Single-pressure contact correction roller pneumatic correction system and method

Abstract

The invention relates to the technical field of production line transmission, in particular to a single-pressure contact correction roller pneumatic correction system and method.The single-pressure contact correction roller pneumatic correction system comprises a rack, a driving roller, a driven roller, a correction roller and an adjusting air cylinder, the correction roller is arranged between the driving roller and the driven roller in a swinging mode, and an operation side shaft head of the correction roller is connected with a piston rod of the adjusting air cylinder. The system is further provided with a photoelectric detection unit used for detecting the shielding state of the belt edge on the light beams. The pneumatic control unit comprises a reversing valve connected with the air source and the adjusting air cylinder; and the control unit is used for receiving the detection signal and controlling the reversing valve. When the belt deviates towards one side and completely shields the light beam on the side, a trigger signal is generated; the control unit responds to the trigger signal, drives the deviation rectifying roller to move axially through the pneumatic control unit, and pushes the belt to rectify deviation in the opposite direction; when the belt returns and does not shield the light beams, the system controls the adjusting air cylinder to enable the deviation rectifying roller to reset automatically. According to the invention, non-contact detection, pneumatic driving and automatic resetting are realized, the deviation rectification response is rapid, and the precision is high.

Description

Technical Field

[0001] This invention relates to the field of production line transmission technology, specifically to a single-pressure contact correction roller pneumatic correction system and method. Background Technology

[0002] In continuous production lines such as belt conveyors, printing machinery, and textile machinery, the stable operation of belts is crucial. However, due to installation errors, uneven tension, load variations, or inherent belt defects, lateral deviation is prone to occur during operation. Deviation can lead to serious malfunctions such as material spillage, belt edge wear, and even belt tearing, causing production interruptions and economic losses. Traditional mechanical deviation correction devices, such as fixed guide rollers or self-aligning idlers, are mostly passive contact or mechanical linkages, which suffer from problems such as delayed response, low adjustment accuracy, easy damage to the belt, or complex structure. Although some pneumatic or electric deviation correction systems have been applied, their control strategies are mostly based on simple on / off detection, only performing "impact-type" deviation correction and emergency stop reset after severe belt deviation. The deviation correction process is rough, easily causing system oscillations, and cannot achieve smooth and precise preventive adjustment. Summary of the Invention

[0003] The purpose of this invention is to provide a single-pressure contact correction roller pneumatic correction system and method, which is capable of...

[0004] In a first aspect, this application provides a single-pressure contact correcting roller pneumatic correction system, including a frame, a driving roller, a driven roller, a correcting roller, and an adjusting cylinder. The correcting roller is oscillatingly disposed between the driving roller and the driven roller. The operating side shaft of the correcting roller is connected to the piston rod of the adjusting cylinder. The system also includes:

[0005] The photoelectric detection unit includes a first detection unit located on the operating side of the belt and a second detection unit located on the driving side, for detecting the blocking state of the light beam by the belt edge;

[0006] A pneumatic control unit includes a reversing valve connected to an air source, the reversing valve being connected to the regulating cylinder via an air circuit;

[0007] The control unit has its signal input terminal connected to the photoelectric detection unit and its control output terminal connected to the reversing valve in the pneumatic control unit.

[0008] In some embodiments, the regulating cylinder is a double-outlet cylinder, the reversing valve is a double-electrically controlled solenoid valve, and the two output ports of the reversing valve are respectively connected to the two air chambers of the regulating cylinder through air passages.

[0009] In some embodiments, an electrical control valve is provided on the air path of each of the two output ports of the reversing valve to control the air flow rate of the air path connected to the two air ports of the regulating cylinder.

[0010] In some embodiments, a reset elastic element is included, disposed on the adjusting cylinder, for limiting the sliding of the piston rod.

