Adaptive adjusting system of rolling support of adaptive type belt gallery based on complex working condition

Abstract

The application discloses an adaptive adjusting system of a rolling support of an adaptive belt gallery based on complex working conditions, and relates to the technical field of support adjusting of belt galleries. The system comprises a rolling support body mechanism, a closed-loop lubricating execution mechanism, a multi-dimensional wear sensing unit, an adaptive pre-tightening compensation mechanism and an edge computing control unit. The multi-dimensional wear sensing unit is arranged to collect full-dimensional data of the support operation in real time, and the edge computing control unit is used for intelligent identification and adaptive regulation of the working conditions. The closed-loop lubricating execution mechanism is used for precise lubrication of the rolling pair as required, effectively avoiding the problems of lubricating grease loss and lubrication failure under complex working conditions. The adaptive pre-tightening compensation mechanism is used for real-time compensation of the fitting gap caused by wear, avoiding impact vibration and structural degradation caused by excessive gap, greatly prolonging the maintenance-free period and service life of the support, and reducing the operation and maintenance cost.

Description

Technical Field

[0001] This invention relates to the field of belt conveyor support adjustment technology, specifically an adaptive adjustment system for rolling supports of belt conveyors based on complex working conditions. Background Technology

[0002] Belt conveyor corridors are core load-bearing structures in continuous bulk material conveying systems in industries such as mining, metallurgy, power, and ports. They are widely used in long-distance, high-capacity material conveying scenarios. The structural safety of large-span belt conveyor corridors directly determines the continuous and stable operation of the entire conveying system. Rolling supports, as the core connecting component between the ends of the belt conveyor corridor and the underlying supporting structures, play a crucial role in releasing the deformation of the corridor structure caused by changes in ambient temperature, material load fluctuations, and uneven foundation settlement through the relative displacement of the rolling pairs. This prevents localized stress concentration caused by rigid constraints between the corridor and the supporting structure, thus preventing safety accidents such as corridor structural cracking and support failure. They are key components ensuring the long-term safe service of belt conveyor corridors and play a vital role in the durability and operational reliability of the conveying system throughout its entire lifecycle.

[0003] In typical application scenarios such as dry tailings disposal and ore conveying in mines, belt conveyor rolling supports are subjected to complex and harsh working conditions such as heavy alternating loads, frequent start-stop impacts, high dust intrusion, oil pollution, wind and soil corrosion, and alternating dry and wet conditions. At the same time, they must withstand multi-directional coupled vibrations and eccentric loads generated during the operation of the conveyor. This places extremely stringent requirements on the lubrication protection performance, wear resistance, operational stability, and maintenance-free performance of the rolling pairs of the supports.

[0004] Existing conventional belt conveyor roller bearings mostly adopt open or semi-open raceway-roller mating structures, equipped only with fixed single-point oil lubrication structures. This cannot adapt to the dynamic lubrication requirements of the rolling pairs under complex working conditions, and is prone to problems such as grease loss and lubrication failure. The contact surface between the roller and the raceway is prone to rapid wear under the coupled action of dust, oil erosion and alternating loads. The resulting clearance after wear will further aggravate structural vibration and impact loads, forming a vicious cycle of structural deterioration. At the same time, existing bearings lack effective wear compensation mechanisms and real-time monitoring capabilities of operating status, requiring frequent manual shutdowns for inspection, grease replenishment and maintenance. This not only significantly increases equipment operation and maintenance costs, but also easily leads to safety hazards such as bearing structural failure and instability of conveyor operation due to untimely maintenance. It is difficult to meet the long-term safe and stable operation requirements of belt conveyor under complex working conditions. Therefore, it is of great significance to develop an adaptive adjustment system for belt conveyor roller bearings adapted to complex working conditions. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of existing technologies and provide an adaptive adjustment system for belt conveyor rolling bearings based on complex working conditions. It can collect real-time all-dimensional data of bearing operation by setting up a multi-dimensional wear sensing unit, and realize intelligent identification and adaptive control of working conditions in conjunction with an edge computing control unit. Combined with a closed-loop lubrication actuator, it realizes precise lubrication of the rolling pair on demand, effectively avoiding the problems of grease loss and lubrication failure under complex working conditions. Through an adaptive preload compensation mechanism, it compensates for the fit clearance caused by wear in real time, avoiding impact vibration and structural deterioration caused by excessive clearance, and significantly extending the maintenance-free cycle and service life of the bearing.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: an adaptive adjustment system for a belt conveyor rolling support based on complex working conditions, the system comprising: a rolling support body mechanism, a closed-loop lubrication actuator, a multi-dimensional wear sensing unit, an adaptive preload compensation mechanism, and an edge computing control unit;

[0007] The rolling support body mechanism includes a support base plate, a support top plate, and a roller assembly located between the two. The support base plate is used to fix the bracket embedded part of the belt conveyor support structure, and the support top plate is used to fix the end column of the belt conveyor. Both the top surface of the support base plate and the bottom surface of the support top plate are provided with limiting roller tracks. The limiting roller tracks are used to cooperate with the roller assembly to form a rolling pair to release the deformation of the conveyor structure.

[0008] The closed-loop lubrication actuator includes a grease storage unit for storing grease, a pumping actuator for pumping grease, and a distributed oil injection pipeline. The distributed oil injection pipeline has an oil injection hole at the end and is connected to the pumping actuator. The oil injection hole is used to deliver grease to the mating contact surface between the roller assembly and the limiting raceway. The pumping actuator is connected to the grease storage unit, and its control end is electrically connected to the edge computing control unit.

[0009] The multi-dimensional wear sensing unit includes a wear sensing component for collecting wear data, a temperature sensing component for collecting temperature data, and a vibration sensing component for collecting vibration amplitude data. Each component is located at the limiting raceway, and the signal output terminals are all electrically connected to the edge computing control unit.

