emitting module is projected parallel to the design centerline of the belt conveyor installation path, forming a longitudinal positioning reference line that runs through the entire installation path;

[0113] The transverse laser reference line and the longitudinal laser reference line intersect perpendicularly in space, forming a two-dimensional laser reference plane, wherein:

[0114] The horizontal reference line is used to determine the deviation of the intermediate frame in the left and right directions. The deviation is obtained based on the change in the projection position of the horizontal laser reference line within the field of view of the laser receiving and sensing module.

[0115] The longitudinal baseline is used to determine the deviation in the front and rear directions of the intermediate frame. The deviation is obtained based on the illumination measurement results of the laser receiving unit using the longitudinal laser baseline.

[0116] Step S2: Hoist the intermediate frame to the designed position so that the laser receiving and sensing module on the intermediate frame is within the effective sensing range of the two-dimensional laser reference plane, wherein the longitudinal laser reference line can illuminate the photosensitive area of ​​the longitudinal laser receiving unit, and the transverse laser reference line is within the visible field of view of the transverse visual sensing unit.

[0117] Step S3: The laser receiving and sensing module detects the deviation of the intermediate frame relative to the horizontal laser reference line and the vertical laser reference line in real time, obtains deviation data including the horizontal deviation value and the vertical deviation value, and uploads it to the central control and processing module.

[0118] Specifically, the longitudinal deviation value is the distance between the center of the spot formed by the longitudinal laser reference line in the photosensitive area of ​​the longitudinal laser receiving unit and the center of the longitudinal reference; the lateral deviation value is the position offset of the projection position formed by the lateral laser reference line in the field of view of the lateral visual perception unit relative to the lateral reference feature.

[0119] In step S4, the central control and processing module compares the lateral deviation value and the longitudinal deviation value with their respective preset allowable deviation thresholds.

[0120] Step S5: When the lateral and / or longitudinal deviation values ​​exceed the allowable deviation threshold, determine the adjustment direction and adjustment steps, and send an adjustment command to the automatic adjustment module at the corresponding position;

[0121] Specifically, determining the adjustment direction includes: adjusting the intermediate frame to the left or right based on the sign of the lateral deviation value; adjusting the intermediate frame towards the head or tail of the conveyor belt based on the sign of the longitudinal deviation value; the formula for calculating the number of adjustment steps is: number of adjustment steps = (actual deviation value × reduction ratio × subdivision coefficient) / (lead × margin coefficient), where the margin coefficient ranges from 0.9 to 0.95.

[0122] Step S6: The automatic adjustment module adjusts the position of the intermediate frame according to the adjustment instructions until the lateral deviation value and / or longitudinal deviation value are both less than or equal to the allowable deviation threshold.

[0123] Specifically, during the adjustment of the position of the intermediate frame, if the deviation value of a single intermediate frame still does not reach the allowable threshold range after 20 cycles of adjustment, the adjustment will automatically stop and an abnormal alarm will be issued, indicating that there may be a hardware failure or the installation conditions do not meet the requirements; if the total adjustment time of a single intermediate frame exceeds 5 minutes, an alarm will also be issued and the adjustment will stop.

[0124] The aforementioned laser-based method for controlling the installation deviation of the intermediate frame of a belt conveyor utilizes a high-precision laser reference surface to achieve real-time detection and automatic correction of the transverse and longitudinal deviations of the intermediate frame, improving installation accuracy from centimeter-level to millimeter-level and completely eliminating subjective errors from manual measurement. Automated control replaces cumbersome manual operations, significantly shortening adjustment time and reducing construction costs, while an anomaly protection mechanism ensures the safety and controllability of the adjustment process. The laser reference, based on a non-physical medium, overcomes the limitations of traditional steel wire references, which are susceptible to wind and vibration, maintaining a high-precision, unified reference even under long-distance and complex working conditions.

[0125] See Figure 3 A third aspect of the present invention provides a belt conveyor intermediate frame installation deviation control system based on laser-based wire laying, comprising:

[0126] The laser emitting module is installed at both ends of the installation path of the belt conveyor to establish longitudinal and transverse laser reference lines, forming a two-dimensional installation reference plane;

[0127] A laser receiving and sensing module is installed at the center point of each intermediate frame to acquire the pose deviation information of the intermediate frame relative to the two-dimensional laser reference plane. Specifically: in the longitudinal direction, the module receives the light spot signal formed by the longitudinal laser reference line in the photosensitive area and performs position analysis to calculate the longitudinal deviation of the intermediate frame; in the lateral direction, the module visually perceives the projection position formed by the lateral laser reference line within the field of view and calculates the lateral deviation data of the intermediate frame based on the offset of the projection position relative to the lateral reference feature.

