An automatic deviation correction system and method for a tape machine belt

Abstract

The application discloses a kind of automatic deviation correction system and method of tape machine belt, belong to the technical field of tape conveyor operation control.This method includes: collecting multiple groups of real-time pressure data of carrier roller and multiple groups of real-time offset distance data of belt edge;Pressure data is compared with the preset reference pressure range to generate pressure deviation flag, and the distance out-of-limit flag is generated by comparing the offset distance data with the preset safety offset threshold;When pressure deviation flag and distance out-of-limit flag exist simultaneously, calculate the comprehensive deviation correction start coefficient according to the carrier roller position corresponding to the deviation flag and the belt edge position corresponding to the out-of-limit flag;When the coefficient is greater than the start threshold, generate the first layer deviation correction instruction containing the carrier roller adjustment angle and adjustment direction and send it to the hydraulic actuator to perform the tilting action.Secondary adjustment can also be performed by generating the second layer deviation correction correction coefficient according to the new pressure difference after the first action.The system implements the above method steps.

Description

Technical Field

[0001] This invention relates to the field of belt conveyor operation control technology, specifically to an automatic belt correction system and method for belt conveyors. Background Technology

[0002] During operation, belt misalignment frequently occurs on conveyor belts due to factors such as material drop point deviation, idler roller installation errors, and uneven belt tension. Belt misalignment not only leads to material spillage and accelerated wear on the belt edges, but in severe cases, it can cause belt tearing or equipment shutdown. Most existing automatic belt correction methods rely on a single detection method, such as installing displacement sensors at the belt edge to detect offset, or judging the tendency of misalignment solely by detecting the force on the idlers. Methods relying solely on edge offset detection are prone to frequent false triggering of adjustments due to belt vibration and dust interference, while pressure detection methods struggle to accurately reflect the true direction and severity of belt misalignment. Both methods, when used alone, fail to balance the timeliness of correction response with the necessity of the action. Regarding correction strategies, existing technologies often directly trigger fixed adjustment actions after detecting misalignment, or fail to effectively utilize the actual response results to correct the next adjustment. These open-loop adjustment methods cannot adapt to the dynamic changes in conveyor belt operating conditions, such as differences in pressure and offset response caused by load fluctuations and changes in belt elastic elongation. When an adjustment fails to achieve the desired effect, the system lacks an automatic compensation mechanism and can only wait for the next independent detection and trigger. The correction process carries the risk of overshoot or repeated adjustments, which affects the stability of the conveyor belt and increases the number of ineffective actions of the actuator.

[0003] To address the above issues, it is necessary to solve how to integrate two different sources of detection information—abnormal roller pressure and belt edge misalignment—to perform directional correction actions when necessary, and how to automatically generate compensation correction amounts and complete fine-grained secondary adjustments based on the degree of deviation when the initial adjustment fails to bring the pressure difference back to the normal range. Summary of the Invention

[0004] This invention provides an automatic belt correction system and method for conveyor belts, which solves the problem of inaccurate triggering of correction actions due to single detection information, and the problem of failure to automatically compensate and correct when the initial adjustment does not achieve the expected results.

[0005] The objective of this invention can be achieved through the following technical solutions:

[0006] This invention provides an automatic belt correction method for a conveyor belt, comprising: collecting real-time pressure data of multiple sets of idler rollers and real-time offset distance data of multiple sets of belt edges during the operation of the conveyor belt; comparing the real-time pressure data of each set of idler rollers with the corresponding preset reference pressure range to generate a pressure deviation flag; comparing the real-time offset distance data of each set of belt edges with the corresponding preset safety offset threshold to generate a distance exceedance flag; when there is at least one pressure deviation flag and at least one distance exceedance flag, calculating a comprehensive correction start coefficient based on the idler roller positions corresponding to all pressure deviation flags and the belt edge positions corresponding to all distance exceedance flags; when the comprehensive correction start coefficient is greater than the preset start threshold, generating a first-level correction command including the idler roller adjustment angle and adjustment direction; and sending the first-level correction command to the hydraulic actuator of the corresponding idler roller to cause the idler roller to perform a first tilting action according to the adjustment angle and adjustment direction.

[0007] By combining the dual-dimensional judgment of idler pressure and belt edge offset, and calculating the correction activation coefficient by integrating the idler position and belt edge position, correction is triggered only when the overall belt operation status truly requires intervention. This effectively avoids erroneous adjustments caused by single-point signal fluctuations, and improves the rationality and accuracy of correction intervention.

[0008] As a technical solution of the present invention, when generating a pressure deviation flag, the left and right pressure values ​​of the current idler are extracted from the real-time pressure data of the idler, and the left-right pressure difference is calculated; a preset reference pressure range corresponding to the current idler is obtained, which includes a lower limit and an upper limit of the reference pressure difference; when the real-time pressure difference is less than the lower limit of the reference pressure difference, a negative pressure deviation flag containing the idler number and a negative deviation direction is generated; when the real-time pressure difference is greater than the upper limit of the reference pressure difference, a positive pressure deviation flag containing the idler number and a positive deviation direction is generated. Preferably, the preset reference pressure range is calibrated based on the idler pressure difference value during the no-load operation of the conveyor belt, so that the pressure deviation judgment has its own operating reference and reduces the interference of load changes on the judgment.