[0011] Secondly, this application provides a single-pressure contact correction roller pneumatic correction method, applied to the above-mentioned pneumatic correction system; the pneumatic correction method includes the following steps:

[0012] S1: Edge detection: The photoelectric detection unit detects in real time whether the edge of the belt completely blocks the light beam emitted by the light transmitter to the corresponding light receiver;

[0013] S2: Signal triggering: When the belt shifts towards the operating side and completely blocks the operating side beam, a first triggering signal is generated; when the belt shifts towards the drive side and completely blocks the drive side beam, a second triggering signal is generated.

[0014] S3: Pneumatic correction: In response to the first trigger signal, the drive roller operating side shaft head is moved in the first direction, pushing the belt to the drive side for correction; In response to the second trigger signal, the drive roller operating side shaft head is moved in the second direction opposite to the first direction, pushing the belt to the operating side for correction;

[0015] S4: Automatic Reset: When the belt returns to a position where it does not completely block any light beam, the corresponding trigger signal is released, and the adjusting cylinder is controlled to return the roller operating side shaft head to the center.

[0016] In some embodiments, the real-time detection in step S1 specifically refers to:

[0017] Acquire a continuously varying analog electrical signal from the optical signal receiver, the amplitude of which varies with the degree to which the light beam is blocked by the edge of the belt.

[0018] In some embodiments, step S2 specifically includes:

[0019] Based on the analog electrical signal, calculate the offset signal characterizing the real-time position of the belt;

[0020] The offset signal is compared with a preset threshold corresponding to a state where the beam is completely blocked to generate the first trigger signal or the second trigger signal.

[0021] In some embodiments, step S2 further includes:

[0022] The offset signal is differentiated to obtain an offset change gradient signal that characterizes the belt offset speed and direction.

[0023] In some embodiments, the aerodynamic correction in step S3 specifically includes a predictive control step:

[0024] Before the absolute value of the offset signal reaches the complete occlusion threshold, when the absolute value of the offset change gradient signal exceeds a preset gradient sensitivity threshold, a predictive control signal is generated in advance.

[0025] Based on the predictive control signal, the control air path provides the regulating cylinder with a continuously adjustable gas flow rate that is opposite to the current offset trend, driving the correction roller to apply a preventative fine-tuning correction force to the belt.

[0026] In some embodiments, an adaptive optimization step is also included:

[0027] Monitor and record historical operational data during the corrective action process;

[0028] Based on the changing trends of the historical operating data, the control algorithm parameters used to generate the predictive control signal are dynamically adjusted, and / or the system reference pressure supplied to the regulating cylinder is adjusted.

[0029] The beneficial effects of this invention are as follows: By using a non-contact photoelectric detection unit to sense the belt edge position in real time, combined with a fast-response pneumatic actuator and intelligent control unit, precise and automatic correction of belt misalignment is achieved. Its significant advantages are: First, the design employing a single-pressure contact correcting roller combined with a bidirectional adjusting cylinder results in a compact structure, large corrective force, and direct action; the built-in reset elastic element in the cylinder enables automatic and smooth return to center after the correction action, requiring no additional power, thus saving energy and ensuring reliability. Second, based on analog quantity detection and predictive control algorithms, the system can capture minute trends in belt misalignment and implement gentle, continuous preventative fine-tuning before the misalignment reaches a dangerous threshold, suppressing misalignment at its inception, greatly reducing drastic correction actions, making belt operation extremely smooth, and extending equipment lifespan. Finally, the system possesses adaptive optimization capabilities, dynamically adjusting control parameters based on historical operating data to adapt to different belt speeds, tensions, and load conditions, exhibiting strong robustness and a high degree of intelligence. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the structure of a single-pressure contact correction roller pneumatic correction system according to the present invention;

[0031] Figure 2 for Figure 1 Enlarged view of section A;

[0032] Figure 3 This is a flowchart of a single-pressure contact correction roller pneumatic correction method according to the present invention.

