Automatic calibration method for pressure sensor and transmitter of automatic belt conveyor cleaning device

Abstract

The invention provides an automatic calibration method for pressure sensors and transmitters of an automatic belt conveyor cleaning device. The automatic calibration method comprises the following steps that S1, output values of the transmitters corresponding to the pressure sensors on the left side and the right side are collected to serve as original output values; s2, based on a preset correction coefficient, the original output values are corrected through a transmitter, and corrected output values are output; s3, performing deviation calculation on the original output value to obtain a relative deviation value; s4, the relative deviation value is compared with a preset deviation threshold value, if the relative deviation value is smaller than or equal to the deviation threshold value, the current correction coefficient is maintained, otherwise, iterative adjustment of the correction coefficient is triggered, automatic calibration is achieved, the problem that left pressure and right pressure are not matched is solved, and efficiency and equipment applicability are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of dock unloading, and more specifically, to an automatic calibration method for pressure sensors and transmitters of an automated belt conveyor cleaning device. Background Technology

[0002] At docks, several belt conveyors working in tandem are often used to transport ore powder or ore lumps containing moisture. Because of the moisture content, the ore powder or ore lumps are sticky and easily adhere to the conveyor belt. Even after the conveyor belt has transported the ore powder or ore lumps to the next conveyor belt, some ore powder or ore lumps will still stick to the conveyor belt and continue to move with it to the bottom wall of the conveyor belt. Subsequently, the ore powder or ore lumps are likely to fall off the conveyor belt under their own weight, which can easily cause loss of ore powder or ore lumps during the transportation process. Some ore powder or ore lumps may even fall onto the rollers of the belt conveyor, which can easily lead to belt conveyor malfunctions.

[0003] Therefore, it is necessary to clean the belt conveyor. Currently, there are two cleaning methods: one is manual cleaning, which involves manually operating cleaning equipment, which is inefficient; the other is to install an automatic cleaning device, such as the first-generation automated belt conveyor cleaning device applied for by the applicant, publication number: CN115009811A. The above solution has successfully verified the feasibility of automated cleaning in actual use, but the following technical problems still exist: 1. After communicating with sensor and transmitter manufacturers, it was learned that the accuracy of sensors and transmitters of the same batch and model still has certain differences. Therefore, after installation, the left and right pressure mismatch of the sensor will occur; 2. Other reasons for the left and right pressure mismatch, such as installation conditions, component aging, etc. Therefore, when the left and right pressure mismatch occurs, it is usually necessary to recalibrate the pressure sensor and transmitter by laboratory weight calibration. After calibration, the debugging personnel will modify the PLC low-level program to achieve the left and right pressure matching problem.

[0004] Therefore, the debugging efficiency and equipment applicability are poor. In view of this, those skilled in the art need to improve the automatic cleaner to overcome the above-mentioned defects. Summary of the Invention

[0005] The main purpose of this application is to provide an automatic calibration method for pressure sensors and transmitters in an automated belt conveyor cleaning device, which can automatically calibrate and solve the problem of pressure mismatch between the left and right sides, thereby greatly improving efficiency and the applicability of the equipment.

[0006] To achieve the above objectives, in a first aspect, this application provides an automatic calibration method for pressure sensors and transmitters in an automated belt conveyor cleaning device. The automatic calibration method for pressure sensors and transmitters in an automated belt conveyor cleaning device is characterized by comprising the following steps: S1. Collect the output values ​​of the transmitters corresponding to the pressure sensors on the left and right sides as the raw output values; S2. Based on the preset correction coefficient, the original output value is corrected by the transmitter and the corrected output value is output. S3. Perform deviation calculation on the original output value to obtain the relative deviation value; S4. Compare the relative deviation value with the preset deviation threshold. If the relative deviation value is less than or equal to the deviation threshold, maintain the current correction coefficient; otherwise, trigger iterative adjustment of the correction coefficient.