[0009] When generating distance exceedance signs, the real-time left and right edge offset distances of the current detection point are extracted from the real-time offset distance data of the belt edge. A preset safety offset threshold, including the left and right edge safety offset limits, is obtained. If the real-time left edge offset distance is greater than the left edge safety offset limit, a left edge exceedance sign is generated, containing the detection point's location coordinates and the exceedance side being the left. If the real-time right edge offset distance is greater than the right edge safety offset limit, a right edge exceedance sign is generated, containing the detection point's location coordinates and the exceedance side being the right. The preset safety offset threshold can be calculated and determined based on the belt width and idler roller trough angle, ensuring that the offset judgment matches the belt structure parameters and leaving a reasonable allowable offset range while guaranteeing safe operation.

[0010] A preferred method for calculating the comprehensive correction start-up coefficient is as follows: Obtain the number of positive idlers with a positive deviation direction and the number of negative idlers with a negative deviation direction from all pressure deviation indicators; obtain the number of left-edge exceedance indicators with the exceedance side on the left and the number of right-edge exceedance indicators with the exceedance side on the right; calculate the idler pressure deviation weight based on the number of positive and negative idlers, which is equal to the absolute value of the difference between the number of positive and negative idlers divided by their sum; calculate the belt edge exceedance weight based on the number of left-edge and right-edge exceedance indicators, which is equal to the absolute value of the difference between the number of left-edge and right-edge exceedance indicators divided by their sum; add the idler pressure deviation weight and the belt edge exceedance weight to obtain the comprehensive correction start-up coefficient. More preferably, the idler pressure deviation weight and the belt edge exceedance weight are each multiplied by a preset proportional coefficient before being added together to obtain the comprehensive correction start-up coefficient. By simultaneously considering the symmetrical distribution of pressure deviation and edge exceedance, the overall trend of belt misalignment can be effectively reflected, avoiding false initiation of correction due to local or symmetrical disturbances.

[0011] One technical solution for generating the first-layer correction command is as follows: First, obtain the set of first idlers corresponding to positive pressure deviation markers and the set of second idlers corresponding to negative pressure deviation markers; select the idler with the largest real-time pressure difference from the first idler set as the first target idler, and select the idler with the smallest real-time pressure difference from the second idler set as the second target idler; calculate a first adjustment angle based on the real-time pressure difference of the first target idler, which is proportional to the real-time pressure difference; calculate a second adjustment angle based on the real-time pressure difference of the second target idler, which is also proportional to the real-time pressure difference; determine the larger of the first and second adjustment angles as the idler adjustment angle; determine the adjustment direction based on the deviation direction of the idler with the larger adjustment angle; and encapsulate the idler adjustment angle, adjustment direction, and the idler's number into a first-layer correction command. Thus, the correction command directly originates from the idler with the most severe pressure deviation, enabling the adjustment action to quickly respond to asymmetrical belt tension.

[0012] To ensure the controllability of the adjustment process, preferably, the adjustment angle of the idler roller is limited to the preset maximum single adjustment angle range to prevent excessive single adjustment from impacting the belt operation.

[0013] As a further improvement of the present invention, after the idler roller performs its first tilting action according to the adjustment angle and direction, a preset stabilization time interval is waited for; the new left-side pressure value and the new right-side pressure value of the idler roller are re-acquired, and a new real-time pressure difference is calculated; if the new real-time pressure difference falls within the preset reference pressure range, a first-layer correction success flag is generated and fed back to the centralized control system; if the new real-time pressure difference does not fall within the preset reference pressure range, a second-layer correction coefficient is generated based on the relationship between the new real-time pressure difference and the preset reference pressure range. Through closed-loop feedback verification, the correction effect can be confirmed in a timely manner, and secondary intervention preparations can be made for situations where expectations are not met.

[0014] One approach to generating the second-layer correction coefficient is as follows: When the new real-time pressure difference is less than the lower limit of the reference pressure difference, calculate the absolute value of the first deviation between the lower limit of the reference pressure difference and the new real-time pressure difference, and divide the absolute value of the first deviation by the lower limit of the reference pressure difference to obtain the negative correction coefficient; when the new real-time pressure difference is greater than the upper limit of the reference pressure difference, calculate the absolute value of the second deviation between the new real-time pressure difference and the upper limit of the reference pressure difference, and divide the absolute value of the second deviation by the upper limit of the reference pressure difference to obtain the positive correction coefficient; the negative or positive correction coefficient is used as the second-layer correction coefficient and stored in association with the idler roller number. Based on this, a secondary adjustment angle is calculated according to the current actual adjustment angle of the idler roller and the second-layer correction coefficient. The secondary adjustment angle is equal to the actual adjustment angle multiplied by the second-layer correction coefficient. A second-layer correction command is generated based on the current adjustment direction of the idler roller and the secondary adjustment angle. The second-layer correction command is sent to the hydraulic actuator of the idler roller, causing the idler roller to perform a secondary tilt adjustment based on the first tilting action. After the secondary tilt adjustment is completed, a preset stabilization time interval is waited for again, and the pressure values ​​on the left and right sides of the idler roller are collected for verification. This layered closed-loop correction mechanism enables the correction process to have the ability to approximate step by step, and can quantitatively correct for insufficient or excessive correction, thereby improving the final correction accuracy.