[0033] Reference numerals: 1. Driven roller; 2. Driven roller; 3. Correcting roller; 4. Adjusting cylinder; 5. Photoelectric detection unit; 51. First detection unit; 511. First optical signal transmitter; 512. First optical signal receiver; 52. Second detection unit; 521. Second optical signal transmitter; 522. Second optical signal receiver; 6. Pneumatic control unit; 61. Reversing valve; 62. Electrical control valve; 7. Reset elastic element. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0035] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0036] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0037] In the description of the embodiments of the present invention, it should be noted that if terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of the invention is in use, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. Furthermore, terms such as "first," "second," and "third" are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0038] Furthermore, the use of terms such as "horizontal," "vertical," and "sag" does not imply that the component must be absolutely horizontal or suspended, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0039] In continuous production lines such as belt conveyors, printing machinery, and textile machinery, the stable operation of belts is crucial. However, due to installation errors, uneven tension, load variations, or inherent defects in the belt itself, lateral deviation is prone to occur during operation. Deviation can lead to serious malfunctions such as material spillage, belt edge wear, and even belt tearing, causing production interruptions and economic losses. Traditional mechanical deviation correction devices, such as fixed guide rollers or swing-arm self-aligning idlers, are mostly passive contact or mechanical linkages, which suffer from problems such as delayed response, low adjustment accuracy, easy damage to the belt, or complex structure. Although some pneumatic or electric deviation correction systems have been applied, their control strategies are mostly based on simple on / off detection, only performing "impact-type" deviation correction and emergency stop reset after severe belt deviation. The deviation correction process is rough, easily causing system oscillation, and cannot achieve smooth and precise preventive adjustment. In view of this, this application provides a single-pressure contact deviation roller pneumatic deviation correction system and method.

[0040] Example 1

[0041] Reference Figure 1 and Figure 2 This application provides a single-pressure contact correcting roller pneumatic belt-shifting system. The core function of this system is to perform real-time, automatic lateral belt deviation correction, ensuring the stability and reliability of the conveying process. The main structure of the system includes a frame serving as the mounting and support base. Two rollers for driving and tensioning the belt are arranged in parallel on the frame, namely a driving roller 1 and a driven roller 2. The driving roller 1 is typically driven to rotate by an external power source, thereby driving the belt wrapped around it and the driven roller 2 to move together. Between the driving roller 1 and the driven roller 2, near the belt, a dedicated correcting roller 3 is provided. The unique feature of this correcting roller 3 is that it is not fixedly installed but is oscillatingly mounted on the frame. Specifically, the drive-side shaft of the correcting roller 3 is fixedly mounted on the drive-side plate or support of the frame via an adjustable bearing assembly. This mounting method allows the correcting roller 3 to rotate around its drive-side axis but strictly limits its horizontal freedom of movement. In contrast, the installation method of the operating side shaft head of the alignment roller 3 is completely different. It is placed flat and accommodated in a horizontally elongated guide hole or groove on the operating side of the frame. This elongated hole provides the operating side shaft head of the alignment roller 3 with space to move freely along a specific trajectory in the horizontal plane, so that the entire alignment roller 3 can swing at a certain angle like a pendulum with the fixed point on the drive side as the fulcrum.

[0042] The cylinder body of the adjusting cylinder 4 is fixed by a mounting bracket. The end of the piston rod of the adjusting cylinder 4 is hinged to the operating side shaft of the correction roller 3 via a connecting component, specifically a fisheye bearing. The use of the fisheye bearing allows the linear push-pull motion of the piston rod to be effectively converted into the horizontal movement of the operating side shaft of the correction roller 3, while compensating for possible small angular deviations, ensuring smooth and reliable power transmission. The adjusting cylinder 4 itself is preferably a cylinder with an internally integrated reset elastic element 7. Typically, a first compression spring and a second compression spring are pre-installed in the air chambers on both sides of its piston. When there is no compressed air in either of the two air chambers of the cylinder, the preload of the two compression springs is balanced, which can stably hold the piston in a certain intermediate position. This, in turn, positions the operating side shaft of the correction roller 3 at the center of the elongated guide hole via the piston rod. At this time, the correction roller 3 is parallel to the driving roller 1 and the driven roller 2, and is in a neutral state without any applied correction offset force. In addition, the reset elastic element 7 can be integrated inside the cylinder as a compression spring as described above, or it can be configured externally, for example, by setting a tension spring or compression spring assembly on the piston rod movement path. Its purpose is always to provide a restoring force to return the correction roller 3 to the center position when there is no pneumatic power.