[0010] The adaptive preload compensation mechanism is located at both ends of the limiting raceway and includes an elastic preload component for providing preload force and an electrically controlled adjustment actuator for adjusting the preload force. The control end of the electrically controlled adjustment actuator is electrically connected to the edge computing control unit.

[0011] The edge computing control unit receives data collected by the multi-dimensional wear sensing unit, sends precise lubrication control commands for rolling pairs to the closed-loop lubrication actuator, and sends wear clearance compensation control commands to the adaptive preload compensation mechanism.

[0012] Furthermore, the edge computing control unit performs the following operations when identifying operating conditions and generating adaptive control commands:

[0013] The signal receiving port acquires wear data, temperature data, and vibration amplitude data transmitted by the multi-dimensional wear sensing unit in real time, and filters various types of data to remove invalid interference data.

[0014] The filtered effective data is imported into the built-in working condition identification model. Combined with preset load level thresholds, temperature thresholds, and vibration thresholds, the wear influence coefficient, temperature influence coefficient, and vibration influence coefficient are calculated respectively, and then expressed using formulas. The comprehensive working condition influence coefficient is calculated to determine the current operating condition and wear status of the rolling support. , , The operating condition weighting coefficient is obtained through orthogonal experiments based on the actual operating load characteristics of the belt conveyor, the corrosion level of the operating environment, and the structural vibration characteristics. The wear influence coefficient is the ratio of the actual detected wear amount to the reference wear amount of the support. The temperature influence coefficient is the ratio of the actual measured temperature of the friction surface to the reference working temperature of the support. The vibration influence coefficient is the ratio of the actual detected vibration amplitude to the support reference vibration amplitude.

[0015] Based on the determined operating conditions and wear status, and combined with the comprehensive operating condition influence coefficient, the built-in control parameter library is retrieved to match the corresponding lubrication control parameters and preload compensation parameters.

[0016] Based on the matched parameters, corresponding lubrication control commands and preload compensation commands are generated and transmitted to the pumping actuator of the closed-loop lubrication actuator and the electronically controlled regulating actuator of the adaptive preload compensation mechanism through the signal transmission port, respectively.

[0017] Furthermore, the closed-loop lubrication actuator performs the following operations when precisely lubricating the rolling pairs:

[0018] The system receives lubrication control commands transmitted from the edge computing control unit, parses the lubrication frequency and basic grease parameters contained in the commands, and combines them with the comprehensive operating condition influence coefficient transmitted from the edge computing control unit, using a formula... The precise amount of oil injected in a single operation was calculated, of which... The comprehensive operating condition impact coefficient is calculated by the edge computing control unit. This refers to the total frictional contact area between the roller assembly and the limiting raceway. The basic grease density per unit area is obtained by calculation and calibration based on the grease type and support design parameters using lubrication theory. The lubricating grease loss compensation coefficient is obtained by on-site measurement and calibration based on the dust concentration and wind speed level of the on-site environment.

[0019] The pumping actuator starts according to the oil injection frequency obtained from the analysis and the calculated single precise oil injection volume, and pumps the lubricating grease in the grease storage unit into the distributed oil injection pipeline at a preset pressure.

[0020] The grease is delivered to each injection hole through a distributed oil injection pipeline, and then delivered to the mating contact surface between the roller assembly and the limiting raceway through the oil injection hole;

[0021] After the preset amount of oil is added in a single cycle, the pumping actuator stops working. If a continuous lubrication command is received, the pumping and delivery steps are repeated according to the analyzed oil injection frequency.

[0022] Furthermore, the adaptive preload compensation mechanism performs the following operations when compensating for wear clearance:

[0023] The electronically controlled regulating actuator receives the wear clearance compensation control command transmitted from the edge computing control unit, parses the displacement adjustment parameters contained in the command, and combines the comprehensive operating condition influence coefficient and wear influence coefficient transmitted from the edge computing control unit, using the formula... The target preload value is calculated, where The comprehensive operating condition influence coefficient, The reference preload of the support is obtained through mechanical simulation calibration based on the design bearing capacity of the support and the structural parameters of the roller assembly. The basic preload compensation value corresponding to the wear amount is obtained by calibrating the wear amount detection values ​​of the raceway and rollers through a contact mechanics model. This is the wear influence coefficient;

[0024] The electronically controlled adjustment actuator generates a corresponding driving force based on the analyzed displacement adjustment parameters and the calculated target preload value, which pushes the elastic preload assembly to produce a slight displacement along the extension direction of the limiting raceway.

[0025] During the displacement process, the elastic preload component changes the clamping force on the limiting raceway and gradually adjusts it to the calculated target preload value, thereby compensating for the fit clearance between the limiting raceway and the roller assembly.

[0026] Once the preload reaches the preset value, the electronically controlled adjustment actuator maintains the current driving force, and the elastic preload component maintains the preset preload state until a new wear clearance compensation adjustment command is received.

[0027] Furthermore, the multi-dimensional wear sensing unit performs the following operations when collecting and transmitting operational data:

[0028] Wear sensing components, temperature sensing components, and vibration sensing components are activated simultaneously to continuously collect data on the wear amount of the contact surface between the roller assembly and the limiting raceway, the real-time temperature of the contact surface, and the vibration amplitude during the operation of the rolling support.

[0029] Each sensing component converts the collected raw data into electrical signals, which are then initially integrated through the internal signal transmission module.

[0030] The integrated electrical signal is transmitted to the signal receiving end of the edge computing control unit via a shielded transmission line;

[0031] Each sensing component continuously collects data at a preset collection frequency. When the collected data exceeds the preset warning range, the collection frequency is automatically increased and the data transmission rate is accelerated.