[0015] Before generating the first-level correction command, the adjustment objects can be optimized based on the spatial relationship between the over-limit position and the idler position. Specifically, the idler numbers corresponding to all pressure deviation signs are obtained to form a list of idlers to be adjusted, and the coordinates of the detection points corresponding to all distance over-limit signs are obtained to form a list of over-limit positions. The installation coordinates of each idler in the list of idlers to be adjusted are spatially matched with the coordinates of each detection point in the list of over-limit positions, and the straight-line distance between each idler and each over-limit point is calculated. The idler with the smallest straight-line distance to the over-limit point in the list of over-limit positions is selected as the priority adjustment idler, and its number is added to the first-level correction command. When calculating the straight-line distance, the three-dimensional spatial installation coordinates of the idler and the three-dimensional coordinates of the belt edge of the over-limit point are obtained; the sum of the squares of the differences in the horizontal coordinate, vertical coordinate, and height is calculated, and then the square root is taken to obtain the straight-line distance. By introducing spatial position association, the idler closest to the over-limit position of the belt edge is prioritized for adjustment, so that the correction effect is applied more directly to the actual area where the belt deviation occurs, improving the timeliness and effectiveness of the correction.

[0016] This invention also includes an automatic belt alignment system for conveyor belts. The system includes a memory, a processor, and a computer program stored in the memory and running on the processor. When executing the computer program, the processor implements the steps of the aforementioned automatic belt alignment method for conveyor belts. Based on multi-sensor fusion and hierarchical closed-loop control, this system can autonomously complete belt deviation detection, decision-making, precise adjustment, and effect verification under complex conveyor belt operating conditions, significantly improving the stability and safety of belt operation.

[0017] The beneficial effects of this invention are:

[0018] By collecting real-time pressure data from multiple sets of idler rollers and real-time offset distance data from multiple sets of belt edges during the operation of the conveyor belt, and comparing them with the corresponding preset benchmark pressure range and preset safety offset threshold, pressure deviation flags and distance over-limit flags are generated. Only when both pressure deviation and distance over-limit flags are present simultaneously is a comprehensive correction activation coefficient calculated based on the idler roller position involved in the deviation flag and the belt edge position involved in the over-limit flag. The first-level correction command is generated when this coefficient exceeds the preset activation threshold. This method ensures that correction action is only triggered when pressure anomalies and edge offsets are simultaneously confirmed and the comprehensive assessment of the deviation degree meets the activation conditions. This avoids erroneous adjustments caused by fluctuations in a single signal, making the judgment of correction timing and necessity more accurate, and reducing unnecessary mechanical actions and belt operation interference. After the first-level correction action is executed and a preset stabilization time interval is waited, the pressure values ​​on the left and right sides of the same idler roller are re-acquired, and a new real-time pressure difference is calculated. If the new real-time pressure difference does not fall within the preset reference pressure range, a negative or positive correction coefficient is generated based on the absolute value of the deviation between the new real-time pressure difference and the upper and lower limits of the reference pressure difference, serving as the second-level correction coefficient. This correction coefficient is multiplied by the current actual adjustment angle to obtain the secondary adjustment angle, generating a second-level correction command to adjust the idler roller's tilt based on the existing tilt. This process automatically generates a quantified correction amount and performs compensation adjustment using the pressure response deviation after the first adjustment, forming a closed-loop successive approximation correction. This adapts to response differences caused by belt tension and load variations, improving the final convergence effect of deviation correction and reducing overshoot risk. Attached Figure Description

[0019] The invention will now be further described with reference to the accompanying drawings.

[0020] Figure 1 This is a flowchart of the automatic belt alignment method for conveyor belts;

[0021] Figure 2 This is a flowchart of the process for generating the idler roller pressure deviation indicator;

[0022] Figure 3 This is a flowchart of the comprehensive correction initiation coefficient calculation and correction initiation determination process;

[0023] Figure 4 This is a flowchart of the double-layer correction control process for conveyor belt idlers; Detailed Implementation

[0024] 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. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0025] See Figure 1 This invention provides an automatic belt deviation correction method for a conveyor belt, comprising the following steps: collecting real-time pressure data of multiple sets of idler rollers and real-time offset distance data of multiple sets of belt edges during conveyor belt operation; comparing the real-time pressure data of each set of idler rollers with the corresponding preset reference pressure range to generate a pressure deviation flag; comparing the real-time offset distance data of each set of belt edges with the corresponding preset safety offset threshold to generate a distance exceedance flag; when at least one pressure deviation flag and at least one distance exceedance flag exist, calculating a comprehensive correction start coefficient based on the idler roller positions corresponding to all pressure deviation flags and the belt edge positions corresponding to all distance exceedance flags; when the comprehensive correction start coefficient is greater than the preset start threshold, generating a first-layer correction command including the idler roller adjustment angle and adjustment direction; sending the first-layer correction command to the hydraulic actuator of the corresponding idler roller, causing the idler roller to perform a first tilting action according to the adjustment angle and adjustment direction.

