Mechatronic conveying device and method for diagnosing the adhesion state thereof

Abstract

The present application relates to the technical field of conveying belt, in particular to a mechatronic conveying device and a method for diagnosing the suction state thereof. The device comprises a rack, a conveying belt surface, a vacuum cavity, a vacuum generating device and a core airflow management assembly. The airflow management assembly is composed of a porous flow equalization layer and a flow channel substrate, and a plurality of self-adaptive nonlinear flow channels are arranged in the flow channel substrate. When the suction holes are not covered by materials, flow separation zones are formed in the flow channels, resulting in a significant increase in flow resistance. When the suction holes are covered by materials, the flow channels maintain low flow resistance, so that the negative pressure is preferentially distributed to the effective suction area without additional control, achieving passive negative pressure intelligent distribution of "high resistance for leak holes and low resistance for suction holes". This design significantly reduces invalid leakage, reduces the power consumption of the vacuum pump while maintaining the target vacuum degree, thereby improving the suction force and conveying efficiency of the effective suction area.

Description

Technical Field

[0001] This invention relates to the field of conveyor belt technology, specifically to an electromechanical integrated conveyor device and its adsorption state diagnosis method. Background Technology

[0002] In automated production lines, mechatronic conveying devices employing the principle of negative pressure adsorption are key equipment for conveying sheet materials such as films, sheets, and paper. These devices generate a vacuum beneath the conveyor belt, using pressure difference to adsorb materials and achieve stable, slip-free conveying.

[0003] However, existing negative pressure conveying devices suffer from three long-standing unresolved core problems, hindering improvements in their energy efficiency, reliability, and intelligence:

[0004] First, there is a contradiction between overall energy consumption and effective local adsorption. When conveying discontinuous materials or materials smaller than the belt width, numerous uncovered suction holes on the conveyor belt will cause severe vacuum leakage. The vacuum pump has to continuously extract large amounts of useless air to maintain the system's base pressure, resulting in energy waste of up to 50%-70%. More seriously, this leads to a decrease in the overall vacuum level of the system, directly weakening the adsorption force in the effective adsorption area.

[0005] Second, there is a contradiction between simple mechanical structures and complex intelligent control. To alleviate the aforementioned energy consumption problem, high-end solutions employ zoned solenoid valve control, which uses sensors to detect the material position and switches the vacuum in the corresponding area accordingly. While effective, this solution introduces a large number of sensors, controllers, and actuators, making the system complex and costly. Furthermore, it suffers from a high failure rate and frequent maintenance in harsh industrial environments such as dust, humidity, and vibration, ultimately reducing the overall reliability of the equipment.

[0006] Third, there is a contradiction between macroscopic operation and microscopic state perception. Operators can only perceive abnormalities through macroscopic vacuum gauge readings or post-event results such as product misalignment or detachment, and cannot perform real-time, online quantitative assessment and early warning of the adsorption efficiency of individual or local adsorption points. This leads to maintenance work relying entirely on experience and periodic inspections, making predictive maintenance impossible, resulting in low troubleshooting efficiency and significant losses from unplanned downtime.

[0007] Therefore, the industry urgently needs a new type of mechatronic conveying solution that can innovate from the underlying principles of pneumatics and combines high efficiency, energy saving, inherent reliability and intelligent sensing capabilities. Summary of the Invention

[0008] The purpose of this invention is to provide an electromechanical integrated conveying device and its adsorption state diagnosis method to solve the problems mentioned in the background art.

[0009] This invention is achieved through the following technical solutions:

[0010] An electromechanical integrated conveying device includes a frame, a conveyor belt surface disposed on the frame, a vacuum chamber located below the conveyor belt surface, and a vacuum generating device communicating with the vacuum chamber. The conveyor belt surface is provided with multiple suction holes. The device also includes an airflow management component disposed between the conveyor belt surface and the vacuum chamber. The airflow management component includes:

[0011] A porous flow equalization layer, located below the conveyor belt surface, is used to locally diffuse the airflow from each suction hole and provide basic flow resistance;

[0012] A flow channel substrate is located below the porous flow equalization layer, and a plurality of adaptive nonlinear flow channels are formed therein, which are respectively connected to local regions of the porous flow equalization layer. Each flow channel connects its corresponding region to the vacuum cavity.

