Real-time monitoring and automatic deviation correcting device for belt deviation of shuttle-type material distributing machine

Abstract

The invention discloses a real-time monitoring and automatic deviation correcting device for belt deviation of a shuttle type material distributing machine. The device comprises a deviation monitoring mechanism, a control unit, a hydraulic driving unit and a deviation correcting executing mechanism. The deviation monitoring mechanism is used for detecting the transverse displacement in the running process of the conveying belt in real time, and the transverse displacement amount and the change characteristics of the transverse displacement amount are obtained. Meanwhile, the stress variation generated in the belt deviation process can be monitored; the control unit is in signal connection with the deviation monitoring mechanism and is used for establishing judgment logic according to the transverse displacement, the displacement variation trend or the stress variation and judging the deviation state of the belt; when a preset judgment condition is met, outputting a deviation adjusting instruction; the hydraulic driving unit drives the deviation rectifying executing mechanism to actively adjust the running direction of the belt, and automatic deviation rectifying is achieved. According to the invention, continuous monitoring and automatic adjustment of the belt deviation state can be realized, and the reliability of deviation identification and the system response capability are improved.

Description

Technical Field

[0001] This invention relates to the field of concrete conveying equipment technology, and more specifically, to a real-time monitoring and automatic correction device for belt misalignment of a shuttle concrete placing boom. Background Technology

[0002] During the concrete construction of large ship locks, shuttle concrete placing booms typically need to undertake the task of continuous concrete transport over long distances and with large volumes. Due to the large lateral width of the ship lock structure, a single production line often needs to be equipped with multiple concrete conveyor belts, each tens of meters long, to achieve long-distance transport of concrete from a centralized supply point to the designated storage area.

[0003] In existing technologies, concrete conveyor belts commonly employ U-shaped idler structures and side rollers on both sides of the belt to limit lateral displacement and prevent belt misalignment. However, during actual long-distance operation, the belt is prone to continuous misalignment due to factors such as uneven material distribution, changes in conveying resistance, tension fluctuations, and equipment installation errors. The aforementioned passive limiting structures can only delay the development of misalignment to a certain extent and cannot effectively correct existing misalignment. Once the belt misalignment exceeds the limit, it can easily cause concrete spillage, accelerated wear on the belt edges, and even equipment shutdown and safety hazards.

[0004] Furthermore, traditional belt conveyors, when experiencing belt misalignment, typically rely on manual inspection and adjustment of idler rollers or supports. This is not only labor-intensive and slow to respond, but also fails to meet the construction requirements of continuous and stable concrete transport in lock engineering projects. Therefore, there is an urgent need for an automated belt misalignment device capable of real-time monitoring and proactive correction to improve the operational reliability of long-distance conveyor belts. Summary of the Invention

[0005] The purpose of this invention is to provide a real-time monitoring and automatic correction device for belt misalignment of a shuttle fabric laying machine, in order to solve the above-mentioned problems existing in the prior art.

[0006] The application is as follows: A real-time monitoring and automatic correction device for belt misalignment of a shuttle fabric conveyor includes: a misalignment monitoring mechanism, a control unit, a hydraulic drive unit, and a correction execution mechanism; The belt misalignment monitoring mechanism includes a displacement monitoring unit, which is set on at least one side of the width direction of the conveyor belt running path. It is used to detect the lateral displacement of the belt edge relative to the fixed detection reference on the belt conveyor in real time, or to detect the lateral offset angle of the belt running direction relative to the longitudinal center line of the belt, and generate a corresponding position signal. The control unit is signal-connected to the belt misalignment monitoring mechanism and is configured to: receive the position signal, determine whether the belt has misaligned or has a tendency to misalign according to a predetermined judgment logic; and generate a belt misalignment command when the determination is yes. The hydraulic drive unit is connected to the control unit and is used to receive the adjustment command and output hydraulic power. The belt correction actuator is connected to the hydraulic drive unit and is used to respond to the hydraulic power to adjust the posture of the belt support or guide component to generate a guiding force to correct belt deviation until the parameter detected by the deviation monitoring mechanism falls back below the first lateral displacement threshold, thereby completing the automatic belt correction. The control unit continuously receives feedback signals from the belt misalignment monitoring mechanism and stops outputting the belt misalignment command when the position signal indicates that the belt has returned to the normal operating range.