[0032] Furthermore, the grease storage unit is a sealed grease storage structure with a grease guide cavity inside. The outlet end of the guide cavity is connected to the oil inlet end of the pumping actuator. A grease filling port is provided at the top of the grease storage unit, and a sealing cap is provided at the grease filling port. An anti-stick coating is provided on the inner wall of the grease storage unit, and a slag discharge port is provided at the bottom of the grease storage unit, with a shut-off valve at the slag discharge port. In addition, a liquid level detection device is also provided inside the grease storage unit. The signal output end of the liquid level detection device is electrically connected to the edge computing control unit. The liquid level detection device is used to detect the remaining amount of grease in the grease storage unit in real time and transmit the data to the edge computing control unit.

[0033] Furthermore, the distributed oil injection pipeline is continuously laid out along the extension direction of the limiting raceway. There are multiple oil injection holes, which are evenly spaced along the length of the distributed oil injection pipeline. The oil outlet of each oil injection hole faces the mating contact surface between the roller assembly and the limiting raceway. An anti-clogging filter screen is installed at the oil outlet. The anti-clogging filter screen has a detachable structure. The diameter of the oil injection hole gradually decreases along the oil outlet direction, forming a conical oil outlet channel. The distributed oil injection pipeline is made of hard wear-resistant pipe material, and its outer wall is wrapped with an anti-corrosion protective layer. The distributed oil injection pipeline and the limiting raceway are connected and fixed by fixing clips. The fixing clips are used to maintain a relatively fixed positional relationship between the distributed oil injection pipeline and the limiting raceway.

[0034] Furthermore, the wear sensing component is embedded inside the friction mating surface of the limiting raceway, with its detection end flush with the friction mating surface of the limiting raceway. The wear sensing component is a contact wear detection structure. Multiple temperature sensing components are arranged at both ends and the middle of the limiting raceway. The temperature sensing components are non-contact infrared temperature measurement structures, with their detection ends facing the mating contact surface between the roller assembly and the limiting raceway. The vibration sensing component is arranged on the outer side of the end of the limiting raceway and is fixedly connected to the rolling support body mechanism. The vibration sensing component is a triaxial vibration detection structure used to detect the vibration amplitude data of the rolling support in the axial, transverse, and vertical directions.

[0035] Furthermore, the elastic pretensioning assembly includes a pretensioning push plate and elastic elements. The pretensioning push plate abuts against the end of the limiting raceway. One end of the elastic element is connected to the side of the pretensioning push plate away from the limiting raceway, and the other end of the elastic element is connected to the output end of the electronically controlled adjustment actuator. There are multiple elastic elements, which are evenly spaced along the height direction of the pretensioning push plate. The elastic elements adopt a disc spring assembly structure, which is composed of multiple disc springs stacked together. A wear-resistant pad is provided on the side of the pretensioning push plate facing the limiting raceway. The wear-resistant pad is in contact with the end of the limiting raceway. The wear-resistant pad is used to reduce frictional wear between the pretensioning push plate and the limiting raceway.

[0036] Furthermore, the pumping actuator includes a drive motor, a hydraulic pump, and a flow control valve. The output end of the drive motor is connected to the hydraulic pump, the inlet end of the hydraulic pump is connected to the grease storage unit, the outlet end of the hydraulic pump is connected to the flow control valve, and the outlet end of the flow control valve is connected to the distributed oil injection pipeline. The control end of the drive motor is electrically connected to the edge computing control unit, and the regulating end of the flow control valve is electrically connected to the edge computing control unit. The pumping actuator also includes a pressure detection device, which is installed on the pipeline between the hydraulic pump and the flow control valve. The signal output end of the pressure detection device is electrically connected to the edge computing control unit. The pressure detection device is used to detect the grease pumping pressure in the pipeline and transmit the data to the edge computing control unit.

[0037] Compared with existing technologies, this adaptive adjustment system for rolling supports of belt conveyors based on complex working conditions has the following advantages:

[0038] This invention collects real-time all-dimensional data of the support's operation by setting up a multi-dimensional wear sensing unit, and realizes intelligent identification and adaptive control of working conditions in conjunction with an edge computing control unit. Combined with a closed-loop lubrication actuator, it realizes precise lubrication of the rolling pair on demand, effectively avoiding the problems of grease loss and lubrication failure under complex working conditions. Through an adaptive pre-tightening compensation mechanism, it compensates for the fit clearance caused by wear in real time, avoiding impact vibration and structural deterioration caused by excessive clearance. This significantly extends the maintenance-free cycle and service life of the support, reduces operation and maintenance costs, and effectively ensures the long-term stable operation and structural safety of the belt conveyor rolling support under complex working conditions.

[0039] Other advantages, objectives and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination or study, or may be learned from the practice of the invention. Attached Figure Description

[0040] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0041] Figure 1 This is a schematic diagram of the adaptive adjustment system for the rolling support of the belt conveyor corridor based on complex working conditions.

[0042] Figure 2 A flowchart illustrating the workflow of an adaptive adjustment system for rolling bearings in a belt conveyor corridor, designed for complex working conditions.

[0043] Figure 3 This is a flowchart illustrating the precise lubrication of rolling pairs in a closed-loop lubrication actuator. Detailed Implementation

[0044] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0045] Example 1

[0046] This embodiment is applied to a large-span belt conveyor corridor scenario in a mining ore conveying system. In this scenario, the rolling bearings of the belt conveyor corridor are subjected to complex and harsh conditions such as heavy alternating loads, frequent start-stop impacts, high dust intrusion, wind and soil corrosion, and alternating wet and dry conditions. Simultaneously, they must withstand multi-directional coupled vibrations and eccentric loads generated during corridor operation. Traditional rolling bearings, using open or semi-open raceway and roller mating structures with fixed single-point lubrication designs, cannot meet the dynamic lubrication requirements of the rolling pairs under complex conditions and lack effective wear compensation mechanisms and real-time operational status monitoring capabilities. This easily leads to problems such as grease loss, lubrication failure, rapid wear of the raceway and rollers, and excessive mating clearances, which in turn trigger chain reactions such as increased structural vibration and localized stress concentration, severely affecting the operational stability of the belt conveyor corridor. Therefore, this invention employs an adaptive adjustment system for belt conveyor rolling bearings based on complex operating conditions, achieving intelligent sensing of the bearing's operating status, precise on-demand lubrication of the rolling pairs, and real-time compensation for wear clearances. The overall structural composition of this system is described in [reference needed]. Figure 1 .