[0013] The adaptive nonlinear flow channel is configured such that the airflow remains attached under low flow conditions, while when the flow rate increases to a predetermined range, a flow separation zone and / or a recirculation zone are formed in the flow channel, which significantly increases the flow channel pressure loss growth rate relative to the low flow condition, thereby suppressing the leakage flow at the exposed suction orifice and causing the negative pressure to preferentially concentrate in the suction orifice area covered by the material.

[0014] Optionally, the adaptive nonlinear flow channel includes a contraction section, an expansion section, and an outlet section connected sequentially along the airflow direction. The expansion angle of the expansion section is greater than the contraction angle of the corresponding contraction section, and the ratio of the length of the expansion section to the throat diameter is greater than 2:1, so that the airflow forms a stable separation vortex region in the expansion section under high flow conditions, thereby causing the slope of the pressure loss-flow rate relationship curve to increase in stages.

[0015] Optionally, the adaptive nonlinear flow channel includes two or more stages of series contraction-expansion structures, with each stage of expansion forming a progressively enhanced flow separation zone. This allows the energy dissipation of each separation zone to be superimposed under high flow conditions, thereby making the flow channel's ability to suppress the flow of parallel branches higher than that of a single-stage expansion structure.

[0016] Optionally, the porous flow equalization layer is a porous elastic material layer with uniform porosity, a thickness of 1–5 mm, and an average pore diameter of 50–300 μm, used to establish a transverse pressure equalization effect between each suction hole and provide a stable basic throttling resistance.

[0017] Optionally, the vacuum chamber is divided into multiple negative pressure units along the conveying direction. Each negative pressure unit covers the corresponding area of ​​the flow channel substrate and is connected to the negative pressure main pipe through a connecting pipe, thereby reducing pressure crosstalk between long-distance flow channels.

[0018] Optionally, it also includes multiple pressure sensors, each of which is connected to the low-pressure zone of the corresponding adaptive nonlinear flow channel contraction section via an independent pressure measuring branch.

[0019] Optionally, the pressure sensors are arranged at intervals along a direction perpendicular to the conveying direction, and their distribution corresponds to the transverse arrangement of the adaptive nonlinear flow channel array to form a transverse pressure sampling array, which is used to reflect the adsorption state distribution in the width direction of the conveyor belt.

[0020] Optionally, an electrical control subsystem is also included, which receives signals from each pressure sensor and identifies adsorption state abnormalities and outputs prompt information based on the differences between pressure signals corresponding to different flow channels or the changes of each pressure signal relative to a reference signal.

[0021] A method for identifying the adsorption state based on the above-mentioned mechatronic conveying device includes: acquiring pressure signals corresponding to different adaptive nonlinear flow channels during the conveying process, and judging whether there is air leakage, abnormal coverage, or material damage in the adsorption area corresponding to the flow channel based on the stability, absolute value, or change characteristics of each signal; when the pressure signal corresponding to a certain flow channel changes abnormally relative to the reference state, it is determined that there is an abnormal state in the adsorption area corresponding to the flow channel and a prompt message is output.

[0022] Compared with the prior art, the present invention provides an electromechanical integrated conveying device and its adsorption state diagnosis method, which has the following beneficial effects:

[0023] 1. This invention achieves passive negative pressure intelligent distribution through an adaptive nonlinear flow channel design, characterized by "high resistance at leakage holes and low resistance at adsorption holes." By generating flow separation and a backflow vortex zone in the flow channel under high flow conditions, the flow resistance increases nonlinearly with the flow rate, significantly reducing ineffective leakage. Consequently, the vacuum pump reduces power consumption while maintaining the target vacuum level, thereby directly improving the adsorption force and delivery efficiency of the effective adsorption area.

[0024] 2. The aforementioned energy-saving effects primarily rely on the physical structure of the flow channel itself. Negative pressure priority distribution can be achieved without additional control or high-frequency actuators, and complex sensors are unnecessary. This greatly simplifies the system structure, achieving a higher level of inherent reliability, reducing maintenance requirements, and enhancing modularity and replaceability.

[0025] 3. By setting up a transverse pressure sampling array, this invention enables the system to perform real-time, online quantitative sensing of the adsorption state distribution along the width of the conveyor belt. It can not only quickly locate common faults such as blockages and leaks, but also perform advanced diagnostics of micro-cracks inside materials through spectral analysis, achieving early warning and predictive maintenance, and greatly reducing unplanned downtime. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0027] Figure 2This is a cross-sectional schematic diagram of the entire invention;

[0028] Figure 3 This is a schematic diagram of the airflow management component in this invention.