[0043] The sensing portion of the system is handled by the photoelectric detection unit 5. The photoelectric detection unit 5 includes at least two sets of through-beam photoelectric sensors: a first detection unit 51 located on the operating side of the belt and a second detection unit 52 located on the driving side, precisely positioned on either side of the belt's predetermined operating centerline, i.e., the operating side and the driving side. Each sensor set consists of a light signal transmitter and a corresponding light signal receiver. The first detection unit 51 includes a first light signal transmitter 511 located above the belt on the operating side and a first light signal receiver 512 located below the belt. The second detection unit 52 includes a second light signal transmitter 521 located above the belt on the operating side and a second light signal receiver 522 located below the belt. The light signal transmitter and receiver are mounted opposite each other, allowing the light beam emitted by the transmitter to pass horizontally through the space near the belt edge and reach the receiver. The light signal transmitter and receiver are typically encapsulated in a robust protective housing and mounted on a frame using a bracket. The height of their optical axes must match the height of the belt edge. The photoelectric detection unit 5 operates in a non-contact mode, its core function being to monitor in real time whether the belt edge intrudes into and blocks the light beam path. When the belt is centered, neither of its edges blocks the light beam, and the receivers on both sides can receive the light signal normally. Once the belt deviates laterally, its edges will move to one side until they completely block the light beam on that side.

[0044] Reference Figure 1 and Figure 2The system's execution drive section consists of a pneumatic control unit 6. The core of the pneumatic control unit 6 is a reversing valve 61, whose inlet port P is connected to the factory's compressed air source via a pipeline. The outlet of the reversing valve 61, depending on its type, is connected to the air port of the regulating cylinder 4 via a corresponding pneumatic pipeline. In a preferred embodiment, the reversing valve 61 is a dual-electro-controlled three-position five-way center-leaking solenoid valve, and the regulating cylinder 4 is a double-acting cylinder. In this case, the two working outlets A and B of the solenoid valve are connected to the two air chamber interfaces C and D of the regulating cylinder 4 via two independent air paths. A first throttle valve and a second throttle valve can also be connected in series in the connecting pipeline to adjust the airflow speed into and out of the cylinder, thereby controlling the speed of the correction action. The dual-electro-controlled three-position five-way central venting solenoid valve has a unique valve core position characteristic: when neither of the pilot magnets at either end is energized, the valve core is in the neutral position under the action of the spring. At this time, port P is closed, and ports A and B are both connected to the exhaust port T, allowing the two chambers of the regulating cylinder 4 to be connected to the atmosphere and in a depressurized state. When one of the solenoids is energized, the valve core reverses direction, connecting port P to one working port (such as port A) for gas supply, and simultaneously connecting the other working port (such as port B) to port T for exhaust, thereby driving the cylinder piston to move in one direction; conversely, when the other solenoid is energized, it drives the piston to move in the opposite direction.

[0045] The command center of the system is the control unit. The control unit is typically a programmable logic controller (PLC) or a dedicated control circuit board. Its signal input terminals are connected via cables to the output terminals of the first optical signal receiver 512 and the second optical signal receiver 522 in the photoelectric detection unit 5, receiving photoelectric status signals from the operation side and the drive side in real time. The control output terminal of the control unit is connected via a drive circuit to the electromagnet coil of the reversing valve 61 in the pneumatic control unit 6, sending commands to energize or de-energize the electromagnet. The internal logic of the control unit is programmed to determine, according to the changes in the input photoelectric signal and a preset correction strategy, which electromagnet to output a control signal to, and the duration of the control signal, thereby precisely commanding the actions of the pneumatic control unit 6 and the regulating cylinder 4.