[0128] The central control and processing module is used to compare the deviation data with the preset threshold and generate corresponding adjustment instructions.

[0129] An automatic adjustment module is installed at four support points of each intermediate frame. It is used to drive the intermediate frame to move in three-dimensional space based on adjustment commands to eliminate deviations during the installation process.

[0130] The data management visualization module is used to display deviation data and adjustment status in real time, automatically record operation data, and generate installation calibration reports;

[0131] The environmental compensation module is used to correct the impact of environmental factors on the stability and measurement accuracy of the laser reference line.

[0132] It should be noted that in this embodiment, the environmental compensation module collects environmental parameters in real time through temperature sensors, humidity sensors, and atmospheric pressure sensors installed on site. When the ambient temperature changes by more than ±5℃ relative to the equipment's calibrated temperature, the relative humidity changes by more than 20%, or the atmospheric pressure changes by more than 5kPa, the module will correct the deviation measurement value according to the compensation coefficient calibrated in advance through experiments. If the environmental conditions exceed the normal operating range of the equipment, a red warning will be automatically issued, and it will be recommended to suspend the installation work until the environmental conditions return to the allowable range before construction can continue.

[0133] Compared with the first aspect embodiment, the above-described laser-based belt conveyor intermediate frame installation deviation control system of this invention overcomes the limitations of traditional steel wire references, which are easily affected by wind and vibration, by using an environmental compensation module to monitor and correct temperature, humidity, and air pressure in real time (temperature change ±5℃, humidity change 20%, air pressure change 5kPa). This maintains a high-precision, unified reference under long-distance and complex working conditions, effectively suppressing error accumulation. The data management visualization module supports real-time monitoring of the entire process, automatic recording of operation data, and generation of installation calibration reports, enabling digital traceability management of installation quality and ensuring high-precision positioning and long-term stable operation of the belt conveyor intermediate frame.

[0134] See Figure 4 A fourth aspect of the present invention provides a method for controlling the installation deviation of the intermediate frame of a belt conveyor based on laser line marking, applied to the installation deviation control system for the intermediate frame of a belt conveyor described in the third aspect of the present invention, and further includes the following steps:

[0135] Step S7: When both the lateral deviation and longitudinal deviation values ​​meet the requirements, stop the adjustment and complete the installation and positioning of the current intermediate frame.

[0136] Specifically, the method for stopping the adjustment action is as follows:

[0137] The central control and processing module sends a deceleration command to the automatic execution and adjustment module, which controls the motor to gradually reduce its speed according to a predetermined deceleration curve.

[0138] When the motor speed drops below the preset safety threshold, the motor drive current is cut off, and the motor stops running;

[0139] After the motor stops, the position of the support feet is locked by an electromagnetic brake or mechanical locking mechanism to ensure that the position of the intermediate frame remains stable.

[0140] After locking, perform 3 to 5 deviation checks to confirm that the intermediate frame position is stable and the deviation value consistently meets the design requirements;

[0141] Once the deviation detection is passed, an installation completion notification will be issued, and subsequent fixing operations will continue.

[0142] Step S8: During the adjustment process, the installation status and deviation data of the intermediate frame are displayed in real time, and the final qualified data is automatically recorded after the positioning is completed.

[0143] Step S9: After all intermediate frames on the entire belt conveyor installation path have been installed and positioned, an installation calibration report including all key data will be automatically generated.

[0144] Specifically, the final qualified data includes: intermediate frame number, installation date and time, final lateral deviation value, final longitudinal deviation value, total number of adjustments, total adjustment time, operator number, ambient temperature and humidity, and laser emitter operating status data.

[0145] The aforementioned laser-based belt conveyor intermediate frame installation deviation control method achieves fully digital and transparent management by displaying the installation status and deviation change trend in real time. Before positioning is completed, 3 to 5 deviation checks are performed and the intermediate frame is locked using an electromagnetic brake to ensure stable intermediate frame position and consistently meet deviation requirements, improving installation accuracy from centimeter-level to millimeter-level. Furthermore, complete data, including intermediate frame number, final deviation value, number of adjustments and time consumption, and environmental parameters, is automatically recorded, generating a traceable installation calibration report. This enables digital management of installation quality, providing reliable data support for subsequent maintenance, auditing, and operational optimization, effectively reducing overall installation costs and ensuring long-term stable operation of the belt conveyor.