[0029] In the diagram: 1. Frame; 2. Conveyor belt surface; 21. Suction hole; 3. Vacuum chamber; 31. First negative pressure unit; 32. Second negative pressure unit; 33. Third negative pressure unit; 4. Vacuum generator; 5. Common negative pressure main pipe; 6. Airflow management component; 61. Porous flow equalization layer; 62. Flow channel substrate; 63. Adaptive nonlinear flow channel; 631. First stage; 632. Second stage; 7. Photoelectric sensor; 8. Pressure sensor; 9. Connecting pipe; 91. First solenoid valve; 92. Second solenoid valve; 93. Third solenoid valve. Detailed Implementation

[0030] 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. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] Reference Figure 1 – Figure 3 As shown, this embodiment illustrates a mechatronic conveying device, including a frame 1 and a conveyor belt surface 2 mounted on the frame 1. The conveyor belt surface 2 is made of a high-strength, low-permeability material (such as polyurethane-coated fabric) and has multiple suction holes 21 precisely machined in a matrix (hole diameter example Φ1.0mm, hole spacing example 5mm). The device also includes a vacuum chamber 3 located below the conveyor belt surface 2, and a vacuum generating device 4 (such as a rotary vane vacuum pump) connected to the vacuum chamber 3 via a pipeline.

[0032] The core innovation of this invention lies in the airflow management component 6 and the electrical control subsystem that works in conjunction with it. It is an independent modular design that can be disassembled, replaced, or produced in a standardized manner.

[0033] 1. Airflow management component structure

[0034] The airflow management component 6 is located between the conveyor belt surface 2 and the vacuum chamber 3, and adopts a layered design from top to bottom:

[0035] (1) Porous flow uniform layer 61

[0036] Located below the conveyor belt surface 2, it is made of open-cell polyurethane foam with uniform porosity (thickness example 3 mm, pore size example 50 μm, porosity example 30%).

[0037] Function: Provides basic flow resistance for all suction orifices 21 and performs localized lateral diffusion of the incoming airflow to equalize the flow rate between orifices. The main flow direction remains vertical, ensuring that the negative pressure is concentrated in the suction orifice area covered by material.

[0038] (2) Flow channel substrate 62

[0039] Located below the porous flow equalization layer 61, it is precision injection molded from engineering plastic (such as PEEK) and pressed against the porous flow equalization layer 61 by a sealing ring around its perimeter to achieve fluid communication.

[0040] Multiple adaptive nonlinear flow channels 63 are internally processed, each flow channel corresponding to a local region of the porous flow equalization layer 61 (e.g., a 2x2 suction hole region), and the downstream outlet is connected to the vacuum chamber 3.

[0041] The adaptive nonlinear flow channel 63 is a two-stage, cascaded contraction-expansion structure. By increasing the expansion angle (example >18°), flow separation and backflow vortex regions are induced, causing the flow resistance to increase nonlinearly with the flow rate.

[0042] Example of specific geometric parameters (which can be optimized within a certain range):

[0043] First stage 631: contraction angle a1 is about 12°, throat diameter d1 is about 0.8mm, expansion angle b1 is about 20°, and length L1 is about 1.8mm (L1 / d1>2).

[0044] Second-stage 632: contraction angle a2 approximately 10°, throat diameter d2 approximately 0.6mm, expansion angle b2 approximately 25°, length L2 approximately 1.5mm (L2 / d2>2).

[0045] Parameter source and verification: The above example values ​​have been optimized through CFD simulation and experimental verification to ensure low flow resistance at low flow rates and significant nonlinear flow resistance generated by the separated flow at high flow rates, thus suppressing leakage from the exposed suction orifice.

[0046] Thus, the adaptive nonlinear flow channel 63 is configured such that: in the low flow state, the airflow maintains attached flow and the flow resistance is low; while when the flow rate increases to a predetermined range, a flow separation zone and a backflow vortex zone are formed in the flow channel, so that the flow channel pressure loss growth rate is significantly increased relative to the low flow state, thereby suppressing the leakage flow at the exposed suction hole 21 and causing the negative pressure to preferentially concentrate in the suction hole 21 area covered by the material.

