Belt conveyor disc brake control device and method

Abstract

The invention relates to a device and a method for controlling a disc brake of a belt conveyor. The device comprises a signal acquisition module for acquiring running state signals including the running speed of a conveying belt, the load weight, the gradient of a conveyor and the type of a braking instruction; the driving control module is used for adjusting the braking force of the disc brake according to the braking force control signal; the man-machine interaction module and / or the communication interface unit are / is respectively used for local control of an operator and remote control of an upper system; and the main control module adopts a PLC (Programmable Logic Controller), is connected with the signal acquisition module, the driving control module, the man-machine interaction module and the communication interface module, and is used for identifying a current braking working condition according to the running state signal, obtaining an optimal PID (Proportion Integration Differentiation) parameter matched with the current working condition, generating a braking force control signal and outputting the braking force control signal to the driving control module. The PID optimization control strategy is adopted, and the braking accuracy and reliability of the disc type braking control device under the complex working condition of the belt conveyor are improved.

Description

Technical Field

[0001] This invention relates to the field of coal mine transmission control technology; specifically, this invention relates to a control device and method for a disc brake of a belt conveyor. Background Technology

[0002] With the development of industrial automation and intelligence, coal mine belt conveyors are currently developing towards long distances and high power. Disc brakes can provide stable braking force in special working conditions such as downward conveying, preventing slippage or loss of control, which is of great significance to the safe operation of belt conveyors.

[0003] Currently, the electrical control devices for disc brakes are mainly based on traditional PLC control, which has problems such as a single control mode and a lack of process monitoring. Summary of the Invention

[0004] In view of the above, the present invention provides a control device and method for a disc brake of a belt conveyor, thereby solving or at least alleviating one or more of the above-mentioned problems and other problems existing in the prior art.

[0005] To achieve the aforementioned objective, a first aspect of the present invention provides a control device for a disc brake of a belt conveyor, wherein the device comprises:

[0006] The signal acquisition module is used to acquire operating status signals in real time, including conveyor belt speed, load weight, conveyor slope, and braking command type.

[0007] The drive control module is used to adjust the braking force of the disc brake according to the braking force control signal;

[0008] The human-machine interaction module and / or communication interface unit are provided, wherein the human-machine interaction module is used to support local control by operators; and the communication interface module is used to communicate data with the upper-level system and support remote control by the upper-level system.

[0009] The main control module, employing a programmable logic controller (PLC), is connected to the signal acquisition module, the drive control module, the human-machine interaction module, and the communication interface module. The main control module is used for:

[0010] Receive the operating status signal output by the signal acquisition module, and identify the current braking condition based on the operating status signal;

[0011] Based on the identified current braking condition, an adaptive PID control strategy is adopted to obtain the optimal PID parameters for the current braking condition.

[0012] The braking force control signal is generated based on the optimal PID parameters and output to the drive control module.

[0013] In the device described above, optionally, the main control module stores the preset optimal PID parameters determined by simulation or experiment in the parameter library, and obtains the optimal PID parameters under different operating conditions by calling the preset optimal PID parameters or optimizing the PID parameters in real time based on fuzzy logic algorithm.

[0014] When operating conditions change, the main control module realizes online self-tuning of PID parameters through a fuzzy rule base, and dynamically adjusts the PID parameters based on the preset optimal PID parameter combination according to the braking speed deviation and the deviation change rate.

[0015] In the device described above, optionally, the main control module is configured as follows:

[0016] Identify the current braking condition and classify it into different types, including full-load emergency braking, no-load normal shutdown, and load maintenance on inclined road sections;

[0017] When the current operating condition is full-load emergency braking, increase the proportional coefficient and decrease the integral coefficient;

[0018] When the current operating condition is a sloped road section with sustained load, increase the integral coefficient and appropriately decrease the proportional coefficient.

[0019] In the device described above, optionally, the human-machine interaction module includes a touch screen and a status indicator unit for displaying the operating status and braking process data in real time, and providing a function to query historical braking process data.