[0007] Furthermore, the predetermined determination logic includes at least one of the following: (1) The absolute value of the belt lateral displacement calculated based on the position signal exceeds the first lateral threshold. ; (2) In multiple consecutive sampling periods, the lateral displacement shows a monotonically changing trend, and its cumulative change exceeds the trend threshold.

[0008] Furthermore, the control unit is also configured to calculate the lateral offset angle of the belt operation based on the position signal. The lateral offset angle is determined by comparing the difference in lateral displacement at the same detection point at two different times with the running distance of the belt during that time period. The predetermined determination logic also includes: the lateral offset angle exceeds an angle threshold.

[0009] Furthermore, the belt misalignment monitoring mechanism also includes a force monitoring unit, which is disposed on a guide component, support roller, or limiting component on at least one side of the conveyor belt width direction. This unit is used to detect changes in contact force, support reaction force, or equivalent force caused by the belt edge running obliquely during belt misalignment. The control unit is configured to: establish a functional relationship between the force change and the belt's lateral displacement based on the geometric relationship of the increased running path caused by the oblique running of the belt edge, and based on the maximum allowable force change... The corresponding second lateral displacement threshold is calculated. And when the change in force exceeds At that time, it was determined that the belt had deviated from its intended path.

[0010] Furthermore, the control unit determines the first lateral displacement threshold based on the displacement monitoring unit and the force monitoring unit, respectively. Second lateral displacement threshold The smaller of the first lateral displacement threshold and the second lateral displacement threshold is used as the final correction determination threshold. When the detected lateral displacement exceeds the When this occurs, the adjustment command is triggered.

[0011] Furthermore, the belt alignment actuator includes a rotary alignment idler, and the hydraulic drive unit drives the rotary alignment idler to rotate about its vertical axis, thereby changing the deflection angle of its roller surface relative to the belt running direction. .

[0012] Furthermore, the control unit adjusts the lateral displacement based on the real-time detected amount. ,according to The relational calculation of the target adjustment angle of the correction actuator Where K is the preset correction ratio coefficient.

[0013] Compared with the prior art, the embodiments of the present invention achieve the following beneficial effects: By continuously sampling the lateral displacement of the conveyor belt and combining it with the displacement change trend for judgment, the continuous deviation trend can be identified before the lateral displacement reaches the absolute threshold. This allows for the initiation of belt misalignment control before significant belt deviation occurs, improving the system's responsiveness to the initial stage of misalignment. Simultaneously, this invention establishes two independent judgment logics—a displacement monitoring unit and a force monitoring unit—to set displacement and force thresholds respectively, and determines the corresponding allowable deviation range based on the functional relationship between force change and lateral displacement. When either judgment logic meets the trigger condition, a misalignment command is output, or the smaller of the displacement thresholds determined by the two logics is used as the final control threshold, thus maintaining stable misalignment identification capability under different operating conditions. Since force change reflects the stress state of the belt edge at the guide or limiting components, while displacement reflects the geometric deviation of the belt, these two monitoring methods characterize the belt's operating state from both mechanical and geometric dimensions, reducing the possibility of misjudgment due to environmental disturbances, load fluctuations, or instantaneous impacts caused by a single detection parameter.