[0026] In specific implementation, please refer to Figure 2 Pressure sensors are installed at the bearing seats at both ends of the conveyor belt idlers, collecting the left-side pressure value generated by the belt and material load on the left side of the idler and the right-side pressure value generated by the load on the right side of the idler. The processor sequentially reads the left-side and right-side pressure values ​​for each idler from the multiple sets of real-time pressure data collected. For each idler, the real-time pressure difference is obtained by subtracting the right-side pressure value from the left-side pressure value, and the real-time pressure difference is calculated using the following formula:

[0027]

[0028] in: This represents the real-time pressure difference. This indicates the pressure value on the left. This indicates the pressure value on the right side.

[0029] For each idler roller, the processor retrieves the preset reference pressure range corresponding to the currently processed idler roller from a pre-stored reference parameter table. The preset reference pressure range includes a lower limit and an upper limit for the reference pressure difference. The calibration of the preset reference pressure range is performed under no-load conditions on the conveyor belt: when the conveyor belt is unloaded and the belt is in the normal central position, multiple sets of left and right pressure values ​​generated within a preset time period are continuously collected for each idler roller. The pressure difference for each set is calculated, and then the arithmetic mean and standard deviation of all idler roller pressure differences are calculated. The result of subtracting three times the standard deviation from the arithmetic mean is taken as the lower limit of the reference pressure difference, and the result of adding three times the standard deviation to the arithmetic mean is taken as the upper limit of the reference pressure difference. The lower and upper limits of the reference pressure difference are stored together with the idler roller number.

[0030] After obtaining the real-time pressure difference value of the currently processed idler roller, along with its corresponding lower and upper limits, the processor compares the real-time pressure difference value with both the lower and upper limits. If the real-time pressure difference value is less than the lower limit, a negative pressure deviation flag is generated, containing the idler roller number and a negative indicator indicating the direction of deviation. If the real-time pressure difference value is greater than the upper limit, a positive pressure deviation flag is generated, containing the idler roller number and a positive indicator indicating the direction of deviation. If the real-time pressure difference value is neither less than the lower nor greater than the upper limit, no pressure deviation flag is generated. This process is repeated for all idler rollers' real-time pressure data to generate the pressure deviation flags.

[0031] In practice, the real-time offset distance data of the belt edge is collected by multiple laser displacement sensors or image detection devices arranged along the conveyor belt line. Each set of real-time offset distance data corresponds to a detection point and includes the position coordinates of the detection point, the real-time left edge offset distance, and the real-time right edge offset distance. The real-time left edge offset distance represents the offset of the left edge of the belt relative to the preset reference position at the detection point, and the real-time right edge offset distance represents the offset of the right edge of the belt relative to the preset reference position at the detection point.

[0032] The processor sequentially extracts the real-time left edge offset distance and real-time right edge offset distance corresponding to each detection point from multiple sets of real-time belt edge offset distance data collected. For each detection point, the processor retrieves the preset safety offset threshold corresponding to the current detection point from a pre-stored threshold parameter table. The preset safety offset threshold includes the left edge safety offset limit value and the right edge safety offset limit value, which are calculated and determined based on the belt width and idler roller trough angle of the conveyor belt.

[0033] In some embodiments, the preset safety offset threshold is calculated as follows: The belt width of the conveyor belt and the idler groove angle of the conveyor roller group are obtained; the left edge safety offset limit and the right edge safety offset limit are both calculated according to the following formula:

[0034]

[0035] in: This indicates the safety offset limit value for the left edge or the safety offset limit value for the right edge. Indicates the belt width. This indicates the idler roller trough angle. The calculated left and right edge safety offset limits are associated with and stored along with the corresponding detection point coordinates. The belt width and idler roller trough angle are design parameters for the conveyor belt system, input and stored during the system configuration phase.

[0036] Optionally, when the left and right sides of the belt are symmetrical, the left edge safety offset limit value and the right edge safety offset limit value are taken as the same value, and are respectively assigned to the left edge safety offset limit value and the right edge safety offset limit value in the preset safety offset threshold.

[0037] After obtaining the left and right edge safety offset limits of the current detection point, the processor compares the real-time left edge offset distance with the left edge safety offset limit. If the real-time left edge offset distance is greater than the left edge safety offset limit, a left edge exceedance flag is generated. The left edge exceedance flag includes the position coordinates of the current detection point and the exceedance side identifier, which is denoted as the left side.