[0020] In the device described above, optionally, the main control module, the human-machine interaction module, and the communication interface module are integrated into an electrical control box, which is a mine-use explosion-proof and intrinsically safe structure with a touch screen window on the outer shell.

[0021] In the aforementioned device, optionally, the controlled objects of the drive control module include a normally open solenoid valve, a normally closed solenoid valve, and an oil pump motor. The drive control module is configured to: upon receiving a conventional braking control signal, control the oil pump motor to stop and de-energize the normally closed solenoid valve to cut off the oil circuit, thereby achieving slow-speed braking of the disc brake; upon receiving an emergency braking control signal, control the normally open solenoid valve to energize and open the braking oil circuit, thereby achieving rapid braking of the disc brake.

[0022] Optionally, in the device described above, the device includes a safety protection module connected to the main control module, and its functions include comprehensive motor protection and remote linkage protection.

[0023] The comprehensive motor protection includes: monitoring the operating status of the oil pump motor, and automatically issuing a stop request and outputting a fault signal when a motor operating fault is detected;

[0024] The remote linkage protection includes: outputting the fault signal to the upper system for alarm and linkage processing, and automatically executing the parking procedure when an emergency brake signal from the outside is received.

[0025] To achieve the aforementioned objective, a second aspect of the present invention provides a method for controlling a disc brake on a belt conveyor, wherein the method is applied to an apparatus as described in any of the preceding first aspects. The method includes the following steps:

[0026] Collect operating status signals, including conveyor belt speed, load weight, conveyor slope, and braking command type;

[0027] The current braking condition is identified based on the operating status signal;

[0028] Based on the identified current braking condition, an adaptive PID control strategy based on fuzzy logic algorithm is adopted to obtain the optimal PID parameters;

[0029] The braking force control signal is generated based on the optimal PID parameters to adjust the braking force of the disc brake.

[0030] In the aforementioned method, optionally, the adaptive PID control strategy based on fuzzy logic algorithm includes: obtaining the optimal PID parameters under different operating conditions by calling preset optimal PID parameters or real-time optimization parameters;

[0031] Obtaining the preset optimal PID parameters includes the following steps:

[0032] A mathematical model of the braking system, incorporating nonlinear and hysteresis characteristics, is established to characterize the mapping relationship between the braking force control signal and the conveyor belt speed.

[0033] Define the optimization objectives and construct fitness evaluation criteria;

[0034] Initialize the calculation parameters of the fuzzy logic algorithm and set the search range for the PID parameters;

[0035] The optimal combination of PID parameters is obtained by iterative calculation using a fuzzy logic algorithm, and then embedded into the PID controller.

[0036] In the method described above, optionally, the optimization objective includes constraints on overshoot, settling time, and steady-state error;

[0037] The fitness evaluation criterion is the following fitness function:

[0038]

[0039] in, , , These are the weighting coefficients.

[0040] The disc brake control device for belt conveyors of the present invention adopts a PID optimized control strategy to improve the braking accuracy and reliability of the disc brake control device under complex working conditions of belt conveyors.

[0041] The present invention further provides a control method for a disc brake of a belt conveyor, which also has the above-mentioned advantages. Attached Figure Description

[0042] The disclosure of this invention will become more apparent from the accompanying drawings. It should be understood that these drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention. In the drawings:

[0043] Figure 1 This is a schematic block diagram of an embodiment of the disc brake control device for a belt conveyor according to the present invention;

[0044] Figure 2 This is a schematic diagram of an embodiment of the disc brake control device for a belt conveyor according to the present invention;

[0045] Figure 3 This is a schematic flowchart of an embodiment of the disc brake control method for belt conveyors of the present invention. Detailed Implementation

[0046] Referring to the accompanying drawings and specific embodiments, the structure, composition, features, and advantages of the belt conveyor disc brake control device and method of the present invention will be described below by way of example; however, all descriptions should not be construed as limiting the present invention in any way.

[0047] Furthermore, for any single technical feature described or implied in the embodiments mentioned herein, or any single technical feature shown or implied in the various figures, the present invention still allows for any combination or deletion of these technical features (or their equivalents) without any technical obstacle, and thus these further embodiments according to the present invention should also be considered within the scope of this description.

