A belt slip detection and automatic tensioning system and method for belt conveyors

Abstract

This invention discloses a belt runout detection and automatic tensioning system and method for conveyor belts, belonging to the technical field of conveyor equipment. The system includes a sensing unit, a signal processing unit, a control system, and an actuator. The sensing unit uses non-contact displacement sensors, arranged at multiple points below the return belt, to detect belt runout. The signal processing unit filters and amplifies the detected signals. The control system receives the processed signals, analyzes and makes decisions, and then drives the actuator. The actuator uses a servo motor and lead screw structure to drive the conveyor belt drum to move and adjust the tension. This method uses the sensing unit to detect the runout in real time, and the control system judges and drives the actuator to adjust, forming an outer closed-loop control with runout as feedback, while the actuator itself constitutes an inner closed-loop displacement control. This invention achieves automatic and quantitative detection of belt runout and precise and automatic adjustment of tension, improving tension accuracy and equipment automation.

Description

Technical Field

[0001] This invention relates to the field of conveyor equipment technology, and in particular to a belt conveyor belt runout detection and automatic tensioning system and method. Background Technology

[0002] With the development of intelligent construction and prefabricated buildings in the construction industry, the level of automation in the concrete transportation process is crucial for beam factories, which are key locations for producing precast components. Belt conveyors are becoming increasingly popular in this process due to their ability to transport concrete over long distances continuously and uniformly. However, after long-term operation, the belt tension will decrease due to stretching deformation, which manifests as belt jumping or undulating on the return trip.

[0003] Currently, assessing belt runout primarily relies on manual visual inspection. This method demands a high level of experience from personnel and cannot quantitatively measure the amount of runout. After runout is detected, common tensioning methods such as counterweight tensioning or spring tensioning have limitations, making precise and dynamic tension adjustment difficult. More importantly, in existing methods, the detection of belt runout and the adjustment of tension are two separate processes, lacking an effective coordination and feedback mechanism. This prevents timely, automatic closed-loop control, thus impacting conveying efficiency, equipment operational stability, and safety. Summary of the Invention

[0004] The purpose of this invention is to provide a belt skipping detection and automatic tensioning system and method for belt conveyors, which aims to solve the problems of inaccurate manual detection, outdated tensioning methods, and disconnect between detection and execution.

[0005] This invention is achieved using the following technical solution: a belt runout detection and automatic tensioning system for a belt conveyor, characterized in that it includes a sensing unit for detecting the runout of the return belt of the belt conveyor; a control system communicatively connected to the sensing unit for receiving runout data and generating control commands; and an actuator communicatively connected to the control system for adjusting the belt tension according to the control commands; wherein the action feedback of the actuator and the detection result of the sensing unit constitute a closed-loop control.

[0006] Furthermore, the sensing unit is a non-contact displacement sensor array arranged at multiple points along the belt running direction.

[0007] Furthermore, the non-contact displacement sensor is a laser displacement sensor or an ultrasonic displacement sensor.

[0008] Furthermore, it also includes a signal processing unit, which is connected between the sensing unit and the control system, and is used to filter and amplify the detection data of the sensing unit.

[0009] Furthermore, the control system includes a servo controller and a driver; the actuator includes a servo motor and a lead screw driven by the servo motor, the lead screw being connected to the roller motor of the belt conveyor.

[0010] Furthermore, the driver and the actuator form an inner closed loop for controlling the displacement of the lead screw; the control system and the sensing unit form an outer closed loop for controlling the belt runout.

[0011] A method for detecting and automatically tensioning belt runout, characterized by comprising the following steps: S1: Start the system and detect the real-time vibration of the belt during operation through the sensing unit; S2: The control system acquires the fluctuation data and determines whether it exceeds a preset threshold; S3: If the tension exceeds the limit, the control system controls the actuator to adjust the belt tension. S4: After the actuator operates, the runout is detected again by the sensing unit, and steps S2-S3 are repeated until the runout meets the preset threshold. The beneficial effects of the belt runout detection and automatic tensioning system and method for belt conveyors described in this invention include: By using non-contact sensing and automatic tensioning, the high-risk operations of visual inspection and manual adjustment at heights are avoided, significantly reducing safety risks.

[0012] For heavy-duty belt conveyors, the actuator with a motor-driven lead screw provides tension, replacing heavy manual operation and greatly reducing the labor intensity of workers.