[0047] In this embodiment, the construction and assembly of each core mechanism of the system are completed first. The rolling support body mechanism, as the basic load-bearing structure of the system, consists of a support base plate, a support top plate, and a roller assembly between the two. The support base plate is fixedly connected to the corbel embedded parts of the belt conveyor support structure, and the support top plate is fixedly connected to the end columns of the belt conveyor. Limiting raceways are machined on the top surface of the support base plate and the bottom surface of the support top plate. The roller assembly and the limiting raceways cooperate to form a rolling pair, thereby releasing the deformation of the conveyor structure caused by changes in ambient temperature, fluctuations in material load, and uneven settlement of the foundation.

[0048] The closed-loop lubrication actuator is equipped with a grease storage unit, a pumping actuator, and distributed oil injection pipelines. The grease storage unit adopts a sealed grease storage structure with an internal grease guide chamber, a grease filling port at the top with a sealing cap, an anti-stick coating on the inner wall, and a slag discharge port at the bottom with a shut-off valve. The grease storage unit also has a built-in level sensor for real-time monitoring of the remaining grease level. The pumping actuator consists of a drive motor, a hydraulic pump, a flow control valve, and a pressure sensor. The pressure sensor is located between the hydraulic pump and the flow control valve. On the pipeline between them, the pumping pressure of the grease in the pipeline is used to detect the grease pumping pressure in the pipeline; the distributed oil injection pipeline is continuously laid out along the extension direction of the limiting raceway, and multiple oil injection holes are evenly spaced along the length of the pipeline. The oil outlets are all facing the mating contact surface between the roller assembly and the limiting raceway. A detachable anti-clogging filter screen is installed at the oil outlet. The diameter of the oil injection hole gradually decreases along the oil outlet direction to form a conical oil outlet channel. The pipeline is made of hard wear-resistant pipe material, the outer wall is wrapped with an anti-corrosion protective layer, and it is relatively fixed to the limiting raceway by fixing clips.

[0049] The multi-dimensional wear sensing unit is equipped with multiple components at the limiting raceway. The wear sensing components are embedded inside the friction mating surface of the limiting raceway, with the detection end flush with the friction mating surface, forming a contact wear detection structure. The temperature sensing components are respectively arranged at both ends and the middle of the limiting raceway, forming a non-contact infrared temperature measurement structure, with the detection end facing the mating contact surface between the roller assembly and the limiting raceway. The vibration sensing components are arranged on the outer side of the end of the limiting raceway and fixedly connected to the rolling support body mechanism, forming a triaxial vibration detection structure used to detect the vibration amplitude of the support in the axial, lateral, and vertical directions.

[0050] The adaptive preload compensation mechanism is located at both ends of the limiting raceway and consists of an elastic preload assembly and an electrically controlled adjustment actuator. The elastic preload assembly includes a preload push plate and elastic elements. Multiple elastic elements are evenly spaced along the height of the preload push plate, and each elastic element uses a disc spring assembly structure. A wear-resistant pad is installed on the side of the preload push plate facing the limiting raceway and fits against the end of the limiting raceway. One end of each elastic element is connected to the preload push plate, and the other end is connected to the output end of the electrically controlled adjustment actuator. The edge computing control unit, as the core control component of the system, is electrically connected to the closed-loop lubrication actuator, the multi-dimensional wear sensing unit, and the adaptive preload compensation mechanism, respectively, to receive various operating data and send control commands. The overall system workflow is described in [link to system description]. Figure 2 .

[0051] After system assembly is completed, the multi-dimensional wear sensing unit is activated to collect and transmit operational data. The wear sensing component, temperature sensing component, and vibration sensing component are activated simultaneously to continuously collect data on the wear amount of the contact surface between the roller assembly and the limiting raceway, the real-time temperature of the contact surface, and the vibration amplitude of the rolling support during operation. Each sensing component converts the collected raw data into electrical signals, which are initially integrated through the internal signal transmission module. The integrated electrical signals are then transmitted to the signal receiving end of the edge computing control unit via a shielded transmission line. Each sensing component continuously collects data at a preset collection frequency. When the collected data exceeds the preset warning range, the collection frequency is automatically increased and the data transmission rate is accelerated to provide an accurate and real-time data source for subsequent operating condition identification.

[0052] After receiving the collected data, the edge computing control unit enters the working condition identification and adaptive control command generation stage. First, it acquires wear data, temperature data and vibration amplitude data transmitted by the multi-dimensional wear sensing unit in real time through the signal receiving port, and filters various types of data to remove invalid interference data. Then, it imports the filtered valid data into the built-in working condition identification model, and calculates the wear influence coefficient, temperature influence coefficient and vibration influence coefficient respectively by combining the preset load level threshold, temperature threshold and vibration threshold.

[0053] In the specific implementation process of this embodiment, through formula The comprehensive working condition influence coefficient is calculated to determine the current operating condition and wear status of the rolling support. , , The operating condition weighting coefficient is obtained through orthogonal experiments based on the actual operating load characteristics of the belt conveyor, the corrosion level of the operating environment, and the structural vibration characteristics. The wear influence coefficient is the ratio of the actual detected wear amount to the reference wear amount of the support. The temperature influence coefficient is the ratio of the actual measured temperature of the friction surface to the reference working temperature of the support. The vibration influence coefficient is the ratio of the actual detected vibration amplitude to the support reference vibration amplitude. The edge computing control unit, based on the determined operating conditions and wear status, and in conjunction with the comprehensive operating condition influence coefficient, retrieves the built-in control parameter library, matches the corresponding lubrication control parameters and preload compensation parameters, and then generates corresponding lubrication control commands and preload compensation commands based on the matched parameters. These commands are transmitted through the signal transmission port to the pumping actuator of the closed-loop lubrication actuator and the electronically controlled adjustment actuator of the adaptive preload compensation mechanism, respectively.