[0047] 2. Vacuum chamber partitioning and control

[0048] The vacuum chamber 3 is divided into multiple independent negative pressure units (e.g., first negative pressure unit 31, second negative pressure unit 32, and third negative pressure unit 33) along the conveying direction. Each negative pressure unit covers a row of adaptive nonlinear flow channels 63 on the flow channel substrate 62. Each negative pressure unit is connected to the common negative pressure main pipe 5 through a connecting pipe 9 controlled by solenoid valves (first solenoid valve 91, second solenoid valve 92, and third solenoid valve 93). The electrical control subsystem detects the material position through photoelectric sensors 7 installed at the inlet and outlet of each negative pressure unit. The control logic is as follows: when material enters the first negative pressure unit 31, the first solenoid valve 91 is opened; when material leaves the first negative pressure unit 31 and the inlet sensor detects no new material, the first solenoid valve 91 is closed after a delay, and the second solenoid valve 92 of the second negative pressure unit 32 is opened in advance, realizing relay conveying with the "negative pressure adsorption zone" moving synchronously with the material, thereby greatly saving energy.

[0049] 3. Pressure sensing and adsorption state diagnosis

[0050] (1) Pressure sensing module

[0051] An independent miniature pressure measuring branch is installed near the throat of the first stage of each adaptive nonlinear flow channel 63, connected to a high dynamic response pressure sensor 8. All sensor signals are connected to the data acquisition card of the electrical control subsystem.

[0052] The pressure measuring branch pipe is preferably 6mm in length and 1mm in diameter to reduce disturbance to the main airflow, while effectively tracking rapid pressure fluctuations within the flow channel.

[0053] The sensors are arranged at intervals along the vertical conveying direction to form a transverse pressure sampling array, reflecting the adsorption state distribution in the width direction of the conveyor belt.

[0054] (2) Basic diagnosis

[0055] The electrical control subsystem analyzes the steady-state values ​​and fluctuations (P, σ) of each pressure signal in real time.

[0056] Adsorption is normal: P is stable (example -35kPa), σ is small;

[0057] Insufficient adsorption (material warping): The absolute value of P decreases (example -15 kPa), and σ may increase;

[0058] Flow channel blockage: P approaches 0 kPa, σ ≈ 0;

[0059] Pore ​​exposure: P fluctuates wildly near 0 kPa, and σ value is large.

[0060] When an anomaly is detected, the system will issue an alarm and locate the abnormal unit through the HMI interface.

[0061] (3) Advanced diagnostics – identification of microcracks inside materials

[0062] Suitable for rigid or brittle materials (glass, silicon wafers, ceramic plates, etc.).

[0063] Implementation method: The pressure signal is divided into frames, windowed, and subjected to Fast Fourier Transform (FFT) to calculate the short-time average energy E of the 150–600 Hz frequency band.

[0064] The system pre-stores the statistical distribution of normal operating condition E; when E exceeds the abnormal threshold (such as mean + 3σ) for multiple consecutive sampling periods and the peak value continues to appear, an advanced alarm is triggered to locate the adsorption point that may have cracks.

[0065] Output: The alarm message indicates the material number and approximate location, which can be linked to the downstream sorting mechanism to remove abnormal materials.

[0066] 4. Modular design and installation

[0067] The airflow management component 6 is a separate module that can be disassembled and replaced as a whole.

[0068] The porous flow equalization layer 61 and the flow channel substrate 62 are sealed with medical-grade double-sided adhesive or hot melt method to ensure interlayer communication and no leakage.

[0069] The module has a metal frame around it, which facilitates quick installation and maintenance.

[0070] 5. Delivery and Diagnostic Methods

[0071] Step S1. Adaptive conveying: The material covers the flow channel below the suction hole for low-resistance adsorption, while the exposed flow channel of the suction hole has high resistance to suppress leakage.

[0072] Step S2. Online sensing: Real-time acquisition of pressure signals from all flow channels.

[0073] Step S3. Intelligent Analysis: Basic diagnostics determine blockage or adsorption abnormalities, while advanced diagnostics identify microcracks. Abnormal conditions trigger alarms, while normal data is recorded and cyclically processed.