[0038] The processor synchronously compares the real-time right edge offset distance with the right edge safe offset limit. If the real-time right edge offset distance is greater than the right edge safe offset limit, a right edge exceedance flag is generated. The right edge exceedance flag includes the position coordinates of the current detection point and the exceedance side identifier, which is recorded as the right side.

[0039] If the real-time left edge offset distance is less than or equal to the left edge safety offset limit, no left edge over-limit flag is generated; if the real-time right edge offset distance is less than or equal to the right edge safety offset limit, no right edge over-limit flag is generated. The real-time belt edge offset distance data corresponding to all detection points is iterated in the above manner to generate over-limit flags. Each left or right edge over-limit flag is recorded and included in the subsequent over-limit quantity statistics.

[0040] In specific implementation, please refer to Figure 3 After generating a preset number of pressure deviation markers and a preset number of distance exceedance markers, the processor initiates the calculation process for the comprehensive correction start coefficient. The processor iterates through all generated pressure deviation markers, reading and classifying the deviation direction identifier in each marker. Pressure deviation markers with positive deviation direction identifiers are grouped into the positive deviation set, and the total number of markers in the positive deviation set is counted to obtain the number of positive idlers. Similarly, pressure deviation markers with negative deviation direction identifiers are grouped into the negative deviation set, and the total number of markers in the negative deviation set is counted to obtain the number of negative idlers.

[0041] The processor iterates through all generated distance violation flags, reading and classifying the violation side identifiers in each flag. Distance violation flags with the violation side identifier on the left are added to the left violation set, and the total number of flags in the left violation set is counted to obtain the left edge violation count. Similarly, distance violation flags with the violation side identifier on the right are added to the right violation set, and the total number of flags in the right violation set is counted to obtain the right edge violation count.

[0042] After obtaining the number of forward idlers, the number of reverse idlers, the number of left edge exceedances, and the number of right edge exceedances, the processor calculates the overall corrective braking start coefficient. The calculation of the overall corrective braking start coefficient involves three steps: idler pressure deviation weight calculation, belt edge exceedance weight calculation, and weighted summation. The processor combines these three steps into a single unified formula for calculation. The overall corrective braking start coefficient is calculated according to the following formula:

[0043]

[0044] in: This represents the overall corrective action initiation coefficient; This represents the first preset scaling factor. The value range is greater than or equal to 0.5 and less than or equal to 0.8. Based on the pre-set weighting requirement of idler roller pressure data in the correction determination, this embodiment... The value is 0.6, which is based on the fact that the idler pressure data directly reflects the stress state of the idler and is given a higher weight than the belt edge offset data in the correction start judgment. This represents the second preset scaling factor. The value range is greater than or equal to 0.2 and less than or equal to 0.5. Based on the pre-set weighting requirements of belt edge offset data in the correction determination, this embodiment... The value is set to 0.4, based on belt edge offset data as an auxiliary criterion. It is assigned a lower weight than the idler roller pressure data in the correction initiation decision. and The sum is 1.0; Indicates the number of forward idlers; Indicates the number of negative idler rollers; This represents the absolute value of the difference between the number of positive idlers and the number of negative idlers. When the number of positive idlers is equal to the number of negative idlers, this absolute value is zero, and the calculation result of the idler pressure deviation weight is zero. This represents the sum of the number of forward idlers and the number of reverse idlers. This sum is used as the denominator in the calculation of the idler pressure deviation weight. When the value is zero, to avoid abnormal division operations, the processor directly resets the roller pressure deviation weight to zero; Indicates the number of items that exceed the limit on the left edge; Indicates the number of right-edge exceedances; This represents the absolute value of the difference between the number of left edge exceedances and the number of right edge exceedances. When the number of left edge exceedances is equal to the number of right edge exceedances, this absolute value is zero, and the result of the belt edge exceedance weight calculation is zero. This represents the sum of the number of belt edge exceedances on the left and right edges. This sum is used as the denominator in the calculation of the belt edge exceedance weight. When the value is zero, in order to avoid division operation errors, the processor directly resets the belt edge over-limit weight to zero.

[0045] Optionally, before calculating the idler pressure deviation weight, the processor checks if the sum of the number of positive and negative idlers is zero. If the sum is zero, it indicates that no pressure deviation flag has been generated in the current cycle, and the processor directly assigns the idler pressure deviation weight to zero. Before calculating the belt edge over-limit weight, the processor checks if the sum of the number of left edge over-limits and the number of right edge over-limits is zero. If the sum is zero, it indicates that no distance over-limit flag has been generated in the current cycle, and the processor directly assigns the belt edge over-limit weight to zero. If both the idler pressure deviation weight and the belt edge over-limit weight are zero, the overall correction start coefficient is zero.