[0014] Once deviation is detected, the control unit calculates the target adjustment amount of the correction actuator based on the real-time detected lateral displacement and according to the preset control function relationship; the hydraulic drive unit drives the correction actuator to generate corresponding attitude adjustment, thereby forming a guiding force corresponding to the current degree of deviation, realizing a continuously adjustable closed-loop control process. Attached Figure Description

[0015] Figure 1 This is a schematic diagram illustrating the working principle of a real-time monitoring and automatic correction device for belt misalignment of a shuttle fabric laying machine, provided in an embodiment of the present invention.

[0016] Among them: 1-rotary alignment roller, 2-hydraulic support rod, 3-oil supply line, 4-oil return line, 5-first gear pump, 6-second gear pump. Detailed Implementation

[0017] The present invention will now be described in detail with reference to the accompanying drawings.

[0018] Example 1

[0019] The present invention discloses a real-time monitoring and automatic correction device for belt misalignment of a shuttle concrete placing boom, which is installed at the running path of the conveyor belt of a concrete conveyor belt. The device includes: a misalignment monitoring mechanism, a control unit, a hydraulic drive unit, and a correction execution mechanism.

[0020] The belt misalignment monitoring mechanism is installed on at least one side of the conveyor belt's running path width direction. It is used to detect in real time the lateral displacement of the belt edge relative to a fixed detection reference on the conveyor belt, or to detect the lateral offset angle of the belt's running direction relative to the belt's longitudinal centerline, and generate corresponding position signals. The lateral displacement is the change in distance between the belt edge and the reference limiting structure, or the lateral offset angle is the deflection angle of the belt's running direction relative to the conveyor belt's longitudinal reference line.

[0021] The control unit is signal-connected to the belt misalignment monitoring mechanism and is configured to: receive the position signal, determine whether the belt has misaligned or has a tendency to misalign according to a predetermined judgment logic; and generate a belt misalignment adjustment command when the determination is yes.

[0022] In this embodiment, the control unit is preset with a first lateral displacement threshold under normal belt operation. This range represents the permissible lateral displacement range of the belt during normal operation, and can be set according to the belt width B, the idler arrangement, and the minimum edge safety distance C. For example, ,in To account for margins in installation and measurement errors.

[0023] The hydraulic drive unit is connected to the control unit and is used to receive the adjustment command and output hydraulic power. The belt correction actuator is connected to the hydraulic drive unit and is used to respond to the hydraulic power to adjust the posture of the belt support or guide component to generate a guiding force to correct belt deviation until the parameter detected by the deviation monitoring mechanism falls back below the first lateral displacement threshold, thereby completing the automatic belt correction. The control unit continuously receives feedback signals from the belt misalignment monitoring mechanism and stops outputting the belt misalignment command when the position signal indicates that the belt has returned to the normal operating range.

[0024] In this embodiment, the belt misalignment monitoring mechanism includes laser displacement sensors disposed on both sides of the conveyor belt in the width direction, located directly above the edges of the conveyor belt when it is normally centered. After initial installation or major overhaul of the equipment, a reference calibration is first performed: the belt is started to run stably and centered under no off-center load. At this time, the control unit records the distance values ​​measured by the two sensors, which are used as the lateral reference positions on both sides. and During operation, the sensor continuously measures the actual position of the belt edge. and The control unit calculates the lateral displacement of the edges of the belts on both sides in real time. , .

[0025] Under normal circumstances, and The deviation fluctuates slightly near zero. To eliminate detection errors caused by belt vibration or lateral sway and obtain a comprehensive, interference-resistant deviation, the control unit calculates the composite displacement. This value represents the lateral displacement of the belt center, directly reflecting the offset of the belt centerline relative to the machine centerline.

[0026] In this embodiment, the predetermined determination logic of the control unit includes: Threshold determination: The absolute value of the lateral displacement of the belt calculated based on the position signal. Then through real-time comparison With the preset first lateral displacement threshold ,like This is considered a serious deviation, and correction is immediately triggered. For example, for a belt with a bandwidth B=500mm, setting C=100mm and Δ=20mm, the first lateral displacement threshold can be calculated according to the base offset interval formula. This threshold can be fine-tuned on-site based on actual deviation observations, and is preset in the control unit.