[0054] Upon receiving the lubrication control command, the closed-loop lubrication actuator initiates the precision lubrication process for the rolling pairs. The execution steps of this process are detailed below. Figure 3 The closed-loop lubrication actuator first receives the lubrication control command transmitted by the edge computing control unit, parses the oil injection frequency and basic grease injection parameters contained in the command, and then calculates the precise oil injection amount for a single operation by combining the comprehensive operating condition influence coefficient transmitted by the edge computing control unit. In the specific implementation process of this embodiment, the formula is used... The precise amount of oil injected in a single operation was calculated, of which... The comprehensive operating condition impact coefficient is calculated by the edge computing control unit. This refers to the total frictional contact area between the roller assembly and the limiting raceway. The basic grease density per unit area is obtained by calculation and calibration based on the grease type and support design parameters using lubrication theory. The lubricating grease loss compensation coefficient is obtained by on-site measurement and calibration based on the dust concentration and wind speed level of the on-site environment.

[0055] The pumping actuator starts based on the analyzed oil injection frequency and the calculated precise single oil injection volume. The drive motor drives the hydraulic pump to pump the grease in the grease storage unit into the distributed oil injection pipeline at a preset pressure. The pressure detection device monitors the pumping pressure in the pipeline in real time and transmits the data to the edge computing control unit. The grease is delivered to each oil injection hole through the distributed oil injection pipeline and delivered to the mating contact surface between the roller assembly and the limiting raceway through the conical oil outlet channel. After the single preset oil injection volume is completed, the pumping actuator stops working. If a continuous lubrication command is received, the above pumping and delivery steps are repeated according to the analyzed oil injection frequency. The liquid level detection device in the grease storage unit transmits the remaining grease data to the edge computing control unit in real time, realizing real-time monitoring of the remaining grease.

[0056] Simultaneously, the adaptive preload compensation mechanism initiates the wear gap compensation process. The electronically controlled adjustment actuator receives the wear gap compensation control command transmitted from the edge computing control unit, parses the displacement adjustment parameters contained in the command, and then calculates the target preload value by combining the comprehensive working condition influence coefficient and wear influence coefficient transmitted from the edge computing control unit. In the specific implementation process of this embodiment, the formula is used... The target preload value is calculated, where The comprehensive operating condition influence coefficient, The reference preload of the support is obtained through mechanical simulation calibration based on the design bearing capacity of the support and the structural parameters of the roller assembly. The basic preload compensation value corresponding to the wear amount is obtained by calibrating the wear amount detection values ​​of the raceway and rollers through a contact mechanics model. The wear impact coefficient is calculated. The electronically controlled adjustment actuator generates a corresponding driving force based on the analyzed displacement adjustment parameters and the calculated target preload value. This force pushes the elastic preload component to produce a slight displacement along the extension direction of the limiting raceway. During this displacement, the elastic preload component changes its clamping force on the limiting raceway, gradually adjusting to the calculated target preload value. This ensures precise compensation of the clearance between the limiting raceway and the roller assembly. Once the preload reaches the preset value, the electronically controlled adjustment actuator maintains the current driving force, and the elastic preload component maintains the preset preload state until a new wear clearance compensation control command is received.

[0057] In summary, this embodiment applies an adaptive adjustment system for rolling supports in complex working conditions to a large-span belt conveyor for ore transport in a mine. Through a multi-dimensional wear sensing unit, real-time and accurate acquisition of all dimensions of support operation data is achieved, providing reliable data support for working condition identification. The edge computing control unit, relying on the acquired data, completes intelligent identification of working conditions and accurate generation of control commands, fulfilling the core requirement of adaptive control for the system. The closed-loop lubrication actuator achieves on-demand and precise lubrication of the rolling pairs according to the control commands, fundamentally solving the problems of grease loss and lubrication failure under complex working conditions, and preventing rapid wear of the contact surfaces between the rollers and raceways under the coupled effects of dust, oil erosion, and alternating loads.

[0058] Example 2

[0059] This embodiment is applied to the scenario of a large-span conveyor belt corridor in a port bulk cargo terminal. In this scenario, the rolling bearings of the conveyor belt corridor are subjected to a complex working condition of high humidity and salt spray corrosion, slight settlement of the foundation caused by tides, instantaneous heavy load impact during material loading and unloading, and erosion by sea salt dust carried by sea breeze. At the same time, due to the continuous requirements of terminal operations, the corridor needs to operate uninterruptedly throughout the year. Traditional rolling bearings not only have the problem that the lubricating grease is easily deteriorated by salt spray and that the oil injection channel is blocked by sea salt dust, but also that slight settlement of the foundation and instantaneous heavy load will accelerate the non-uniform wear of the rollers. The existing compensation structure has a lag in response and cannot adapt to the gap changes in real time. Frequent manual maintenance will not only interrupt the terminal operation process, but also easily lead to the failure of the bearing due to inadequate maintenance operations in the salt spray environment. Therefore, based on the aforementioned embodiment, the adaptive adjustment system of the rolling bearing of the conveyor belt corridor based on complex working conditions is optimized for scenario adaptation and applied to the conveyor belt corridor of the port bulk cargo terminal, realizing the integrated control of intelligent sensing, precise lubrication, rapid gap compensation and anti-corrosion protection of the bearing under the complex working condition of high humidity and salt spray.