[0048] It should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0049] Figure 1 This is a schematic block diagram of one embodiment of the disc brake control device for a belt conveyor according to the present invention.

[0050] like Figure 1 As shown, the control device for the disc brake of the belt conveyor in this embodiment adopts a modular design, which facilitates maintenance and upgrades. The device includes a main control module and signal acquisition module, drive control module, safety protection module, human-machine interaction module, and communication interface module connected to the main control module, and is connected to a centralized control system.

[0051] The information acquisition module is used to collect various operating status signals of the belt conveyor in real time, providing basic data support for braking condition identification and control strategy generation. In this embodiment, the operating status signals include conveyor belt speed, load weight, conveyor slope, and braking command type.

[0052] For example, the conveyor belt speed can be acquired by a speed sensor, which can be installed at the end of the conveyor roller shaft or near the surface of the conveyor belt; the load weight can be estimated by a weighing sensor or indirect parameters such as motor current monitored by a current transformer, reflecting the amount of material currently carried by the conveyor; the conveyor slope can be detected by an inclination sensor or an inertial measurement unit (IMU) to determine whether it is on an uphill, downhill, or horizontal section, which can be used for subsequent load holding control on inclined sections; the braking command type comes from the operation command issued by the operator through the local human-machine interaction module, and / or the remote control command issued by the upper system through the communication interface, and its types include normal stop command, emergency braking command, and holding brake command.

[0053] According to an optional embodiment, the information acquisition module is also used to monitor the oil pressure in the hydraulic circuit of the disc brake via a pressure sensor. This pressure value is directly related to the braking force and can be used as a variable for feedback adjustment in closed-loop control.

[0054] The information acquisition module processes and transmits the various signals to the main control module, ensuring that it can accurately capture the transient response of the system under complex conditions such as sudden load changes, slippage, or emergency braking, and providing reliable and real-time status input for subsequent PID optimization control strategies.

[0055] In optional embodiments, the signal acquisition module also provides status indication signals such as power-on, brake in position, flexible brake engagement, and system fault for the main control module to acquire. It also provides corresponding passive signal contacts to improve stability and anti-interference capabilities.

[0056] The drive control module receives the braking force control signal output from the main control module and converts it into specific action commands for the hydraulic system actuators, thereby achieving precise control of the disc brake under different braking conditions. Depending on the type of control signal received, this module can execute multiple braking modes, including conventional braking, emergency braking, and load-holding braking, to meet the safety and stability requirements of complex operating scenarios.

[0057] In this embodiment, the disc brake uses a hydraulic drive to achieve braking and releasing actions, with the braking force provided by a hydraulic drive mechanism. Exemplarily, the hydraulic drive mechanism includes basic components such as an oil pump, oil tank, solenoid valve, brake cylinder, and connecting pipelines. The drive control module controls the actuators in the hydraulic drive mechanism (e.g., normally open solenoid valves, normally closed solenoid valves, and the oil pump motor) to adjust the oil pressure in the brake cylinder, thereby achieving precise control of different braking modes of the disc brake. In this embodiment, the actuator uses a switching solenoid valve, which features simple structure, high reliability, fast response speed, low cost, and compliance with fail-safe design. Furthermore, the normally closed solenoid valve is used for conventional braking (flexible braking), while the normally open solenoid valve is used for emergency braking, providing redundant safety characteristics.

[0058] In normal braking mode, such as during unloaded normal shutdown, the drive control module achieves smooth braking without impact or overshoot, and the conveyor belt speed decreases uniformly. For example, when the drive control module responds to a slow braking command from the main control module, it stops the oil pump motor and de-energizes the normally closed solenoid valve, cutting off the oil circuit to the brake cylinder. The brake is then applied slowly and smoothly through the natural pressure relief process of the hydraulic drive mechanism. During brake release, the oil pump motor is started, and the normally closed solenoid valve is energized and engaged, introducing pressurized oil into the brake cylinder and pushing the brake arm open, achieving shock-free brake release and preventing slippage or vibration of the conveyor belt due to sudden release.