[0046] After obtaining the overall correction start coefficient, the processor compares it with a pre-set start threshold. The pre-set start threshold is a constant between 0 and 1, set and stored during the system configuration phase based on the conveyor belt's operating conditions. The value of the pre-set start threshold determines the trigger sensitivity of the correction action. If the overall correction start coefficient is greater than the pre-set start threshold, a correction start signal is generated, triggering the subsequent first-level correction instruction generation process. If the overall correction start coefficient is less than or equal to the pre-set start threshold, no correction action is triggered, and the processor returns to continue collecting the real-time roller pressure data and belt edge offset distance data for the next cycle.

[0047] In specific implementation, please refer to Figure 4 When the overall correction activation coefficient exceeds the preset activation threshold, the processor initiates the generation process of the first-level correction instruction. The processor acquires all generated positive pressure deviation flags, extracts the idler number contained in each positive pressure deviation flag, and combines all extracted idler numbers into a first idler set. Simultaneously, the processor acquires all generated negative pressure deviation flags, extracts the idler number contained in each negative pressure deviation flag, and combines all extracted idler numbers into a second idler set.

[0048] For each idler number in the first idler set, the processor retrieves the left and right pressure values ​​corresponding to that idler number from the real-time pressure data. It then calculates the difference between the left and right pressure values ​​to obtain the real-time pressure difference value corresponding to that idler number. The processor iterates through all the real-time pressure difference values ​​corresponding to all idler numbers in the first idler set, selects the one with the largest value through numerical comparison, and identifies the idler corresponding to this largest real-time pressure difference value as the first target idler. The first target idler is the idler that experiences the most severe positive pressure deviation among the idlers corresponding to the positive pressure deviation indicator.

[0049] For each idler number in the second idler set, the processor retrieves the left and right pressure values ​​corresponding to that idler number from the real-time pressure data. It then calculates the difference between the left and right pressure values ​​to obtain the real-time pressure difference value for that idler number. The processor iterates through all the real-time pressure difference values ​​corresponding to all idler numbers in the second idler set, selecting the smallest value through numerical comparison. The idler corresponding to this smallest real-time pressure difference value is then identified as the second target idler. The minimum real-time pressure difference value may be negative; the second target idler is the idler experiencing the most severe negative pressure deviation among the idlers corresponding to the negative pressure deviation indicator.

[0050] After determining the first target idler and the second target idler, the processor calculates the first adjustment angle based on the real-time pressure difference of the first target idler. The first adjustment angle is directly proportional to the real-time pressure difference of the first target idler. The first adjustment angle is calculated according to the following formula:

[0051]

[0052] in: This indicates the first adjustment angle, in degrees; Indicates the angle conversion ratio factor. The value range is greater than or equal to 0.1 and less than or equal to 0.5. The specific value is determined based on the response characteristics of the hydraulic actuator and the structural parameters of the idler roller. In this embodiment... The value is 0.2, and the basis for this value is based on multiple field tests. When the value is 0.2, the roller adjustment angle can effectively respond to pressure deviation without exceeding the maximum allowable adjustment rate of the hydraulic actuator; This represents the absolute value of the real-time pressure difference of the first target idler. The real-time pressure difference of the first target idler is obtained by subtracting the pressure value on the right side from the pressure value on the left side corresponding to the first target idler.

[0053] The processor calculates the second adjustment angle based on the real-time pressure difference between the second target idler and the second target idler. The second adjustment angle is directly proportional to the real-time pressure difference between the second target idler and the second target idler. The calculation method for the second adjustment angle involves converting the angle into a proportionality coefficient. Multiply by the absolute value of the real-time pressure difference of the second target idler. The real-time pressure difference of the second target idler is obtained by subtracting the right pressure value from the left pressure value corresponding to the second target idler. The real-time pressure difference of the second target idler is negative, and its absolute value is used in the multiplication operation.

[0054] After obtaining the first and second adjustment angles, the processor compares the values ​​of the first and second adjustment angles and determines the larger value as the idler roller adjustment angle. Once the idler roller adjustment angle is determined, the processor obtains a preset maximum single adjustment angle range. The upper limit of the maximum single adjustment angle range is a preset safety angle value, which is determined based on the stroke limit of the hydraulic actuator and the permissible rotation angle of the idler roller bearing housing. In this embodiment, the upper limit of the maximum single adjustment angle range is set to 5 degrees, and the lower limit is 0 degrees. If the idler roller adjustment angle is greater than the upper limit of the maximum single adjustment angle range, the processor corrects the idler roller adjustment angle to the upper limit of the maximum single adjustment angle range, i.e., to 5 degrees; if the idler roller adjustment angle is less than or equal to the upper limit of the maximum single adjustment angle range, the original calculated value of the idler roller adjustment angle remains unchanged.

[0055] The processor determines the adjustment direction based on the deviation direction of the roller with the larger adjustment angle between the first and second target rollers. Specifically, if the first adjustment angle is greater than the second adjustment angle, the deviation direction corresponding to the first target roller is used as the adjustment direction, and this deviation direction is considered positive. If the second adjustment angle is greater than the first adjustment angle, the deviation direction corresponding to the second target roller is used as the adjustment direction, and this deviation direction is considered negative. The roller adjustment angle, adjustment direction, and the roller number with the larger adjustment angle are encapsulated into a first-level correction instruction. The encapsulation format of the first-level correction instruction includes an instruction type identifier field, a roller number field, an adjustment angle field, and an adjustment direction field.