[0060] The system in this embodiment, based on the aforementioned embodiments, has been adapted and assembled to suit the characteristics of port conditions involving high humidity, salt spray, and sudden heavy loads. The overall structural composition of the system is described in [reference needed]. Figure 1 The system as a whole still includes a rolling bearing body mechanism, a closed-loop lubrication actuator, a multi-dimensional wear sensing unit, an adaptive preload compensation mechanism, and an edge computing control unit. The basic connections and electrical connections of each core mechanism are consistent with the aforementioned embodiments, with only targeted structural optimizations made for port working conditions. The limiting raceway surface of the rolling bearing body mechanism is coated with a salt spray resistant ceramic coating to reduce the corrosion and wear of the raceway by salt spray; the grease storage unit of the closed-loop lubrication actuator is equipped with a constant temperature and humidity control module to prevent the grease from emulsifying and deteriorating in a high humidity environment; the anti-corrosion protection layer of the distributed oil injection pipeline is upgraded to a three-layer composite anti-corrosion structure; the anti-clogging filter is replaced with a corrosion-resistant metal filter with a higher mesh size; and an oleophobic coating is added to the conical oil outlet channel of the oil injection hole to reduce the adhesion of grease residue and sea salt dust.

[0061] Based on the aforementioned sensing components, the multi-dimensional wear sensing unit adds a corrosion sensing component to the outside of the limiting raceway to simultaneously collect data on the corrosion level of the raceway surface. All wiring terminals of the sensing components are sealed with potting compound to improve moisture resistance and salt spray resistance. The wear-resistant pad of the elastic preload component of the adaptive preload compensation mechanism is replaced with a salt spray-resistant copper alloy material, the disc spring assembly is treated with anti-corrosion electroplating, and the electronic control adjustment actuator is equipped with a micro-displacement fast response module to improve the response speed of preload adjustment. The edge computing control unit has a built-in control parameter library specifically for port working conditions and adds linkage control logic for corrosion conditions.

[0062] After the system compatibility assembly is completed, the multi-dimensional wear sensing unit is activated to collect all-dimensional operational data. The wear sensing components, temperature sensing components, vibration sensing components, and the newly added corrosion sensing components are activated simultaneously to collect data on the wear amount of the contact surface between the roller assembly and the limiting raceway, the real-time temperature of the contact surface, the three-dimensional vibration amplitude of the support, and the degree of corrosion on the raceway surface. Each sensing component converts the raw data into electrical signals and initially integrates them before transmitting them to the edge computing control unit via a sealed and shielded transmission line. When abnormal data such as excessive salt spray concentration or sudden increase in vibration amplitude are detected, each sensing component automatically increases the acquisition frequency to provide a highly timely data source for operating condition identification.

[0063] After receiving the collected data, the edge computing control unit performs condition identification and control command generation according to a preset process. The overall system workflow is described in [link to system details]. Figure 2 First, the data on wear, temperature, vibration, corrosion, and other dimensions are filtered to remove invalid and interfering data. Then, the valid data is imported into the built-in port operating condition-specific recognition model. Combined with preset load, temperature, and vibration thresholds, the wear influence coefficient, temperature influence coefficient, and vibration influence coefficient are calculated respectively. In the specific implementation process of this embodiment, the formula is used... The comprehensive working condition influence coefficient is calculated, and the current operating condition, wear status and corrosion degree of the support are determined by combining the data collected by the corrosion sensing component. Then, the port working condition exclusive control parameter library is retrieved, and the corresponding lubrication control parameters, preload compensation parameters and anti-corrosion linkage parameters are matched. Finally, lubrication control instructions and preload compensation instructions are generated and sent to the corresponding actuators. When the corrosion degree exceeds the preset value, a linkage control instruction to increase the lubrication frequency is generated simultaneously.

[0064] After receiving the lubrication control command, the closed-loop lubrication actuator executes the precise lubrication filling process according to the aforementioned embodiment. The execution steps of this process are described below. Figure 3 First, analyze the oil injection frequency and basic grease injection parameters in the instruction, and combine them with the comprehensive working condition influence coefficient, using the formula... The system calculates the precise amount of grease to be injected in a single cycle. Based on the calculation results, the pumping actuator starts, and the drive motor drives the hydraulic pump to pump the grease from the grease storage unit into the distributed grease injection pipeline at a preset pressure. The pressure detection device monitors the pipeline pressure in real time and feeds it back to the edge computing control unit. When an abnormal pipeline pressure is detected, the edge computing control unit automatically adjusts the flow regulating valve to prevent excessive pipeline pressure caused by sea salt dust blockage. The grease is delivered to the mating contact surface of the roller and the limiting raceway through the conical oil outlet channel of the distributed grease injection pipeline. After completing a single grease injection, the pumping actuator operates intermittently at the matched grease injection frequency. The constant temperature and humidity control module of the grease storage unit always maintains stable internal temperature and humidity. The liquid level detection device provides real-time feedback on the remaining amount of grease. When the remaining amount is lower than the preset value, a grease replenishment reminder is sent to the edge computing control unit to achieve refined management of the grease.

[0065] After receiving the preload compensation command, the adaptive preload compensation mechanism initiates the wear clearance compensation process. The electronically controlled actuator analyzes the displacement adjustment parameters in the command, and combines the comprehensive operating condition influence coefficient and the wear influence coefficient, using the formula... The system calculates the target preload value and generates driving force using the added micro-displacement rapid response module. This force pushes the corrosion-resistant elastic preload component to make a slight displacement along the extension direction of the limiting raceway. The elastic preload component changes the clamping force on the limiting raceway through the salt spray resistant copper alloy wear-resistant pad, quickly adjusting to the target preload value to achieve real-time compensation for wear gaps. In response to the instantaneous heavy load impact during port material loading and unloading, when the vibration sensing component detects a sudden increase in vibration amplitude, the electronically controlled adjustment actuator can complete the dynamic fine adjustment of the preload in a short time to offset the gap fluctuations caused by the instantaneous heavy load. After the preload reaches the preset value, the electronically controlled adjustment actuator maintains the driving force until a new compensation command is received.