[0027] Trend determination: using a fixed period to... Perform sampling. If N consecutive sampled values ​​satisfy... or This means that it exhibits a continuous unidirectional increasing or decreasing trend, and the cumulative change exceeds the trend threshold. If the belt shows a clear tendency to deviate, it will trigger correction in advance. This trend judgment can effectively filter out false alarms caused by instantaneous fluctuations due to belt vibration. For example, the control unit uses... Sampling is performed at fixed intervals. If five consecutive sampled values ​​show a unidirectional monotonically increasing or decreasing trend, and the cumulative change exceeds a set trend threshold, the result is considered a positive trend. If so, it is determined that there is a deviation trend.

[0028] As a preferred embodiment, the control unit is also configured to calculate the lateral offset angle of the belt running based on the position signal, the lateral offset angle being determined by comparing the difference in lateral displacement at the same detection point at two different times with the running distance of the belt during that time period.

[0029] Therefore, the predetermined decision logic of the control unit also includes angle determination: That is, according to the formula Calculate the short-time average lateral offset angle α, where v is the belt speed and T is the calculation time interval. If α exceeds the angle threshold... This is also considered a deviation, especially applicable when the deviation develops rapidly. In one example... It can be set between 0.5° and 2°.

[0030] As a preferred embodiment, the belt misalignment monitoring mechanism also includes a force monitoring unit. During belt operation, excessive oblique displacement at the edge can cause drastic changes in belt force. To further enhance the stability and durability of the belt system, the force monitoring unit detects the contact force or reaction force in the belt edge area in real time. The force monitoring unit is installed on the guide component or support roller of the conveyor belt and uses devices such as strain gauges, pressure sensors, or load sensors to detect force changes caused by belt misalignment.

[0031] Lateral displacement Δ of the belt x ( t This will cause changes in the belt's edge path; that is, belt offset will be accompanied by a tendency for the belt to lengthen. A longer belt requires greater support from the idlers. Assume the initial path of the belt under normal operating conditions is... L 0, when the belt shifts laterally, the change in the path of the belt edge is Δ. L Path change Δ L With lateral displacement Δ x ( t The relationship between them is: ; When the lateral displacement is much smaller than the initial path, an approximate expression can be used: ; Therefore, the path change Δ L With lateral displacement Δ x ( t There is a definite functional relationship between them.

[0032] When guiding or limiting constraints are present, the path change ΔL will be converted into a force change Δ within the edge constraint region. F ( t The corresponding change in force Δ F ( t This can be monitored using sensors. The relationship between the change in force and the change in path can be expressed as: ; Due to Δ L With Δ x ( t There is a definite relationship between ) and , therefore Δ F ( t It can also be represented as Δ x ( t The function: .

[0033] Based on the allowable stress variation that can balance the safety, stability, and durability of belt operation. This allows us to determine the upper limit of the corresponding path change. .

[0034] If the system design specifies: ; in If the preset proportional coefficient is used (e.g., 2‰), then the corresponding lateral displacement is the preset second lateral offset threshold: .

[0035] By analyzing the change in force Δ F ( t Real-time monitoring of the force changes was detected. At the same time, the control unit can also trigger a correction action.

[0036] To balance operational safety and response sensitivity, the system can employ a dual-threshold independent judgment mechanism, using the smaller of the first and second lateral offset thresholds as the final correction judgment threshold. This allows for early correction when the geometric displacement has not yet increased significantly but the stress has already changed abnormally, thereby improving the system's safety margin and durability. The control strategy is as follows: ; When the real-time lateral displacement Δ x ( t ) to reach the Δ x triggerWhen the belt runs, the control unit sends a deviation adjustment command to the hydraulic drive unit. The hydraulic drive unit drives the deviation correction actuator to adjust the angle or position of the belt support structure or guide structure, so that the belt running direction shifts to the opposite direction of deviation until the lateral displacement or lateral deviation angle detected by the deviation monitoring mechanism falls back below the first lateral displacement threshold, thereby completing the automatic belt deviation correction.