[0056] The processor sends the first-level correction command via the communication bus to the control unit of the hydraulic actuator corresponding to the idler roller number. The control unit of the hydraulic actuator parses the first-level correction command and drives the hydraulic cylinder to perform the first tilting action on the idler roller according to the adjustment angle and direction. The hydraulic actuator pushes one end of the idler roller to rotate along a horizontal axis perpendicular to the belt running direction, causing the idler roller to change its tilt angle relative to the horizontal plane.

[0057] After the first tilting action is completed, the processor starts an internal timer and waits for a preset stabilization time interval. The preset stabilization time interval is a pre-set delay parameter, and its length is determined based on the belt conveyor's running speed and the stabilization time of the hydraulic actuator. In this embodiment, the preset stabilization time interval is set to 3 seconds, based on the assumption that the belt tension stabilizes after 3 seconds of operation at the rated belt speed, and that the vibration and overshoot of the hydraulic actuator have completely decayed within 3 seconds. After the timer reaches the preset stabilization time interval, the processor re-acquires the new left and right pressure values ​​of the idler roller, calculates the difference between the new left and right pressure values, and obtains the new real-time pressure difference value.

[0058] The processor obtains the preset reference pressure range corresponding to the idler roller number. This preset reference pressure range includes a lower limit and an upper limit of the reference pressure difference. The processor determines whether the new real-time pressure difference falls within the closed interval between the lower and upper limits of the reference pressure difference. If the new real-time pressure difference falls within this closed interval, a first-level correction success flag is generated. The first-level correction success flag includes the idler roller number and a status indicator indicating successful correction. The processor feeds back the first-level correction success flag to the centralized control system through the communication interface. The centralized control system records the correction completion status of the idler roller.

[0059] If the new real-time pressure difference does not fall within the closed interval between the lower limit and the upper limit of the reference pressure difference, that is, if the new real-time pressure difference is less than the lower limit of the reference pressure difference or greater than the upper limit of the reference pressure difference, the processor enters the second-level correction coefficient generation process.

[0060] The processor obtains the lower limit and upper limit of the reference pressure difference within the preset reference pressure range corresponding to the idler roller number. When the new real-time pressure difference is less than the lower limit of the reference pressure difference, the processor calculates the absolute value of the first deviation between the lower limit and the new real-time pressure difference, and divides the absolute value of the first deviation by the lower limit to obtain a negative correction coefficient. When the new real-time pressure difference is greater than the upper limit of the reference pressure difference, the processor calculates the absolute value of the second deviation between the new real-time pressure difference and the upper limit of the reference pressure difference, and divides the absolute value of the second deviation by the upper limit to obtain a positive correction coefficient. The processor uses the calculated negative or positive correction coefficient as the second-layer correction coefficient, associates the second-layer correction coefficient with the idler roller number, and stores it in the correction coefficient table in memory.

[0061] After generating the second-layer correction coefficient, the processor reads the current actual adjustment angle of the idler roller from the execution status record in memory. The actual adjustment angle is the tilt angle value actually executed by the idler roller during the first tilting action. The processor multiplies the actual adjustment angle by the second-layer correction coefficient to obtain the secondary adjustment angle. The secondary adjustment angle is calculated as the product of the actual adjustment angle and the second-layer correction coefficient. If the second-layer correction coefficient is a negative correction coefficient, it indicates that the first adjustment angle is insufficient, and the secondary adjustment angle is increased to compensate for the original actual adjustment angle; if the second-layer correction coefficient is a positive correction coefficient, it indicates that the first adjustment angle is excessive, and the secondary adjustment angle is corrected in the opposite direction based on the original actual adjustment angle.

[0062] The processor obtains the current adjustment direction of the idler roller and encapsulates this current adjustment direction and the secondary adjustment angle into a second-level correction instruction. The second-level correction instruction includes an instruction type identifier field, the idler roller number, a secondary adjustment angle field, and an adjustment direction field. The processor sends the second-level correction instruction to the control unit of the idler roller's hydraulic actuator via the communication bus. The control unit of the hydraulic actuator parses the second-level correction instruction and drives the hydraulic cylinder to perform a secondary tilt adjustment based on the idler roller's tilt position established by the first tilting action. The magnitude of the secondary tilt adjustment is the secondary adjustment angle, and the direction remains consistent with the current adjustment direction.

[0063] After the second tilt adjustment is completed, the processor restarts its internal timer to wait for a preset stabilization time interval. This preset stabilization time interval is the same as the waiting time after the first tilt action, which is 3 seconds in this embodiment. After the timer reaches the preset stabilization time interval, the processor again collects the pressure values ​​on the left and right sides of the idler roller, calculates the difference between the new left pressure value and the new right pressure value, and obtains the newly collected real-time pressure difference value. The processor then determines whether the newly collected real-time pressure difference value falls within the preset reference pressure range corresponding to the idler roller, completing the second verification.