[0146] In the installation of modern industrial equipment, precise installation positioning and rapid project progress are key factors for project success. This invention provides a method and system for controlling the installation deviation of intermediate conveyor frames based on laser-based line laying, aiming to solve the problems of large deviations and low efficiency in traditional manual installation. Through high-precision laser measurement and automated adjustment, precise control of intermediate frame installation is achieved. This method not only ensures the accurate positioning of each intermediate frame but also significantly improves installation efficiency, shortens the construction period, and reduces costs. The following is a specific application example of this invention in the installation of intermediate frames for the LC10C ordinary belt conveyor in the Nantong Port grain and oil loading and unloading equipment project.

[0147] The conveyor is 517.9 meters long, with a standard intermediate frame pitch of 3 meters, and is installed on a continuous equipment foundation. The design installation accuracy requirements are: the lateral deviation of the centerline of any intermediate frame from the design centerline on the horizontal plane is ≤ ±1.5 mm, and the height difference (longitudinal deviation) between adjacent intermediate frame support points is ≤ ±1.0 mm.

[0148] I. System Equipment Deployment and Parameter Configuration

[0149] Equipment selection and configuration include:

[0150] Laser emitters: Two high-precision (±1″ accuracy), automatically leveled, and electronically calibrated industrial-grade laser emitters are selected. One emits the longitudinal reference line (parallel to the design centerline), and the other emits the transverse reference line (perpendicular to the design centerline). The laser is visible red light, and the spot diameter is <5mm at a distance of 517.9 meters to ensure clear reference.

[0151] Laser receiving sensor: A dual-axis digital laser measurement unit integrating longitudinal laser receiving and lateral visual perception functions is selected. The longitudinal direction is measured based on laser illumination, and the lateral direction is measured based on visual recognition of the projection position of the lateral laser baseline. The dual-axis detection accuracy is ±0.05mm. The data is transmitted to the control terminal in real time via Bluetooth.

[0152] Control and Execution: A ruggedized industrial panel PC (with built-in customized control software) and a programmable logic controller (PLC) work together for control. Each intermediate frame has an automatic adjustment module pre-installed under each of its four support feet to perform lifting and correction actions.

[0153] Specific on-site deployment includes:

[0154] On the permanent concrete foundations at the head (0 meters) and tail (517.9 meters) of the conveyor, forced centering observation piers were built respectively, and two laser emitters were installed and precisely leveled to ensure that the overlap error between the laser reference line emitted by them and the theoretical center line of the conveyor was less than ±0.5mm.

[0155] Since the distance exceeds 500 meters, a passive relay target mirror is set at about 259 meters to compensate for the laser intensity attenuation. This mirror is used to reflect and enhance the laser signal, ensuring consistent signal strength throughout the entire distance.

[0156] The standard section of the intermediate frame is 3 meters long, and the entire machine requires approximately 173 intermediate frame sections. Therefore, each intermediate frame section is equipped with a laser receiving sensor, resulting in a total of 173 measuring points.

[0157] All sensors and industrial panel PCs are networked via a low-latency wireless mesh network to achieve real-time data transmission. The drivers for each automatic adjustment module are connected to the PLC via a CANopen bus to receive commands.

[0158] II. Calibration Procedure and Working Process (Taking the installation of intermediate frame No. 95 as an example)

[0159] Initialization: Power on, the laser emitter generates a stable reference. The control software loads the designed axis data of the conveyor, and all sensors automatically connect to the network and register.

[0160] Hoisting and positioning: The No. 95 intermediate frame (located at 285.3 meters) was hoisted to the installation position, and the sensor automatically sensed and locked the laser reference.

[0161] Real-time detection: The sensor instantly measures the pose deviation and wirelessly transmits the data to the control terminal. The software interface clearly displays: Lateral deviation (X-axis): +2.8mm (to the right); Longitudinal deviation (Y-axis): -1.9mm (too low);

[0162] Status: Awaiting adjustment;

[0163] Closed-loop automatic adjustment: The control software automatically triggers an adjustment sequence when the deviation exceeds the limit. It calculates and generates the optimal adjustment command based on real-time deviation data and the intermediate frame structure model.

[0164] Adjustment command issuance (example):

[0165] The automatic adjustment module at angles A and D (right side) rises by 1.2mm.