[0046] In some further embodiments, to achieve more precise and continuous control over the magnitude and speed of the corrective force, the basic pneumatic circuit can be upgraded. Specifically, electrical control valves 62 are added to the air lines from the two output ports A and B of the reversing valve 61 to the ports C and D of the regulating cylinder 4. These electrical control valves 62 can be electro-proportional valves, used to continuously adjust the outlet flow rate according to the analog signal output by the control unit; or they can be high-speed switching valves, which adjust the average flow rate by receiving a pulse width modulation signal from the control unit. This configuration enables the control unit to go beyond simple on / off control and achieve stepless adjustment of the cylinder thrust and smooth control of the operating speed.

[0047] Example 2

[0048] Reference Figure 3 The second aspect of this application provides a pneumatic belt alignment method applied to the aforementioned single-pressure contact correcting roller pneumatic belt alignment system. This method is a complete automated control process, starting with continuous monitoring of the belt position and ending with the execution and reset of the belt alignment action.

[0049] S1: Edge Detection: The photoelectric detection unit detects in real time whether the edge of the belt completely blocks the light beam emitted by the light signal transmitter towards the corresponding light signal receiver. The photoelectric detection unit operates continuously, with the light signal transmitter on the operating side of the belt continuously emitting an invisible or visible detection beam, which is horizontally directed towards the light signal receiver on the operating side. Similarly, the light signal transmitter on the driving side of the belt also continuously emits a beam towards the driving side light signal receiver. The control unit reads the status of the two light signal receivers in real time at an extremely high sampling frequency. In the most basic embodiment, the receiver outputs a switching signal, i.e., a high level represents "light beam unobstructed," and a low level represents "light beam completely blocked." The control unit determines whether the belt edge has completely blocked the light path by judging the level status of these two signals. To obtain richer positional information, in a more preferred embodiment, the real-time detection in step S1 uses an analog detection method. That is, the light signal receiver outputs a continuously changing analog electrical signal, the amplitude of which is proportional to the light intensity illuminating the photosensitive element of the receiver. As the edge of the belt gradually approaches and begins to partially block the light beam, the received light intensity decreases, and the amplitude of the output analog electrical signal decreases linearly or non-linearly. When the beam is completely blocked, the signal amplitude drops to its lowest point. This analog signal contains precise positional information of the belt edge relative to the light beam, rather than just a binary state of "on" or "off".

[0050] S2: Signal Trigger: A first trigger signal is generated when the belt shifts towards the operating side and completely blocks the operating side beam. A second trigger signal is generated when the belt shifts towards the drive side and completely blocks the drive side beam. The control unit processes and judges the signals obtained from the photoelectric detection unit. In the switch quantity detection mode, the judgment logic is direct: when the control unit detects that the output of the operating side light signal receiver changes from high level to low level, it immediately determines that "the belt shifts towards the operating side and completely blocks the operating side beam," and then generates a first trigger signal in its internal logic. Similarly, when the output of the drive side receiver is detected to change to low level, a second trigger signal is generated. In the analog quantity detection mode, the processing in step S2 is more refined. The control unit first converts and calibrates the received operating side analog electrical signal and drive side analog electrical signal to digital, and calculates an offset signal that characterizes the real-time position of the belt. This offset signal can usually be the difference between the two signals, and its value and sign directly correspond to the direction and distance of the belt's offset. The control unit has one or more preset thresholds, the most critical of which corresponds to the "beam is completely blocked state." The control unit continuously compares the absolute value of the calculated offset signal with the complete shielding threshold. Once the absolute value of the offset signal reaches or exceeds the threshold, the control unit determines that the belt has shifted to a level requiring intervention and generates a corresponding first or second trigger signal based on the sign of the offset signal (i.e., the direction of offset). Advanced signal processing can also be performed during this analog signal processing, such as differentiating the real-time calculated offset signal. The result of the differentiation is an offset change gradient signal, which characterizes the instantaneous velocity and direction of the belt offset—whether the belt is rapidly moving away from the center or slowly approaching it. This gradient signal is a key parameter for predicting the future offset trend of the belt.