[0037] like Figure 1 As shown in this embodiment, the correction actuator is used to actively adjust the lateral displacement generated during the operation of the fabric laying machine after the correction detection and judgment module outputs the correction command. It mainly consists of a rotating adjustment roller 1, a hydraulic support rod 2, a hydraulic pipeline system, and a bidirectional drive gear pump.

[0038] When the rotating alignment roller 1 deflects relative to the conveying direction, the normal support force on the conveyor belt at the roller generates a lateral component. This lateral component changes the force balance of the conveyor belt, causing it to tend to return to center laterally in the opposite direction of the deflection angle, thus achieving belt alignment. In this embodiment, the control unit uses a proportional control algorithm. Assuming the belt deflects to the right, when it detects... When it is positive, the control unit calculates according to the formula. The required target correction angle is calculated, where K is a pre-set correction ratio coefficient, the size of which is related to factors such as belt width, tension and idler structure parameters. A negative value indicates that the axis of the eccentric roller needs to be rotated to the left by an angle.

[0039] The control unit will The signal is converted into an electrical signal and sent to the hydraulic drive unit. This drives the correction actuator to change the angle between the idler roller and the conveying direction, causing the conveyor belt or fabric to generate a lateral force during operation, thereby correcting the material's trajectory. By controlling the extension or retraction stroke of the hydraulic strut 2, the deflection angle of the rotating correction idler roller 1 can be precisely controlled, achieving continuously adjustable correction action. The hydraulic strut 2 is connected to two gear pumps rotating in opposite directions via two independent oil supply lines 3 and return lines 4. The first gear pump 5 is used to supply oil to one side cavity of the hydraulic strut 2, so that the hydraulic strut 2 extends in the first direction and drives the rotating adjustment roller 1 to deflect in the first correction direction. The second gear pump 6 is used to supply oil to the other side cavity of the hydraulic strut 2, so that the hydraulic strut 2 moves in the opposite direction and drives the rotating alignment roller 1 to deflect in the second alignment direction.

[0040] Two sets of gear pumps operate alternately or independently under the command of the control system, achieving bidirectional drive of the hydraulic strut 2 and avoiding slow correction response caused by lag in the reversing valve or hydraulic dead zone. When the correction detection module determines that the lateral displacement exceeds the preset correction trigger threshold and the offset direction is determined, the control system outputs the corresponding correction control command according to the offset direction. During the correction process, the control system can adjust the working time or output pressure of the gear pumps according to the real-time detected changes in lateral displacement, thereby achieving gradual correction and avoiding oscillations caused by overcorrection.

[0041] During the correction process, the control unit continuously receives detection signals from the deviation monitoring mechanism. As the correction mechanism is activated, the lateral displacement Δx(t) of the conveyor belt gradually decreases, and the calculated idler deflection angle θ(t) decreases accordingly. The control unit stops the correction action when the lateral displacement or lateral deviation angle returns to below the first lateral displacement threshold, thereby achieving a smooth return of the conveyor belt from deviation and avoiding excessive correction or reciprocating oscillation.

[0042] Numerous specific details are set forth in the specification provided herein. However, it will be understood that embodiments of the invention may be practiced without these specific details. In some instances, well-known methods, structures, and techniques have not been shown in detail so as not to obscure the understanding of this specification.

[0043] Furthermore, those skilled in the art will understand that although some embodiments herein include certain features included in other embodiments but not others, combinations of features from different embodiments are intended to be within the scope of the invention and form different embodiments. Any of the claimed embodiments can be used in any combination.