[0059] In emergency braking mode, such as in high-risk conditions like sudden malfunctions under full load, overspeeding, or receiving an external emergency stop signal, the drive control module responds quickly to generate sufficient braking force in the shortest possible time, preventing the accident from escalating. For example, the drive control module immediately responds to the emergency braking signal from the main control module, energizing the normally open solenoid valve to directly and rapidly inject high-pressure oil into the brake cylinder, enabling the brake to quickly and forcefully engage, minimizing the braking distance and preventing the accident from worsening.

[0060] In load-holding braking mode, such as during prolonged shutdowns on inclined sections or when maintaining material position, the drive control module achieves static stability, maintaining a constant braking force after braking to prevent the conveyor from slipping on inclined sections. For example, based on the holding command output from the main control module, the drive control module dynamically adjusts the on / off state of the solenoid valve, coordinating with the intermittent operation of the oil pump to maintain a stable oil pressure in the brake cylinder, thereby continuously providing a constant braking force to prevent the conveyor from slipping or rolling due to gravity. This mode emphasizes the long-term stability and anti-disturbance capability of the braking force, avoiding brake failure due to pressure decay.

[0061] The drive control module can receive control signals from the main control module through digital output ports or communication protocols, and has high response speed and strong anti-interference ability, ensuring the stability and safety of the braking system.

[0062] The human-machine interface module is the interface unit for local operation and information presentation of the device. It supports operators in directly operating, monitoring the status, and querying data of the disc brake control device at the equipment site, significantly improving the system's maintainability and ease of operation. The specific implementation of the human-machine interface can be configured according to actual application requirements, such as using one or more combinations of industrial-grade touch screens, physical button panels, voice prompt devices, or remote graphical clients.

[0063] For example, the human-machine interface module includes a touchscreen to visualize the disc brake. The graphical interface allows operators to easily and intuitively input operating commands, such as start / stop, brake release, brake engagement, and parameter adjustments, lowering the learning curve. Furthermore, the screen can display real-time operating status data of the conveyor and braking system, such as hydraulic pressure values ​​and conveyor belt speed.

[0064] According to an optional embodiment, the human-machine interaction module supports displaying the dynamic relationship of multiple parameters on the screen, such as automatically drawing the "pressure-conveyor belt speed-time" relationship curve and displaying it on the screen, which facilitates the user to perform dynamic analysis of the braking process.

[0065] According to an optional embodiment, the human-machine interaction module has a data storage function, which can record and save braking process data within a certain historical time (which can be set by the user), so as to facilitate users to query and analyze it later, and provide a basis for fault diagnosis, performance evaluation and operation optimization.

[0066] The human-machine interface module also includes a status indicator unit. For example, multiple status indicator lights can be set, such as power on, brake in position, flexible brake engaged, system fault, etc., to intuitively reflect the current operating status of the equipment. The status indicator lights provide intuitive and rapid visual feedback on the equipment status, ensuring that critical states (such as power on, brake in position, fault) can still be identified instantly, even in scenarios such as strong light, touchscreen failure, or remote observation by the operator.

[0067] The communication interface module enables bidirectional communication between the disc brake control device and external systems, supporting remote monitoring, command issuance, and status uploading. This module allows the control device to be seamlessly integrated into mining automation systems, belt conveyor centralized control systems, or other industrial IoT platforms, achieving digital, networked, and intelligent management of brake control. The physical interface type and communication protocol adopted by this module can be selected according to actual engineering requirements and are not limited thereto.

[0068] In this embodiment, the device supports a combined local and remote control operation. For local control (near-field control), the device has a human-machine interface module, allowing operators to directly perform all operations at the equipment site via human-machine interaction. For remote control (remote control), the device connects to a centralized control system through a communication interface module, allowing the system's start-up, shutdown, and operational status monitoring to be controlled by the host system.

[0069] Optionally, in remote control mode, the human-machine interface module can still function as a monitoring terminal, displaying in real-time the commands issued by the upper-level system and the equipment feedback status, ensuring that local personnel are aware of the system's operation. In local control mode, the communication interface module can remain online, and the main control module can still transmit information such as the status of the conveyor, brake, and control device through the communication interface, facilitating remote viewing and recording of the on-site equipment's operating status.