[0051] S3: Pneumatic Correction: In response to the first trigger signal, the drive roller operating side shaft head moves in the first direction, pushing the belt towards the drive side for correction; in response to the second trigger signal, the drive roller operating side shaft head moves in the second direction opposite to the first direction, pushing the belt towards the operating side for correction. Once the control unit generates the first or second trigger signal, it immediately sends a corresponding drive command to the pneumatic control unit. Specifically, when the first trigger signal is valid, the control unit sends an energizing command to the drive circuit of the operating side electromagnet of the reversing valve, such as a dual-electro-controlled solenoid valve, connected to the pneumatic control unit. After the electromagnet is energized, it drives the reversing valve core to move to the left working position. At this working position, compressed air enters from the air source through the P port of the reversing valve into the A port, and then enters the C port of the regulating cylinder, i.e., the left air chamber, through the pipeline and the first throttle valve. At the same time, the D port of the regulating cylinder, i.e., the right air chamber, is connected to the B port of the reversing valve through the pipeline and the second throttle valve, and the B port is connected to the exhaust port T port at this time. Compressed air enters the left chamber of the regulating cylinder, pushing the piston to the right, while the gas in the right chamber is discharged to the atmosphere. The piston's rightward movement, via the piston rod and the fisheye bearing, is converted into a horizontal thrust on the operating side shaft of the alignment roller, forcing it to slide towards the driven roller within the elongated guide hole of the frame. Since the driving side shaft of the alignment roller is fixed, this movement causes the entire alignment roller to oscillate around the driving side fulcrum, generating a lateral frictional component between its roller surface and the running belt. This lateral frictional force continuously acts on the belt, pushing it towards the driving side, thus correcting the belt's deviation towards the operating side. Conversely, when the second trigger signal is valid, the control unit energizes the driving side electromagnet, and the reversing valve switches to the right position. The air path reverses, with compressed air entering the right D port of the regulating cylinder and exhausting from the left C port. The piston moves to the left, pushing the operating side shaft of the correction roller towards the drive roller, causing the correction roller to swing in the opposite direction. The resulting lateral friction pushes the belt towards the operating side, correcting the belt's deviation towards the drive side.

[0052] In a more advanced embodiment that uses analog signal detection and calculates the offset change gradient signal, step S3 may include a predictive control sub-step. The control unit no longer passively waits for the offset to reach the complete shielding threshold, but actively uses the gradient signal for prediction. The control logic sets a gradient sensitivity threshold. During the correction process, the control unit monitors the offset signal and the offset change gradient signal in real time. Even if the absolute value of the current offset signal has not yet reached the complete shielding threshold, if the absolute value of the offset change gradient signal exceeds the preset gradient sensitivity threshold, it indicates that the belt is shifting to one side at a relatively fast speed, and will soon reach a severe misalignment state without intervention. At this time, the control unit generates a predictive control signal in advance. Based on this predictive control signal, the control unit precisely adjusts the electrical control valve in the pneumatic control unit through its output, such as an analog output module or a PWM output port. The control unit instructs the electrical control valve to provide a continuously adjustable gas flow rate to the corresponding chamber of the regulating cylinder, which is opposite to the current belt offset trend. This early intervention, driven by a small amount of force, aims to apply a preventative, gentle, fine-tuning force to the belt, counteracting its tendency to deviate and smoothly returning it to the center area, thus suppressing it before it becomes severe. This predictive control typically employs a proportional-derivative algorithm, where the control signal is proportional to both the current amount of deviation and the rate of deviation, i.e., the gradient, resulting in a timely and smooth response.