[0007] Optionally, the iterative adjustment of the correction coefficient includes: The original output values ​​on both sides are compared, and the correction coefficient for the side with the larger value is adjusted. The iterative adjustment formula is as follows: ,in This represents the correction factor before the nth round of adjustment on the i-th side. β represents the new correction coefficient after the nth round of adjustment on the i-th side, and β represents the iteration step size coefficient. This represents the current relative deviation value of the output participating in the calculation on the i-th side. Indicates the preset deviation threshold; The corrected output value is calculated using the adjusted correction coefficient, and the deviation is calculated on the corrected output value to obtain the corrected deviation value. The corrected deviation value is compared with the preset deviation threshold. If the corrected deviation value is less than or equal to the deviation threshold, the convergence is complete and the iteration stops. Otherwise, the adjustment is continued through the iterative adjustment formula until convergence is complete.

[0008] Optionally, the constraint range for the correction coefficient is: 0.8 ≤ k i ≤1.2, and k i The initial value is 1.

[0009] Optionally, the relative deviation value ,in Y 平均 To output the reference value, Y L Y represents the original output value of the transmitter corresponding to the pressure sensor on the left. R This is the original output value of the transmitter corresponding to the pressure sensor on the right.

[0010] Optionally, β can be set to a value between 0.05 and 0.2.

[0011] Optionally, step S1 may further include preprocessing the original output value, and step S3 may include performing deviation calculation on the preprocessed output value.

[0012] Optionally, the preprocessing is a first-order low-pass filtering process, and the first-order low-pass filtering formula is: ,in This is the filtered output value of the i-th transmitter. This represents the real-time raw output value of the i-th transmitter. The filtered output value of the i-th transmitter at the previous moment, where α is the filtering coefficient.

[0013] Optionally, the value of α can be between 0.1 and 0.5.

[0014] This invention provides an automatic calibration method for pressure sensors and transmitters in an automated belt conveyor cleaning device. Compared with existing technologies, its advantages are as follows: Addressing the problem of cleaning pressure imbalance caused by mismatch between the left and right pressure sensors and transmitters of the electric sweeper, it proposes an automatic adjustment method integrating synchronous signal acquisition, deviation determination, coefficient iterative correction, and convergence verification. This method offers the following significant advantages: 1. Improve the stability and consistency of cleaning operations: By synchronously collecting the output signals of the transmitters on the left and right sides, and iteratively correcting the transmitter gain coefficient based on the unified target output, the matching deviation of different models of sensors and transmitters is effectively eliminated, and the relative deviation of the left and right pressure output is controlled within the threshold range. This avoids problems such as cleaning residue and excessive wear of parts caused by uneven pressure, and ensures uniform cleaning effect throughout the entire area. 2. Enhance system adaptability and fault tolerance: Adopt a one-to-one independent configuration scheme for sensors and transmitters, supporting mixed use scenarios of different models of sensing components, and can adjust and correct parameters according to the differences in characteristics of the left and right sides; at the same time, through stable operating condition verification and coefficient constraint mechanism, it avoids erroneous adjustments caused by signal fluctuations and improves the monitoring reliability under complex operating conditions. 3. Extend the service life of core equipment components: By balancing the left and right cleaning pressure in real time, the force on vulnerable parts such as cleaning brushes or scrapers is evenly distributed, reducing the wear rate of unilateral overload, reducing the frequency of component replacement, and reducing equipment operation and maintenance costs. 4. Achieve intelligent and precise control: This method does not require modification of the actuator hardware. Pressure balance adjustment can be completed through closed-loop correction at the algorithm level. It is compatible with the upgrade and transformation of the control system of existing electric sweepers. It has the characteristics of low implementation cost and strong compatibility, and provides an efficient and feasible technical solution for the intelligent upgrade of sweeping equipment. Attached Figure Description

[0015] The accompanying drawings, which form part of this application, are used to provide a further understanding of the application and to make other features, objects, and advantages of the application more apparent. The illustrative embodiments and descriptions of this application are used to explain the application and do not constitute an undue limitation of the application. In the drawings: Figure 1 This is the circuit control diagram of an automated belt conveyor cleaning device. Detailed Implementation

[0016] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of protection of the present application.