[0070] The safety protection module monitors the operating status of braking components in real time and triggers a protection mechanism promptly upon detecting a fault to prevent equipment damage or the occurrence and escalation of safety accidents. For example, the safety protection module includes a motor integrated protector. When the oil pump motor experiences faults such as overload, short circuit, phase loss, or leakage, the motor integrated protector will immediately activate, automatically issue a stop request, and output a fault signal. The operating current and supply voltage of the oil pump motor can be monitored using current transformers and voltage transformers to detect whether a fault has occurred in the oil pump motor in real time.

[0071] In an optional embodiment, the safety protection module can be linked with a higher-level system. Fault signals output by the safety protection module can be connected to the centralized control system for alarm and linkage processing. Furthermore, the safety protection module can automatically execute a parking procedure in response to an external emergency brake signal.

[0072] The main control module is the core of the device. It is implemented using a high-performance programmable logic controller (PLC) and is responsible for coordinating the data interaction and control logic execution between the signal acquisition module, drive control module, human-machine interaction module, communication interface module and safety protection module. It is the core of realizing intelligent and adaptive braking control.

[0073] The main control module employs a condition-adaptive PID optimization strategy to address the issue that the significant variations in braking conditions of belt conveyors mean that a single PID parameter combination cannot adapt to all conditions. It identifies the current operating condition and calls upon preset optimal PID parameters or real-time optimized parameters to achieve matching between the operating condition and control parameters.

[0074] The main control module receives signals from the signal acquisition module, including conveyor belt speed, load weight, conveyor slope, and braking command type. Based on this real-time data, the working condition identification unit within the main control module establishes a working condition classification model to classify and judge the current braking scenario, dividing the working condition into several typical types, such as full-load emergency braking, no-load normal shutdown, and load maintenance on inclined sections. The above working condition types are only exemplary classifications; in actual applications, the classification rules can be expanded or refined according to on-site requirements.

[0075] After identifying the operating condition, the main control module invokes the corresponding control strategy. Traditional PID parameters are often determined through empirical trial-and-error or ZN tuning methods, which are difficult to adapt to the nonlinear and time-varying characteristics of the braking system. The main control module, however, employs a PID parameter optimization strategy based on fuzzy logic algorithms. Utilizing the global search capability of fuzzy logic algorithms, it achieves dynamic optimization of PID parameters. Specifically, based on the identified current braking condition type, the main control module retrieves the corresponding optimal P (proportional), I (integral), and D (derivative) parameter combinations from a preset parameter library. Then, based on changes in the operating condition, it fine-tunes these parameter combinations using fuzzy logic algorithms, updating the parameters in real time to achieve rapid adaptive behavior. The parameters in this library are obtained through offline simulation or experimental testing. The optimal PID parameter combinations are calculated iteratively using fuzzy logic algorithms, with the dynamic performance indicators of the braking system (such as overshoot, settling time, and steady-state error) as the optimization objective.

[0076] The main control module can combine fuzzy logic algorithms to achieve online self-tuning of PID parameters without establishing a precise mathematical model, using a fuzzy rule base. For example, the self-tuning process uses braking speed deviation and its rate of change as input variables, dynamically adjusting the proportional coefficient (P), integral coefficient (I), and derivative coefficient (D) according to preset fuzzy rules. For instance, when the speed deviation is large, P is increased and D is decreased to improve response speed; when the speed deviation is small, P is decreased and I is increased to eliminate residual error; when the rate of change of deviation is large, D is increased to suppress overshoot.

[0077] Through rapid adaptation of PID parameters, the main control module can maintain good control performance under different operating conditions. For example, under emergency braking conditions, to prioritize response speed, the proportional coefficient is increased and the integral coefficient is decreased; under load maintenance conditions on inclined sections, to prioritize braking force stability, the integral coefficient is increased and the proportional coefficient is appropriately decreased to prevent the conveyor from slipping.

[0078] A simulation experiment of this invention verified the PID optimization strategy based on operating condition adaptation.