[0166] The automatic adjustment module at corners B and C (left side) will maintain the position.

[0167] The automatic adjustment module at corners A and B (front side) rises by 1.6mm.

[0168] The automatic adjustment module at corners C and D (rear side) raises the height by 0.8mm.

[0169] Each automatic adjustment module operates precisely and synchronously according to instructions, ensuring a smooth adjustment process.

[0170] After the initial adjustment, the sensor reported new data: (X: +0.7mm, Y: -0.4mm). The deviation was determined to be within the acceptable range, but for further optimization, the final fine-tuning mode was initiated.

[0171] Fine-tuning: The PLC issues a command to the automatic adjustment module of angle A: slightly raise by 0.2mm;

[0172] Adjustment complete: After approximately 18 seconds, the data stabilized at (X: +0.5mm, Y: -0.3mm), far exceeding the design threshold. The status updated to "Calibration complete";

[0173] Data logging: Automatically generates a complete digital archive of the intermediate shelf for this section.

[0174] III. Project Implementation Results

[0175] During the installation of the 517.9-meter conveyor line in this project, all 173 intermediate frames were calibrated using the method of this invention.

[0176] Efficiency: The average adjustment time for a single intermediate frame section is ≤2 minutes. The total adjustment time for the entire line is reduced by more than 70% compared to traditional manual methods, significantly shortening the project duration.

[0177] Accuracy: After completion, a third party used a laser tracker to perform millimeter-level verification. All 173 measuring points met the design requirements 100%, with a maximum lateral deviation of 1.2mm, a maximum longitudinal deviation of 0.8mm, and a straightness error of less than 3mm throughout the installation, setting a new industry benchmark.

[0178] Cost and Safety: Significantly reduced the demand for surveyors and general laborers, lowered the risks of working at heights and with heavy physical labor, and reduced overall installation costs by approximately 40%.

[0179] Deliverables: An "Installation Quality Report" and a 3D deviation chromatogram containing detailed data for each section of the intermediate frame were automatically generated, realizing the fully digital delivery of installation quality and providing a solid data foundation for the digital asset management system.

[0180] The above embodiments are used to explain the present invention, but not to limit the present invention. Any modifications and changes made to the present invention within the spirit and scope of the claims shall fall within the protection scope of the present invention.

Claims

1. A belt conveyor intermediate frame installation deviation control system based on laser-based line marking, characterized in that, The control system includes: The laser emitting module includes a first laser emitting module and a second laser emitting module, which are respectively positioned at the start and end points of the belt conveyor installation path. The first laser emitting module generates a laser beam that is projected perpendicular to the axis of the belt conveyor installation path, forming a transverse laser reference line at the transverse installation position of the intermediate frame. The second laser emitting module generates a laser beam that is projected parallel to the design centerline of the belt conveyor installation path, forming a longitudinal laser reference line that runs through the entire installation path. The transverse and longitudinal laser reference lines intersect perpendicularly in space, forming a two-dimensional laser reference surface. A laser receiving and sensing module is installed at the center point of each intermediate frame to acquire the pose deviation information of the intermediate frame relative to the two-dimensional laser reference plane. Specifically: in the longitudinal direction, the module receives the light spot signal formed by the longitudinal laser reference line in the photosensitive area and performs position analysis to calculate the longitudinal deviation of the intermediate frame; in the lateral direction, the module visually perceives the projection position formed by the lateral laser reference line within the field of view and calculates the lateral deviation data of the intermediate frame based on the offset of the projection position relative to the lateral reference feature. The central control and processing module is used to compare the pose deviation information with the preset threshold and generate corresponding adjustment instructions. An automatic adjustment module is installed at four support points of each intermediate frame. It is used to drive the intermediate frame to move in three-dimensional space based on adjustment commands to eliminate deviations during the installation process.

2. The belt conveyor intermediate frame installation deviation control system according to claim 1, characterized in that, The automatic adjustment module includes a motor, a servo driver, and an encoder feedback device. The servo driver receives adjustment commands from the central control and processing module and converts the adjustment commands into motor driving torque through pulse distribution and current control, driving the motor to perform forward, reverse, or holding operations. The encoder feedback device detects the angular position of the motor shaft in real time.