[0066] In summary, this embodiment applies the adaptive adjustment system, optimized for port conditions, to the conveyor belt corridor of a bulk cargo terminal. Building upon the aforementioned embodiments, targeted structural optimization and control logic upgrades enable the system to perfectly adapt to complex conditions such as high humidity salt spray, instantaneous heavy loads, and minor foundation settlement. This effectively addresses industry pain points in port scenarios, including grease emulsification and deterioration, blockage of oil injection channels, raceway corrosion and wear, and delayed clearance compensation response. The newly added corrosion sensing component in the multi-dimensional wear sensing unit enables real-time monitoring of support corrosion, making the operating condition identification more aligned with port realities. The constant temperature and humidity control and composite anti-corrosion design of the closed-loop lubrication actuator ensures stable grease performance and unobstructed oil injection lines. The application of a precise lubrication formula ensures that the grease injection volume and frequency perfectly match the dynamic requirements of port conditions.

[0067] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. An adaptive adjustment system for rolling supports of belt conveyors in complex working conditions, characterized in that, The system includes: a rolling support body mechanism, a closed-loop lubrication actuator, a multi-dimensional wear sensing unit, an adaptive preload compensation mechanism, and an edge computing control unit; The rolling support body mechanism includes a support base plate, a support top plate, and a roller assembly located between the two. The support base plate is used to fix the bracket embedded part of the belt conveyor support structure, and the support top plate is used to fix the end column of the belt conveyor. Both the top surface of the support base plate and the bottom surface of the support top plate are provided with limiting roller tracks. The limiting roller tracks are used to cooperate with the roller assembly to form a rolling pair to release the deformation of the conveyor structure. The closed-loop lubrication actuator includes a grease storage unit for storing grease, a pumping actuator for pumping grease, and a distributed oil injection pipeline. The distributed oil injection pipeline has an oil injection hole at the end and is connected to the pumping actuator. The oil injection hole is used to deliver grease to the mating contact surface between the roller assembly and the limiting raceway. The pumping actuator is connected to the grease storage unit, and its control end is electrically connected to the edge computing control unit. The multi-dimensional wear sensing unit includes a wear sensing component for collecting wear data, a temperature sensing component for collecting temperature data, and a vibration sensing component for collecting vibration amplitude data. Each component is located at the limiting raceway, and the signal output terminals are all electrically connected to the edge computing control unit. The adaptive preload compensation mechanism is located at both ends of the limiting raceway and includes an elastic preload component for providing preload force and an electrically controlled adjustment actuator for adjusting the preload force. The control end of the electrically controlled adjustment actuator is electrically connected to the edge computing control unit. The edge computing control unit receives data collected by the multi-dimensional wear sensing unit, sends precise lubrication control commands for rolling pairs to the closed-loop lubrication actuator, and sends wear clearance compensation control commands to the adaptive preload compensation mechanism.

2. The adaptive adjustment system for rolling supports of belt conveyors based on complex working conditions according to claim 1, characterized in that, The edge computing control unit performs the following operations when identifying operating conditions and generating adaptive control commands: The signal receiving port acquires wear data, temperature data, and vibration amplitude data transmitted by the multi-dimensional wear sensing unit in real time, and filters various types of data to remove invalid interference data. The filtered effective data is imported into the built-in working condition identification model. Combined with preset load level thresholds, temperature thresholds, and vibration thresholds, the wear influence coefficient, temperature influence coefficient, and vibration influence coefficient are calculated respectively, and then expressed using formulas. ; The comprehensive working condition influence coefficient is calculated to determine the current operating condition and wear status of the rolling support. , , This is the weighting coefficient for the operating conditions. The wear effect coefficient is... This is the temperature influence coefficient. This is the vibration influence coefficient; Based on the determined operating conditions and wear status, and combined with the comprehensive operating condition influence coefficient, the built-in control parameter library is retrieved to match the corresponding lubrication control parameters and preload compensation parameters. Based on the matched parameters, corresponding lubrication control commands and preload compensation commands are generated and transmitted to the pumping actuator of the closed-loop lubrication actuator and the electronically controlled regulating actuator of the adaptive preload compensation mechanism through the signal transmission port, respectively.

3. The adaptive adjustment system for rolling supports of belt conveyors based on complex working conditions according to claim 1, characterized in that, The closed-loop lubrication actuator performs the following operations when performing precise lubrication of the rolling pairs: The system receives lubrication control commands transmitted from the edge computing control unit, parses the lubrication frequency and basic grease parameters contained in the commands, and combines them with the comprehensive operating condition influence coefficient transmitted from the edge computing control unit, using a formula... The precise amount of oil injected in a single operation was calculated, of which... The comprehensive operating condition impact coefficient is calculated by the edge computing control unit. This refers to the total frictional contact area between the roller assembly and the limiting raceway. The grease density per unit area is the basic grease injection density. This is the grease loss compensation coefficient; The pumping actuator starts according to the oil injection frequency obtained from the analysis and the calculated single precise oil injection volume, and pumps the lubricating grease in the grease storage unit into the distributed oil injection pipeline at a preset pressure. The grease is delivered to each injection hole through a distributed oil injection pipeline, and then delivered to the mating contact surface between the roller assembly and the limiting raceway through the oil injection hole; After the preset amount of oil is added in a single cycle, the pumping actuator stops working. If a continuous lubrication command is received, the pumping and delivery steps are repeated according to the analyzed oil injection frequency.