[0079] This simulation experiment utilizes AMESim simulation software to establish a mathematical model based on a belt conveyor, disc brake, and sensors. It derives the functional relationships between different components, determines relevant parameters, and achieves a comprehensive analysis and study of the disc brake system. Through dynamic characteristic analysis of the system, the drawbacks of the PID control parameters in traditional disc brake control systems are identified.

[0080] As an example, the parameter model is set as follows: the rated speed of the conveyor is 3.5 m / s; the diameter of the brake disc is 1200 mm; the working pressure of the hydraulic actuator is 0-15 MPa; the sensors include a speed sensor (accuracy ±0.01 m / s) and a pressure sensor (accuracy ±0.1 MPa); the control objective is that, during normal shutdown, the speed decreases from 3.5 m / s to 0, the overshoot is ≤5%, the settling time is ≤3 s, and the steady-state error is ≤0.05 m / s.

[0081] The simulation results are shown in Table 1.

[0082] Table 1 Simulation Experiment Results

[0083]

[0084] As shown in Table 1, the overshoot of the working condition adaptive PID control (fuzzy PID) combined with fuzzy logic algorithm is reduced by 74.8% and the settling time is shortened by 47.9% compared with the traditional PID, verifying that the optimization strategy effectively improves the braking response speed and stability, and enhances the dynamic performance of braking control; the steady-state error is reduced from 0.12m / s to 0.03m / s, improving the accuracy of braking control; the maximum temperature of the brake disc is reduced by 22.8%, reducing the risk of thermal fade; the number of conveyor belt slippages is 0, avoiding material spillage and equipment wear, and improving the safety of braking control; under the working condition of sudden change from no load (5t) to full load (20t), the speed fluctuation amplitude of fuzzy PID control is only 30% of that of traditional PID, with enhanced robustness and stronger adaptability of the braking controller to changes in working conditions.

[0085] Figure 2 This is a schematic diagram of an embodiment of the disc brake control device for a belt conveyor according to the present invention.

[0086] like Figure 2 As shown, in this embodiment, the control device is integrated into an electrical control box, which can be a mining-grade explosion-proof and intrinsically safe electrical control box. Multiple indicator lights are installed on the outer casing of the electrical control box, such as those indicating power on, brake engagement, flexible brake activation, and system fault. The electrical control box also monitors the pressure feedback of the hydraulic mechanism via a pressure gauge. Optionally, a new touchscreen window can be added to the outer casing of the electrical control box to display the operating status and receive operating commands, such as real-time display of hydraulic pressure values, equipment status, and plotting pressure-conveyor speed-time curves.

[0087] from Figure 2 As can be seen, the device is equipped with multiple terminals and is connected to the disc brake, hydraulic drive mechanism and AC power supply through electrical circuits. It can be used to collect operating conditions and equipment status information and output braking control signals.

[0088] This embodiment achieves a high degree of integration of the control system and an intrinsically safe explosion-proof design, meeting the safety access requirements of high-risk locations such as underground coal mines while facilitating on-site installation and maintenance. This embodiment provides an optional implementation method, in which the specific models, installation locations, and connection methods of each component can be flexibly adjusted according to actual engineering needs without affecting the effective implementation of the technical solution of this invention.

[0089] Figure 3 This is a schematic flowchart illustrating an embodiment of the belt conveyor disc brake control method of the present invention. The method can be executed by the belt conveyor disc brake control device provided in the foregoing embodiments.

[0090] like Figure 3 As shown, this method performs closed-loop control on the disc brake system of a belt conveyor, collects operating status signals in real time, identifies braking conditions through the collected signals, updates control parameters in real time according to changes in operating conditions, and continues to collect operating status signals.

[0091] For example, the method includes the following specific steps.

[0092] Step 1: Acquire operating status signals. Real-time acquisition of the belt conveyor's operating status data, including conveyor belt speed, load weight, conveyor gradient, and braking command type.