3. A method for controlling the installation deviation of the intermediate frame of a belt conveyor based on laser-based line laying, applied to the belt conveyor intermediate frame installation deviation control system as described in claim 2, characterized in that... Includes the following steps: A laser emitting module is set up on the installation path of the belt conveyor. The laser emitting module generates a horizontal laser reference line and a vertical laser reference line to form a two-dimensional laser reference surface covering the entire installation path. Hoist the intermediate frame to the designed position so that the laser receiving and sensing module on the intermediate frame is within the effective sensing range of the two-dimensional laser reference plane; The laser receiving and sensing module detects the deviation of the intermediate frame relative to the horizontal and vertical laser reference lines in real time, obtains deviation data including the horizontal and vertical deviation values, and uploads it to the central control and processing module. The central control and processing module compares the lateral deviation value and the longitudinal deviation value with their respective preset allowable deviation thresholds; When the lateral and / or longitudinal deviation exceeds the allowable deviation threshold, the adjustment direction and number of adjustment steps are determined, and an adjustment command is sent to the automatic adjustment module at the corresponding position. The automatic adjustment module adjusts the position of the intermediate frame according to the adjustment instructions until the lateral deviation value and / or longitudinal deviation value are both less than or equal to the allowable deviation threshold.

4. The method for controlling the installation deviation of the intermediate frame of a belt conveyor according to claim 3, characterized in that, Methods for installing laser emitting modules along the belt conveyor installation path include: The mounting base for each laser emitting module is leveled and calibrated to ensure that the horizontal deviation of the mounting base is within the set horizontal deviation range; Measure and adjust the three-dimensional coordinates of each laser emitting module so that its deviation from the design centerline is within the set range; The straightness of the laser beam of each laser emitting module is checked at multiple distance points to ensure that the drift of the laser beam is within a set drift range within a set distance range.

5. The method for controlling the installation deviation of the intermediate frame of a belt conveyor according to claim 4, characterized in that, The transverse laser reference line is used to determine the deviation in the left-right direction of the intermediate frame. The deviation is obtained based on the change in the projection position of the transverse laser reference line within the field of view of the laser receiving and sensing module. The longitudinal laser reference line is used to determine the deviation in the front-back direction of the intermediate frame. The deviation is obtained based on the illumination measurement results of the laser receiving unit by the longitudinal laser reference line.

6. The method for controlling the installation deviation of the intermediate frame of a belt conveyor according to claim 3, characterized in that, The longitudinal deviation value is the distance between the center of the spot formed by the longitudinal laser reference line within the photosensitive area of ​​the longitudinal laser receiving unit and the center of the longitudinal reference.

7. The method for controlling the installation deviation of the intermediate frame of a belt conveyor according to claim 3, characterized in that, The determination of the adjustment direction includes: judging whether the intermediate frame is adjusted to the left or right based on the sign of the lateral deviation value; and judging whether the intermediate frame is adjusted towards the head or tail of the belt conveyor based on the sign of the longitudinal deviation value.

8. The method for controlling the installation deviation of the intermediate frame of a belt conveyor according to claim 3, characterized in that, During the adjustment of the position of the intermediate frame, if the deviation value of a single intermediate frame still does not reach the allowable threshold range after a preset number of cyclic adjustments, the adjustment will stop and an alarm will be issued; if the total adjustment time of a single intermediate frame exceeds the preset time, the adjustment will stop and an alarm will be issued.

9. The method for controlling the installation deviation of the intermediate frame of a belt conveyor according to any one of claims 3-8, characterized in that, Also includes: When both the lateral and longitudinal deviation values ​​meet the requirements, stop the adjustment and complete the installation and positioning of the current intermediate frame; During the adjustment process, the installation status and deviation data of the intermediate frame are displayed in real time, and the final qualified data is automatically recorded after positioning is completed. Once all intermediate frames along the entire belt conveyor installation path have been installed and positioned, an installation calibration report containing all key data will be automatically generated.

10. The method for controlling the installation deviation of the intermediate frame of a belt conveyor according to claim 9, characterized in that, The method for stopping the adjustment action includes: The central control and processing module sends a deceleration command to the automatic execution and adjustment module, which controls the motor to gradually reduce its speed according to a predetermined deceleration curve. When the motor speed drops below the preset safety threshold, the motor drive current is cut off, and the motor stops running; After the motor stops, the position of the support feet is locked by an electromagnetic brake or mechanical locking mechanism to ensure that the position of the intermediate frame remains stable. After locking, multiple deviation checks are performed to confirm that the intermediate frame position is stable and the deviation value consistently meets the design requirements. Once the deviation detection is passed, an installation completion notification will be issued, and subsequent fixing operations will continue.

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