[0074] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An electromechanical integrated conveying device, comprising a frame (1), a conveyor belt surface (2) disposed on the frame (1), a vacuum chamber (3) located below the conveyor belt surface (2), and a vacuum generating device (4) communicating with the vacuum chamber (3), wherein the conveyor belt surface (2) is provided with a plurality of suction holes (21), characterized in that: It also includes an airflow management component (6) disposed between the conveyor belt surface (2) and the vacuum chamber (3), the airflow management component (6) comprising: A porous flow equalization layer (61) is located below the conveyor belt surface (2) and is used to locally diffuse the airflow from each suction hole (21) and provide basic flow resistance. The flow channel substrate (62) is located below the porous flow equalization layer (61), and a plurality of adaptive nonlinear flow channels (63) are formed therein, which are respectively connected to local areas of the porous flow equalization layer (61). Each of the adaptive nonlinear flow channels (63) connects the corresponding area to the vacuum cavity (3). The adaptive nonlinear flow channel (63) is configured such that the airflow remains attached under low flow conditions, while when the flow rate increases to a predetermined range, a flow separation zone and / or a recirculation zone are formed in the adaptive nonlinear flow channel (63), so that the pressure loss growth rate of the adaptive nonlinear flow channel (63) is significantly increased relative to the low flow condition, thereby suppressing the leakage flow at the exposed suction hole (21) and causing the negative pressure to be preferentially concentrated in the suction hole (21) area covered by the material; The adaptive nonlinear flow channel (63) includes a contraction section, an expansion section and an outlet section connected sequentially along the airflow direction. The expansion angle of the expansion section is greater than the corresponding contraction angle of the contraction section, and the ratio of the length of the expansion section to the throat diameter is greater than 2:1, so that the airflow forms a stable separation vortex region in the expansion section under high flow conditions, thereby causing the slope of the pressure loss-flow relationship curve to increase in stages. The adaptive nonlinear flow channel (63) includes two or more series-connected contraction-expansion structures. Each expansion section forms a progressively enhanced flow separation zone, which causes the energy dissipation of each separation zone to be superimposed under high flow conditions. This makes the adaptive nonlinear flow channel (63) more effective at suppressing the flow of parallel branches than a single expansion structure. The porous flow equalization layer (61) is a porous elastic material layer with uniform porosity, a thickness of 1–5 mm, and an average pore diameter of 50–300 μm. It is used to establish a transverse pressure equalization effect between each suction hole (21) and provide a stable basic throttling resistance.

2. The mechatronic conveying device according to claim 1, characterized in that: The vacuum chamber (3) is divided into multiple negative pressure units along the conveying direction. Each negative pressure unit covers the corresponding area of ​​the flow channel substrate (62) and is connected to the negative pressure main pipe through the connecting pipe (9), thereby reducing pressure crosstalk between long-distance adaptive nonlinear flow channels (63).

3. The mechatronic conveying device according to claim 1, characterized in that: It also includes multiple pressure sensors (8), each pressure sensor (8) is connected to the low-pressure zone of the corresponding adaptive nonlinear flow channel (63) contraction section through an independent pressure measuring branch pipe.

4. The mechatronic conveying device according to claim 3, characterized in that: Each pressure sensor (8) is arranged at intervals along a direction perpendicular to the conveying direction and corresponds to the transverse arrangement of the adaptive nonlinear flow channel (63) array to form a transverse pressure sampling array, which is used to reflect the adsorption state distribution in the width direction of the conveyor belt.

5. The mechatronic conveying device according to claim 4, characterized in that: It also includes an electrical control subsystem for receiving signals from each pressure sensor (8) and identifying adsorption state abnormalities and outputting prompt information based on the differences between the pressure signals corresponding to different adaptive nonlinear channels (63) or the changes of each pressure signal relative to the reference signal.

6. A method for identifying the adsorption state of the mechatronic conveying device according to any one of claims 3-5, characterized in that, include: During the conveying process, pressure signals corresponding to different adaptive nonlinear flow channels (63) are acquired, and based on the stability, absolute value or change characteristics of each signal, it is determined whether there is air leakage, abnormal coverage or material damage in the adsorption area corresponding to the adaptive nonlinear flow channel (63). When the pressure signal corresponding to a certain adaptive nonlinear flow channel (63) changes abnormally relative to the reference state, it is determined that there is an abnormal state in the adsorption area corresponding to the adaptive nonlinear flow channel (63) and a prompt message is output.

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