[0093] Step 2: Identify the current braking condition based on the operating status signals. A comprehensive analysis of the various signals is performed to determine the current braking scenario. Typical operating conditions include full-load emergency braking (e.g., sudden malfunction or overspeed), no-load normal shutdown (e.g., planned shutdown), and load maintenance on inclined sections (e.g., prolonged shutdown on a slope).

[0094] Step 3: Based on the identified current braking condition, an adaptive PID control strategy based on fuzzy logic algorithm is adopted to obtain the optimal PID parameters. Specifically, an initial optimal PID parameter combination matching the current condition can be called, which can be obtained through offline simulation or experimental testing. When the condition changes dynamically, the PID parameters can be self-tuned online using a fuzzy rule base. As an example, the braking speed deviation and rate of change can be used as input variables, and the proportional coefficient (P), integral coefficient (I), and derivative coefficient (D) can be dynamically adjusted according to fuzzy inference rules. For example, when the braking speed deviation is large, P is increased and D is decreased to improve the response speed; when the speed deviation is small, P is decreased and I is increased to eliminate steady-state error; and when the rate of change of deviation is large, D is increased to suppress overshoot.

[0095] Step 4: Generate a braking control signal based on the dynamically adjusted PID control parameters to adjust the braking force of the disc brake.

[0096] For example, the process of obtaining the optimal PID parameters includes the following steps.

[0097] Step 3.1: Establish a mathematical model of the braking system, clarify the mapping relationship between the braking force control signal and the conveyor speed, and consider nonlinear and hysteresis characteristics.

[0098] Step 3.2: Determine the optimization objectives, for example, using constraints such as "overshoot ≤ 5%, settling time ≤ 2s, and steady-state error ≤ 0.1m / s". Reducing overshoot and shortening settling time improves braking response speed and smoothness, enhancing the dynamic performance of braking control; reducing steady-state error improves the accuracy of braking control.

[0099] Step 3.3: Construct fitness evaluation criteria, for example, using the following fitness function:

[0100]

[0101] in, , , Weighting coefficients are set according to control priorities.

[0102] Step 3.4: Initialize the parameters of the fuzzy logic algorithm and set the search range for the PID parameters.

[0103] Step 3.5: Iteratively calculate using a fuzzy logic algorithm to obtain the PID parameter combination that minimizes the fitness function J as the optimal PID parameter combination, and embed it into the PID controller.

[0104] Through the above steps, the optimal combination of PID parameters can be obtained in advance. Then, the feedback signal of the braking system can be collected in real time during the braking process to judge the changes in the operating conditions, trigger the parameters to be re-optimized, and realize dynamic self-tuning.

[0105] This embodiment addresses the limitations of traditional PID control by combining the dynamic characteristics of a disc brake system with a PID optimization control strategy designed through parameter optimization and algorithm improvement. This strategy optimizes braking torque in real time, achieving adaptive control for different braking scenarios and improving the reliability, stability, and accuracy of the brake controller under complex operating conditions.

[0106] This invention provides a modular disc brake control device design, encompassing flexible braking, redundant control, communication interfaces, and historical alarm data query functions, enabling digital visualization of disc brake control for belt conveyors. Furthermore, this invention utilizes a PID optimized control strategy to improve the braking accuracy and reliability of the disc brake control device under complex operating conditions of belt conveyors.

[0107] The technical scope of this invention is not limited to the contents of the above specification. Those skilled in the art can make various modifications and variations to the above embodiments without departing from the technical concept of this invention, and all such modifications and variations should fall within the scope of this invention.

Claims

1. A belt conveyor disc brake control device, characterized by, The device comprises: a signal acquisition module for acquiring running state signals in real time, the running state signals including the running speed of the conveyor belt, the load weight, the slope of the conveyor and the type of braking instruction; a drive control module for adjusting the braking force of the disc brake according to the braking force control signal; a human-computer interaction module and / or a communication interface unit, the human-computer interaction module being used to support local control by an operator, and the communication interface module being used to communicate data with a host system to support remote control by the host system; a main control module using a programmable logic controller, the main control module being connected with the signal acquisition module, the drive control module, the human-computer interaction module and the communication interface module, and the main control module being used to: receive the running state signals output by the signal acquisition module, and identify the current braking condition according to the running state signals; obtain optimal PID parameters for the current braking condition by using an adaptive PID control strategy according to the identified current braking condition; generate a braking force control signal according to the optimal PID parameters and output the braking force control signal to the drive control module.