[0017] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of this application described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0018] In this application, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "middle," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing this application and its embodiments, and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation.

[0019] Furthermore, in addition to indicating location or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in some cases to indicate a certain dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0020] In addition, the term "multiple" should mean two or more.

[0021] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0022] An automatic calibration method for pressure sensors and transmitters in an automated belt conveyor cleaning device, such as... Figure 1 The diagram shows a circuit diagram of an automated belt conveyor cleaning device, which includes a left pressure sensor, a right pressure sensor, and a matching transmitter. The core problem solved by this invention is the deviation in the output values ​​of the two transmitters under the same pressure, i.e., the cleaning pressure imbalance caused by the mismatch between the left and right pressure sensors and the transmitters.

[0023] The specific method is as follows: Includes the following steps: S1. Collect the output values ​​of the transmitters corresponding to the pressure sensors on both sides as the raw output values. The collected output values ​​are current values. Since vibration and electromagnetic interference are unavoidable during the operation of the electric sweeper, the raw output values ​​need to be preprocessed. In this embodiment, a first-order low-pass filter is used. The formula for the first-order low-pass filter is: ,in This is the filtered output value of the i-th transmitter. This represents the real-time raw output value of the i-th transmitter. The filtered output value of the i-th transmitter at the previous moment, α is the filtering coefficient, which is usually 0.1-0.5. The larger the vibration, the smaller the value. In this embodiment, α=0.3 is preferred. S2, based on the preset correction coefficient k i , where i represents the i-th side, i.e., the correction factor for the left-side transmitter is k. L The correction factor for the transmitter on the right is k. R The original output value is corrected by the transmitter and the corrected output value is output. That is, the left and right pressure matching is achieved through the coefficient constraint mechanism. S3. Perform deviation calculation on the original output value after filtering to obtain the relative deviation value. Specifically: the relative deviation value... ,in Y 平均 To output the reference value, Y L Y is the filtered raw output value of the transmitter corresponding to the pressure sensor on the left. R This is the original output value of the transmitter corresponding to the pressure sensor on the right after filtering. S4. Compare the relative deviation value with the preset deviation threshold. If the relative deviation value is less than or equal to the deviation threshold, the output is considered to be matched and the current correction coefficient can be maintained. Otherwise, the correction coefficient is iteratively adjusted.

[0024] Specifically, the iterative adjustment of the correction coefficient includes: Compare the original output values ​​on both sides and adjust the correction coefficient for the side with the larger value, such as Y. L >Y R Then adjust the correction factor on the left, Y L Less than Y R Then adjust the correction factor on the right.

[0025] The specific iterative adjustment formula is as follows: ,in This represents the correction factor before the nth round of adjustment on the i-th side. β represents the new correction coefficient after the nth round of adjustment on the i-th side, and β represents the iteration step size coefficient. This represents the current relative deviation value of the output participating in the calculation on the i-th side. This represents the preset deviation threshold; β takes a value of 0.05-0.2. To avoid overshoot, β is preferably 1. To prevent the correction coefficient from being too large or too small, which would cause output distortion, the coefficient constraint range is set to 0.8≤k. i The initial value of the correction coefficients on both the left and right sides is 1.

[0026] The corrected output value is calculated using the adjusted correction coefficient, and a deviation calculation is performed on the corrected output value to obtain the corrected deviation value. The corrected deviation value is then compared with a preset deviation threshold. Specifically, when adjusting the correction coefficient on the left, the correction coefficient on the left is adjusted by k. L Change to k L1 The correction factor on the right side remains k. R The corrected deviation value is then... ,and If the corrected deviation value is less than or equal to the deviation threshold, then convergence is complete and iteration stops. Otherwise, the new correction coefficient is used to continue adjusting the value through the iterative adjustment formula until convergence is complete. Finally, the transmitters on both sides output the corrected output signal with the new correction coefficient and send it to the drive unit of the cleaning component.