4. The adaptive adjustment system for rolling supports of belt conveyors based on complex working conditions according to claim 1, characterized in that, The adaptive preload compensation mechanism performs the following operations when compensating for wear clearance: The electronically controlled regulating actuator receives the wear clearance compensation control command transmitted from the edge computing control unit, parses the displacement adjustment parameters contained in the command, and combines the comprehensive operating condition influence coefficient and wear influence coefficient transmitted from the edge computing control unit, using the formula... ; The target preload value is calculated, where The comprehensive operating condition influence coefficient, The reference preload of the support, This is the basic preload compensation value corresponding to the amount of wear. This is the wear influence coefficient; The electronically controlled adjustment actuator generates a corresponding driving force based on the analyzed displacement adjustment parameters and the calculated target preload value, which pushes the elastic preload assembly to produce a slight displacement along the extension direction of the limiting raceway. During the displacement process, the elastic preload component changes the clamping force on the limiting raceway and gradually adjusts it to the calculated target preload value, thereby compensating for the fit clearance between the limiting raceway and the roller assembly. Once the preload reaches the preset value, the electronically controlled adjustment actuator maintains the current driving force, and the elastic preload component maintains the preset preload state until a new wear clearance compensation adjustment command is received.

5. The adaptive adjustment system for rolling supports of belt conveyors based on complex working conditions according to claim 1, characterized in that, The multi-dimensional wear sensing unit performs the following operations during operational data acquisition and transmission: Wear sensing components, temperature sensing components, and vibration sensing components are activated simultaneously to continuously collect data on the wear amount of the contact surface between the roller assembly and the limiting raceway, the real-time temperature of the contact surface, and the vibration amplitude during the operation of the rolling support. Each sensing component converts the collected raw data into electrical signals, which are then initially integrated through the internal signal transmission module. The integrated electrical signal is transmitted to the signal receiving end of the edge computing control unit via a shielded transmission line; Each sensing component continuously collects data at a preset collection frequency. When the collected data exceeds the preset warning range, the collection frequency is automatically increased and the data transmission rate is accelerated.

6. The adaptive adjustment system for rolling supports of belt conveyors based on complex working conditions according to claim 1, characterized in that, The grease storage unit is a sealed grease storage structure with a grease guide cavity inside. The outlet end of the guide cavity is connected to the oil inlet end of the pumping actuator. The top of the grease storage unit is equipped with a grease inlet and a sealing cap. The inner wall of the grease storage unit is coated with an anti-stick coating. The bottom of the grease storage unit is equipped with a slag discharge port and a shut-off valve. The grease storage unit is also equipped with a liquid level detection device. The signal output end of the liquid level detection device is electrically connected to the edge computing control unit. The liquid level detection device is used to detect the remaining amount of grease in the grease storage unit in real time and transmit the data to the edge computing control unit.

7. The adaptive adjustment system for rolling supports of belt conveyors based on complex working conditions according to claim 1, characterized in that, The distributed oil injection pipeline is continuously laid out along the extension direction of the limiting raceway. There are multiple oil injection holes, which are evenly spaced along the length of the distributed oil injection pipeline. The oil outlet of each oil injection hole faces the mating contact surface between the roller assembly and the limiting raceway. An anti-clogging filter screen is installed at the oil outlet. The anti-clogging filter screen is a detachable structure. The diameter of the oil injection hole gradually decreases along the oil outlet direction, forming a conical oil outlet channel. The distributed oil injection pipeline is made of hard wear-resistant pipe material, and its outer wall is wrapped with an anti-corrosion protective layer. The distributed oil injection pipeline and the limiting raceway are connected and fixed by fixing clips. The fixing clips are used to maintain a relatively fixed positional relationship between the distributed oil injection pipeline and the limiting raceway.

8. The adaptive adjustment system for rolling supports of belt conveyors based on complex working conditions according to claim 1, characterized in that, The wear sensing component is embedded inside the friction mating surface of the limiting raceway, with its detection end flush with the friction mating surface of the limiting raceway. The wear sensing component is a contact wear detection structure. There are multiple temperature sensing components, which are respectively arranged at both ends and the middle of the limiting raceway. The temperature sensing components are non-contact infrared temperature measurement structures, with their detection ends facing the mating contact surface between the roller assembly and the limiting raceway. The vibration sensing component is arranged on the outer side of the end of the limiting raceway and is fixedly connected to the rolling support body mechanism. The vibration sensing component is a triaxial vibration detection structure, used to detect the vibration amplitude data of the rolling support in the axial, transverse and vertical directions.

9. The adaptive adjustment system for rolling supports of belt conveyors based on complex working conditions according to claim 1, characterized in that, The elastic preload assembly includes a preload push plate and elastic elements. The preload push plate abuts against the end of the limiting raceway. One end of the elastic element is connected to the side of the preload push plate away from the limiting raceway, and the other end of the elastic element is connected to the output end of the electronically controlled adjustment actuator. There are multiple elastic elements, which are evenly spaced along the height direction of the preload push plate. The elastic elements adopt a disc spring assembly structure, which is composed of multiple disc springs stacked together. A wear-resistant pad is provided on the side of the preload push plate facing the limiting raceway. The wear-resistant pad is in contact with the end of the limiting raceway and is used to reduce frictional wear between the preload push plate and the limiting raceway.

10. The adaptive adjustment system for rolling supports of belt conveyors based on complex working conditions according to claim 1, characterized in that, The pumping actuator includes a drive motor, a hydraulic pump, and a flow control valve. The output end of the drive motor is connected to the hydraulic pump, the inlet end of the hydraulic pump is connected to the grease storage unit, the outlet end of the hydraulic pump is connected to the flow control valve, and the outlet end of the flow control valve is connected to the distributed oil injection pipeline. The control end of the drive motor is electrically connected to the edge computing control unit, and the regulating end of the flow control valve is electrically connected to the edge computing control unit. The pumping actuator also includes a pressure detection device, which is installed on the pipeline between the hydraulic pump and the flow control valve. The signal output end of the pressure detection device is electrically connected to the edge computing control unit. The pressure detection device is used to detect the grease pumping pressure in the pipeline and transmit the data to the edge computing control unit.

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