[0053] S4: Automatic Reset: When the belt returns to a position where it does not completely block any beam, the corresponding trigger signal is released, and the adjusting cylinder is controlled to return the shaft head on the correcting roller side to the center. The purpose of the correction action is to return the belt to the center position. Therefore, when the correction force takes effect and the belt is pushed back to a position where it no longer completely blocks any beam, the reset mechanism is immediately activated. In switch detection mode, when the belt leaves the beam, the light signal receiver receives the light again, and its output jumps from low level to high level. The control unit detects this change and immediately releases the first or second trigger signal generated previously. The release of the trigger signal causes the control unit to stop outputting the energizing command to the solenoid of the reversing valve. For the dual-electrically controlled three-position five-way center-release solenoid valve, once both solenoids are de-energized, the valve core automatically returns to the neutral position under the action of the internal spring. In the neutral position, the C and D ports of the adjusting cylinder are simultaneously connected to the exhaust port T, and the compressed air in the two chambers of the cylinder is quickly discharged into the atmosphere, and the air pressure drops to zero. At this time, the elastic force of the first and second pressure springs preset inside the adjusting cylinder becomes the dominant force. With the piston no longer constrained by air pressure, it is pushed back to the center position of the cylinder under the balancing action of the compression springs on both sides. The piston rod then retracts or extends to its initial length, driving the operating side shaft of the alignment roller to slide back to its center position within the elongated guide hole via the connecting piece. Thus, the alignment roller returns to a neutral state, parallel to both the driving and driven rollers, awaiting the next detection of a misalignment signal. Throughout the reset process, the cylinder depressurization rate can be adjusted via an electrical control valve to achieve a smooth, shock-free return, avoiding secondary disturbance to the belt. In systems with predictive control, the reset process is even more gradual; the control unit gradually reduces the control signal to the electrical control valve according to a smooth decay curve, allowing the pneumatic force to withdraw smoothly and the spring force to engage gently, ensuring the alignment roller returns to its neutral position softly.

[0054] Furthermore, in a more refined system embodiment, the method may also include an adaptive optimization step. The control unit not only executes basic correction logic but also possesses data recording and analysis capabilities. It continuously monitors and records a series of historical operational data during the correction process, such as the number of correction triggers per unit time, the duration of each correction, the average offset, the maximum offset, and the statistical characteristics of the offset change gradient. The algorithm embedded in the control unit analyzes this historical operational data and identifies its changing trends. For example, if the system detects an abnormally high frequency of correction triggers recently, it may indicate insufficient belt tension, material sticking to the rollers, or changes in load conditions. Based on the analysis results, the system can dynamically adjust the parameters of the internal control algorithm, such as adjusting the proportional gain, derivative gain, or gradient sensitivity threshold in predictive control; or adjusting the reference pressure supplied to the entire correction pneumatic system by controlling an external proportional flow pressure reducing valve, thereby enhancing or weakening the overall strength of the correction action. This adaptive optimization enables the correction system to proactively adapt to different operating conditions, maintain long-term stable correction performance, and exhibit higher intelligence and robustness. The entire system and methodology are closely integrated, forming a complete closed loop from perception, decision-making, execution to self-optimization, achieving efficient, precise, and flexible automatic correction of belt misalignment.

[0055] In the description of the embodiments of the present invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention according to the specific circumstances.