[0027] Specifically, for example: Given: =2%, β=0.1, k L =1,k R =1; after filtering, Y L =12mA, Y R =10mA, calculate Y 平均 =11mA, =18.18%>2%, triggering adjustment. Since the output on the left is too large, the correction coefficient on the left is adjusted, i.e., k is adjusted. L k L1 = The corrected output value is Y. L1=0.9838×12=11.8056m A, Y R If the value remains unchanged at 10mA, the corrected deviation δ is approximately 8.2, which is still greater than 2%. Therefore, the iteration continues. Since the left side is still larger, the correction coefficient on the left side is adjusted, i.e., k is adjusted. L1 k L2 The calculated value is 0.9777. At this point, the corrected output value is 11.73 mA. The calculated corrected deviation value δ is approximately 7.9. Since this is still greater than 2%, the iteration continues until it is less than or equal to 2%, at which point it stops.

[0028] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. An automatic calibration method for pressure sensors and transmitters in an automated belt conveyor cleaning device, characterized in that, Includes the following steps: S1. Collect the output values ​​of the transmitters corresponding to the pressure sensors on the left and right sides as the raw output values; S2. Based on the preset correction coefficient, the original output value is corrected by the transmitter and the corrected output value is output. S3. Perform deviation calculation on the original output value to obtain the relative deviation value; S4. Compare the relative deviation value with the preset deviation threshold. If the relative deviation value is less than or equal to the deviation threshold, maintain the current correction coefficient; otherwise, trigger iterative adjustment of the correction coefficient.

2. The automatic calibration method for pressure sensors and transmitters of an automated belt conveyor cleaning device as described in claim 1, characterized in that: The iterative adjustment of the correction coefficient includes: The original output values ​​on both sides are compared, and the correction coefficient for the side with the larger value is adjusted. The iterative adjustment formula is as follows: ,in This represents the correction factor before the nth round of adjustment on the i-th side. β represents the new correction coefficient after the nth round of adjustment on the i-th side, and β represents the iteration step size coefficient. This represents the current relative deviation value of the output participating in the calculation on the i-th side. Indicates the preset deviation threshold; The corrected output value is calculated using the adjusted correction coefficient, and the deviation is calculated on the corrected output value to obtain the corrected deviation value. The corrected deviation value is compared with the preset deviation threshold. If the corrected deviation value is less than or equal to the deviation threshold, the convergence is complete and the iteration stops. Otherwise, the adjustment is continued through the iterative adjustment formula until convergence is complete.

3. The automatic calibration method for pressure sensors and transmitters of an automated belt conveyor cleaning device as described in claim 2, characterized in that: The constraint range for the correction factor is: 0.8 ≤ k i ≤1.2, and k i The initial value is 1.

4. The automatic calibration method for pressure sensors and transmitters of an automated belt conveyor cleaning device as described in claim 3, characterized in that: The relative deviation value ,in Y 平均 To output the reference value, Y L Y represents the original output value of the transmitter corresponding to the pressure sensor on the left. R This is the original output value of the transmitter corresponding to the pressure sensor on the right.

5. The automatic calibration method for pressure sensors and transmitters of an automated belt conveyor cleaning device as described in claim 2, characterized in that: β takes values ​​between 0.05 and 0.

2.

6. The automatic calibration method for pressure sensors and transmitters of an automated belt conveyor cleaning device as described in claim 1, characterized in that: Step S1 also includes preprocessing the original output value, and step S3 performs deviation calculation on the preprocessed output value.

7. The automatic calibration method for pressure sensor and transmitter of an automated belt conveyor cleaning device as described in claim 6, characterized in that: The preprocessing is a first-order low-pass filter, and the formula for a first-order low-pass filter is: ,in This is the filtered output value of the i-th transmitter. This represents the real-time raw output value of the i-th transmitter. The filtered output value of the i-th transmitter at the previous moment, where α is the filtering coefficient.

8. The automatic calibration method for pressure sensor and transmitter of an automated belt conveyor cleaning device as described in claim 1, characterized in that: The value of α ranges from 0.1 to 0.5.

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