[0013] By employing a multi-point sensor array and combining it with signal filtering, the accuracy and anti-interference capability of runout detection are improved. High-precision displacement control is achieved through a servo motor screw mechanism, and the dual closed-loop control strategy of "runout outer loop" and "displacement inner loop" enables the system to respond quickly and adjust precisely, effectively improving the working status and construction efficiency of the belt conveyor.

[0014] It achieves fully automated tensioning from detection and judgment to execution, reduces reliance on human experience, improves the overall automation level of beam plant equipment, and is in line with the development direction of intelligent construction. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. The drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0016] Figure 1 A schematic diagram of the structure of a belt conveyor belt runout detection and automatic tensioning system; Figure 2 This is a schematic diagram of the principle of a belt conveyor belt runout detection and automatic tensioning system. In the diagram, 1-sensing unit, 2-signal processing unit, 3-control system, 4-actuator, 31-servo controller, 32-driver, 41-servo motor, 42-lead screw, 43-drum motor. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0018] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0019] Example 1: like Figure 1-2As shown, this embodiment provides a belt conveyor belt runout detection and automatic tensioning system and method, mainly composed of a sensing unit 1, a signal processing unit 2, a control system 3, and an actuator 4. The sensing unit 1 uses a non-contact displacement sensor, specifically a laser displacement sensor or an ultrasonic displacement sensor. The sensing unit 1 is installed on the truss of the belt conveyor support corridor and located below the return belt. Considering that single-point measurements are susceptible to noise interference, to increase data samples and improve measurement accuracy and reliability, the sensing unit 1 is arranged in an array along the belt running direction. The input terminal of the signal processing unit 2 is electrically connected to each sensor of the sensing unit 1, used to receive the raw belt runout data collected by the sensing unit 1. The signal processing unit 2 integrates a filtering circuit and an amplification circuit. Its core function is to filter out noise from the multiple runout signals input from the sensing unit 1 and amplify the selected effective signals.

[0020] The control system 3 includes a servo controller 31 and a driver 32. The servo controller 31, as the system's control decision center, has its input terminal electrically connected to the output terminal of the signal processing unit 2 to receive processed valid fluctuation signals. The servo controller 31 internally runs a control algorithm to analyze and make decisions on the input fluctuation signals and generate corresponding control commands. The driver 32's command input terminal is electrically connected to the control output terminal of the servo controller 31, while the driver 32's power output terminal is connected to the actuator 4. Based on the commands from the servo controller 31, the driver 32 outputs precise drive signals to control the movement of the actuator 4.

[0021] The actuator 4 adopts a servo motor-screw structure, specifically comprising a servo motor 41 and a screw 42. The drive input end of the servo motor 41 is electrically connected to the driver 32 in the control system 3, receiving its drive signal. The output shaft of the servo motor 41 is mechanically connected to one end of the screw 42 via a coupling to drive the screw 42 to rotate. The nut of the screw 42 is fixedly connected to the mounting base of the roller motor 43 at the end of the belt conveyor. When the servo motor 41 drives the screw 42 to rotate, the nut causes the base of the roller motor 43 to undergo linear displacement along the axial direction of the screw 42, thereby changing the position of the roller and adjusting the overall tension of the belt. The screw 42 mechanism itself has high displacement accuracy and thread self-locking characteristics.

[0022] The working principle and process of this system are as follows: When belt conveyor tensioning is required, it is preferable to start the system when the belt conveyor is unloaded. First, start the belt conveyor itself and wait for it to stabilize before starting the tensioning system to detect and verify the tension force. After the system is powered on, the multi-point sensor unit 1 continuously detects the real-time vibration of the return belt and sends the detected raw data from multiple channels to the signal processing unit 2. The signal processing unit 2 processes the received vibration data set, uses a filtering algorithm to remove noise interference caused by complex working conditions such as concrete block impact, truss vibration, and space dust, amplifies the actual belt vibration signal, and then transmits the processed effective signal to the control system 3.

[0023] The servo controller 31 in the control system 3 receives signals from the signal processing unit 2 and compares and analyzes them with a preset belt runout threshold range. If the analysis result indicates that the current belt runout exceeds the allowable range, the servo controller 31 makes a decision and generates a corresponding displacement adjustment command. This command is transmitted to the driver 32, which then drives the actuator 4 to move. Specifically, the driver 32 controls the servo motor 41 to rotate according to the command, the servo motor 41 drives the lead screw 42 to rotate, and then drives the roller motor 43, which is fixed to the lead screw nut, to move in the direction where the belt needs to be tensioned. In this process, the driver 32, the servo motor 41, and the displacement detection element on the lead screw 42 form an inner closed-loop control loop, which tracks and ensures that the displacement of the lead screw 42 accurately reaches the displacement specified by the controller 31, thereby achieving high-precision displacement control.