Claims

1. A single-pressure contact correction roller pneumatic correction system, characterized in that, The machine includes a frame, a drive roller (1), a driven roller (2), a guide roller (3), and an adjusting cylinder (4). The guide roller (3) is oscillatingly disposed between the drive roller (1) and the driven roller (2). The operating side shaft of the guide roller (3) is connected to the piston rod of the adjusting cylinder (4). The machine also includes: The photoelectric detection unit (5) includes a first detection unit (51) located on the belt operating side and a second detection unit (52) located on the driving side, for detecting the blocking state of the light beam by the belt edge; A pneumatic control unit (6) includes a reversing valve (61) connected to an air source, the reversing valve (61) being connected to the regulating cylinder (4) via an air passage; The control unit has its signal input terminal connected to the photoelectric detection unit (5) and its control output terminal connected to the reversing valve (61) in the pneumatic control unit (6).

2. The pneumatic correction system according to claim 1, characterized in that: The regulating cylinder (4) is a double-outlet cylinder, and the reversing valve (61) is a double-electrically controlled leakage solenoid valve. The two output ports of the reversing valve (61) are respectively connected to the two air chambers of the regulating cylinder (4) through air passages.

3. The pneumatic correction system according to claim 2, characterized in that: Electrical control valves (62) are respectively installed on the air lines of the two output ports of the reversing valve (61) to control the air flow of the two air ports connected to the regulating cylinder (4).

4. The pneumatic correction system according to claim 1, characterized in that: It includes a reset elastic element (7) disposed on the adjusting cylinder (4) to limit the sliding of the piston rod.

5. A pneumatic correction method using a single-pressure contact correction roller, characterized in that, The method is applied to the pneumatic correction system according to any one of claims 1-4; the pneumatic correction method includes the following steps: S1: Edge detection: The photoelectric detection unit detects in real time whether the edge of the belt completely blocks the light beam emitted by the light transmitter to the corresponding light receiver; S2: Signal triggering: When the belt shifts towards the operating side and completely blocks the operating side beam, a first triggering signal is generated; when the belt shifts towards the drive side and completely blocks the drive side beam, a second triggering signal is generated. S3: Pneumatic correction: In response to the first trigger signal, the drive roller operating side shaft head is moved in the first direction, pushing the belt to the drive side for correction; In response to the second trigger signal, the drive roller operating side shaft head is moved in the second direction opposite to the first direction, pushing the belt to the operating side for correction; S4: Automatic Reset: When the belt returns to a position where it does not completely block any light beam, the corresponding trigger signal is released, and the adjusting cylinder is controlled to return the roller operating side shaft head to the center.

6. The method according to claim 5, characterized in that, The real-time detection in step S1 specifically refers to: Acquire a continuously varying analog electrical signal from the optical signal receiver, the amplitude of which varies with the degree to which the light beam is blocked by the edge of the belt.

7. The method according to claim 6, characterized in that, Step S2 specifically includes: Based on the analog electrical signal, calculate the offset signal characterizing the real-time position of the belt; The offset signal is compared with a preset threshold corresponding to a state where the beam is completely blocked to generate the first trigger signal or the second trigger signal.

8. The method according to claim 7, characterized in that, Step S2 also includes: The offset signal is differentiated to obtain an offset change gradient signal that characterizes the belt offset speed and direction.

9. The method according to claim 8, characterized in that, The aerodynamic correction in step S3 specifically includes predictive control steps: Before the absolute value of the offset signal reaches the complete occlusion threshold, when the absolute value of the offset change gradient signal exceeds a preset gradient sensitivity threshold, a predictive control signal is generated in advance. Based on the predictive control signal, the control air path provides the regulating cylinder with a continuously adjustable gas flow rate that is opposite to the current offset trend, driving the correction roller to apply a preventative fine-tuning correction force to the belt.

10. The pneumatic correction method according to claim 9, characterized in that: It also includes an adaptive optimization step: Monitor and record historical operational data during the corrective action process; Based on the changing trends of the historical operating data, the control algorithm parameters used to generate the predictive control signal are dynamically adjusted, and / or the system reference gas flow rate supplied to the regulating cylinder is adjusted.

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