2. The apparatus of claim 1, wherein, The main control module stores preset optimal PID parameters determined through simulation or experiment in a parameter library, and obtains optimal PID parameters under different conditions by calling the preset optimal PID parameters or optimizing PID parameters in real time based on a fuzzy logic algorithm; When the condition changes, the main control module realizes online self-tuning of PID parameters through a fuzzy rule library, and dynamically adjusts PID parameters on the basis of the combination of the preset optimal PID parameters according to the braking speed deviation and the rate of change of the deviation.

3. The apparatus of claim 1, wherein, The main control module is configured to: identify the current braking condition and divide the condition into different types, the condition types including full-load emergency braking, empty-load normal shutdown and load keeping on an inclined section; when the current condition type is full-load emergency braking, increase the proportional coefficient and reduce the integral coefficient; when the current condition type is load keeping on an inclined section, increase the integral coefficient and appropriately reduce the proportional coefficient.

4. The apparatus of claim 1, wherein, The human-computer interaction module includes a touch screen and a state indication unit, and is used to display running state and braking process data in real time, and provide a historical braking process data query function.

5. The apparatus of any one of claims 1-4, wherein, The main control module, the human-computer interaction module and the communication interface module are integrated in an electric control box, the electric control box is of a mine-used explosion-proof and intrinsically safe structure, and a touch screen window is opened on the shell of the electric control box.

6. The apparatus of claim 1, wherein, The control objects of the drive control module include a normally open electromagnetic valve, a normally closed electromagnetic valve and an oil pump motor, and the drive control module is configured to: when a normal braking control signal is received, control the oil pump motor to stop and make the normally closed electromagnetic valve lose power to cut off the oil circuit, so as to realize slow-speed brake holding of the disc brake; and when an emergency braking control signal is received, control the normally open electromagnetic valve to be powered on to conduct the braking oil circuit, so as to realize fast brake holding of the disc brake.

7. The apparatus of claim 1, wherein, The device comprises a safety protection module connected with the main control module, and the functions of the safety protection module include motor comprehensive protection and remote linkage protection; the motor comprehensive protection includes: monitoring the running state of the oil pump motor, and automatically sending a parking request and outputting a fault signal when a motor running fault is detected; The remote linkage protection comprises: outputting the fault signal to an upper system, alarming and linkage processing, and automatically executing a parking program when receiving an emergency brake signal from outside.

8. A control method for a disc brake of a belt conveyor, characterized by, The method is applied to the device of any one of claims 1-7, and comprises the following steps: Collecting running state signals, the running state signals including a conveyor belt running speed, a load weight, a conveyor slope and a brake instruction type; Identifying a current braking working condition according to the running state signals; According to the identified current braking working condition, an adaptive PID control strategy based on a fuzzy logic algorithm is used to obtain optimal PID parameters; According to the optimal PID parameters, a brake force control signal is generated to adjust the brake force of the disc brake.

9. The method of claim 8, wherein, The adaptive PID control strategy based on the fuzzy logic algorithm comprises: optimal PID parameters are obtained under different working conditions by calling preset optimal PID parameters or real-time optimized parameters; Wherein, the preset optimal PID parameters are obtained by the following steps: A mathematical model of a braking system containing nonlinear and lag characteristics is established to represent the mapping relationship between the brake force control signal and the conveyor belt speed; An optimization target is determined, and an adaptability evaluation standard is constructed; The calculation parameters of the fuzzy logic algorithm are initialized, and the search range of the PID parameters is set; Iterative calculation is performed using the fuzzy logic algorithm to obtain an optimal PID parameter combination, and the optimal PID parameter combination is embedded into a PID controller.

10. The method of claim 9, wherein, The optimization target comprises constraint conditions of overshoot, regulation time and steady-state error; The adaptability evaluation standard is an adaptability function as follows:

11. wherein, , , are weight coefficients.

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