Claims

1. A real-time monitoring and automatic correction device for belt misalignment of a shuttle fabric conveyor, characterized in that, include: The system includes a deviation monitoring mechanism, a control unit, a hydraulic drive unit, and a deviation correction actuator. The belt misalignment monitoring mechanism includes a displacement monitoring unit, which is set on at least one side of the width direction of the conveyor belt running path. It is used to detect the lateral displacement of the belt edge relative to the fixed detection reference on the belt conveyor in real time, or to detect the lateral offset angle of the belt running direction relative to the longitudinal center line of the belt, and generate a corresponding position signal. The control unit is signal-connected to the belt misalignment monitoring mechanism and is configured to: receive the position signal and determine whether the belt has misaligned or has a tendency to misalign according to a predetermined judgment logic; And when the determination is yes, an adjustment command is generated; The hydraulic drive unit is connected to the control unit and is used to receive the adjustment command and output hydraulic power. The belt correction actuator is connected to the hydraulic drive unit and is used to respond to the hydraulic power to adjust the posture of the belt support or guide component to generate a guiding force to correct belt deviation until the parameter detected by the deviation monitoring mechanism falls back below the first lateral displacement threshold, thereby completing the automatic belt correction. The control unit continuously receives feedback signals from the belt misalignment monitoring mechanism and stops outputting the belt misalignment command when the position signal indicates that the belt has returned to the normal operating range.

2. The real-time monitoring and automatic correction device for belt misalignment of a shuttle fabric laying machine according to claim 1, characterized in that, The predetermined determination logic includes at least one of the following: (1) The absolute value of the belt lateral displacement calculated based on the position signal exceeds the first lateral displacement threshold. ; (2) In multiple consecutive sampling periods, the lateral displacement shows a monotonically changing trend, and its cumulative change exceeds the trend threshold.

3. The real-time monitoring and automatic correction device for belt misalignment of a shuttle fabric distribution machine according to claim 1, characterized in that, The control unit is also configured to calculate the lateral offset angle of the belt running based on the position signal. The lateral offset angle is determined by comparing the difference in lateral displacement of the same detection point at two different times with the running distance of the belt during that time period. The predetermined determination logic also includes: the lateral offset angle exceeds an angle threshold.

4. The real-time monitoring and automatic correction device for belt misalignment of a shuttle fabric distribution machine according to claim 1, characterized in that, The belt misalignment monitoring mechanism further includes a force monitoring unit, which is disposed on a guide component, support roller, or limiting component on at least one side of the conveyor belt width direction. This unit is used to detect changes in contact force, support reaction force, or equivalent force caused by the belt edge running obliquely during belt misalignment. The control unit is configured to: establish a functional relationship between the force change and the belt's lateral displacement based on the geometric relationship of the increased running path caused by the oblique movement of the belt edge, and based on the maximum allowable force change... The corresponding second lateral displacement threshold is calculated. And when the change in force exceeds At that time, it was determined that the belt had deviated from its intended path.

5. The real-time monitoring and automatic correction device for belt misalignment of a shuttle fabric distribution machine according to claim 1, characterized in that, The control unit determines the first lateral displacement threshold based on the displacement monitoring unit and the force monitoring unit, respectively. Second lateral displacement threshold The smaller of the first lateral displacement threshold and the second lateral displacement threshold is used as the final correction determination threshold. When the detected lateral displacement exceeds the When this occurs, the adjustment command is triggered.

6. The real-time monitoring and automatic correction device for belt misalignment of a shuttle fabric distribution machine according to claim 1, characterized in that, The belt alignment mechanism includes a rotary alignment idler. The hydraulic drive unit drives the rotary alignment idler to rotate around its vertical axis, thereby changing the deflection angle of its roller surface relative to the belt running direction. .

7. The real-time monitoring and automatic correction device for belt misalignment of a shuttle fabric distribution machine according to claim 1, characterized in that, The control unit, based on the real-time detected lateral displacement, according to... The relational calculation of the target adjustment angle of the correction actuator Where K is the preset correction ratio coefficient.

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