[0024] After the lead screw 42 completes the specified displacement, the actuator 4 sends a displacement completion signal back to the control system 3. The control system 3 then instructs the sensing unit 1 to detect the belt runout again, thus forming an outer closed-loop control circuit. The system processes the newly collected runout through the signal processing unit 2 and inputs it into the control system 3 for judgment: if the detected runout meets the preset standard range, the control system 3 determines that the tensioning process is complete, and the system enters standby or monitoring mode; if the detected runout still does not meet the requirements, the control system 3 will make another decision and drive the actuator 4 to perform the next round of adjustment, and so on, until the belt runout is controlled within the qualified threshold.

[0025] Through the above structural design and workflow, the system demonstrates significant beneficial effects: Conveyor belts are typically erected in elevated walkways to transport concrete. This system, through automatic detection of runout and automatic tensioning, completely eliminates the need for manual high-altitude visual inspection and adjustment, significantly reducing worker safety risks.

[0026] For heavy-duty belt conveyors, the tensioning device at the end requires enormous operating force, which is difficult to perform manually. This system uses a servo motor to drive the lead screw to provide tension, fundamentally solving this problem and greatly reducing the labor intensity of workers.

[0027] The system employs non-contact detection of return belt runout, combined with automatic tensioning of the motor screw. Through dual closed-loop collaborative control consisting of an "inner closed loop of screw displacement" and an "outer closed loop of runout detection," the system achieves fast response to belt slack, high detection and adjustment accuracy, and strong operational reliability, thereby improving the construction efficiency of the concrete conveying process in the beam plant.

[0028] This system automates the entire belt tensioning process, reduces reliance on manual experience, improves the overall automation and intelligence level of beam mill equipment, and promotes the development of intelligent construction.

[0029] The above embodiments describe the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Modifications and variations made by those skilled in the art without departing from the spirit and scope of the invention should be within the protection scope of the appended claims.

Claims

1. A belt conveyor belt runout detection and automatic tensioning system, characterized in that, The system includes a sensing unit (1) for detecting the runout of the return belt of the conveyor belt; a control system (3) connected to the sensing unit (1) for receiving runout data and generating control commands; and an actuator (4) connected to the control system (3) for adjusting the belt tension according to the control commands. The action feedback of the actuator (4) and the detection result of the sensing unit (1) constitute a closed-loop control.

2. The belt runout detection and automatic tensioning system for a belt conveyor according to claim 1, characterized in that, The sensing unit (1) is a non-contact displacement sensor array arranged at multiple points along the belt running direction.

3. The belt skipping detection and automatic tensioning system for a belt conveyor according to claim 2, characterized in that, The non-contact displacement sensor is a laser displacement sensor or an ultrasonic displacement sensor.

4. The belt runout detection and automatic tensioning system for a belt conveyor according to claim 1, characterized in that, It also includes a signal processing unit (2), which is connected between the sensing unit (1) and the control system (3) for filtering and amplifying the detection data of the sensing unit (1).

5. The belt runout detection and automatic tensioning system for a belt conveyor according to claim 1, characterized in that, The control system (3) includes a servo controller (31) and a driver (32); the actuator (4) includes a servo motor (41) and a lead screw (42) driven by the servo motor (41), the lead screw (42) being connected to the roller motor (43) of the belt conveyor.

6. The belt skipping detection and automatic tensioning system for a belt conveyor according to claim 5, characterized in that, The driver (32) and the actuator (4) form an inner closed loop for controlling the displacement of the lead screw (42); the control system (3) and the sensing unit (1) form an outer closed loop for controlling the belt runout.

7. A method for detecting and automatically tensioning a belt using the system described in any one of claims 1 to 6, characterized in that, Includes the following steps: S1: Start the system and detect the real-time vibration of the belt during operation through the sensing unit (1); S2: The control system (3) acquires the bounce data and determines whether it exceeds the preset threshold; S3: If the tension exceeds the limit, the control system (3) controls the actuator (4) to adjust the belt tension. S4: After the actuator (4) is activated, the amount of jitter is detected again by the sensing unit (1), and steps S2-S3 are repeated until the amount of jitter meets the preset threshold.

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