[0064] In practice, when the overall correction activation coefficient exceeds the preset activation threshold and the processor enters the preparation stage for generating the first-level correction instruction, the processor executes a selection process to prioritize adjusting idlers. The processor reads all generated pressure deviation flags, extracts the idler number from each flag, and records the extracted idler numbers (after removing duplicates) as a list of idlers to be adjusted. The processor also reads all generated distance exceedance flags, extracts the coordinates of the detection points from each flag, and records the coordinates of all extracted detection points as a list of exceedance locations. The list of idlers to be adjusted contains at least one idler number, and the list of exceedance locations contains the coordinates of at least one detection point.

[0065] The processor retrieves the three-dimensional spatial installation coordinates corresponding to each idler number in the list of idlers to be adjusted from the conveyor belt installation parameter database. The three-dimensional spatial installation coordinates include the idler installation horizontal coordinate, the idler installation vertical coordinate, and the idler installation height coordinate. These coordinates are measured and calibrated using a total station or laser rangefinder during the conveyor belt installation and commissioning phase and then stored in the installation parameter database. The three-dimensional spatial installation coordinates of each idler correspond one-to-one with its idler number. In some embodiments, the idler installation height coordinates are measured using the bottom reference plane of the conveyor belt frame as a reference surface.

[0066] The processor retrieves the three-dimensional coordinates of the belt edge corresponding to the position coordinates of each detection point in the over-limit location list from the detection point calibration parameter database. The three-dimensional coordinates of the belt edge include the x-coordinate and y-coordinate of the over-limit point, and the belt running height coordinates. The x-coordinate and y-coordinate of the over-limit point are determined by the mileage coordinates and lateral offset coordinates of the detection point along the conveyor belt. The belt running height coordinate is the height of the belt bearing surface at the detection point under normal operating conditions. The belt running height coordinate is obtained during the conveyor belt parameter calibration stage by measuring the vertical distance between the belt bearing surface and the reference plane using a laser distance sensor, and is stored in association with the position coordinates of the detection point.

[0067] The processor combines the 3D spatial installation coordinates corresponding to each idler number in the list of idlers to be adjusted with the 3D belt edge coordinates corresponding to the position coordinates of each detection point in the list of over-limit positions, and calculates the straight-line distance between each pair of idlers and the over-limit point. The straight-line distance between the idler and the over-limit point is calculated according to the following formula:

[0068]

[0069] in: This indicates the number in the list of idlers to be adjusted. The list of idler rollers and over-limit positions. The straight-line distance between the points that exceed the limit; Indicates the first The horizontal coordinate of the idler roller installation; Indicates the first The vertical coordinate of the idler roller installation; Indicates the first The coordinates of the installation height of each idler roller; Indicates the first The x-coordinate of the point that exceeds the limit; Indicates the first The ordinate of the point that exceeds the limit; Indicates the first The belt conveyor running height coordinates at each exceeding limit point. All coordinate values ​​are in meters, representing straight-line distances. The calculation results are in meters.

[0070] The processor constructs a distance matrix with roller numbers as rows and over-limit point numbers as columns, filling the corresponding positions in the distance matrix with the straight-line distance between each roller number and each over-limit point. The processor iterates through all distance values ​​in the distance matrix and finds the minimum distance value by numerical comparison. The roller number corresponding to the minimum distance value is determined as the priority adjustment roller. If multiple identical minimum distance values ​​correspond to different roller numbers, the roller with the smallest roller number is selected as the priority adjustment roller. The roller number of the priority adjustment roller is added to the generation process of the first-level correction instruction, so that the first-level correction instruction includes the roller number of the priority adjustment roller. Subsequent roller adjustment angles and directions are calculated and encapsulated for the priority adjustment roller.

[0071] This application also provides an automatic belt correction system for a conveyor belt, including a memory, a processor, and a computer program stored in the memory and running on the processor. The memory stores a preset reference pressure range, a preset safety offset threshold, a preset start threshold, a maximum single adjustment angle range, a preset stabilization time interval, the three-dimensional spatial installation coordinates of the idler rollers, the three-dimensional coordinates of the belt edge at the detection point, and computer program instructions. The processor is configured to execute the computer program to implement the above method steps: collecting multiple sets of real-time idler roller pressure data and multiple sets of real-time belt edge offset distance data during conveyor belt operation; comparing each set of real-time idler roller pressure data with the corresponding preset reference pressure range to generate a pressure deviation flag; comparing each set of real-time belt edge offset distance data with the corresponding preset safety offset threshold to generate a distance exceedance flag; when at least one pressure deviation flag and at least one distance exceedance flag exist, calculating a comprehensive... The system employs a comprehensive correction initiation coefficient. When this coefficient exceeds a preset threshold, before generating the first-level correction command, it acquires a list of idlers to be adjusted and a list of over-limit positions. It calculates the straight-line distance between each idler and each over-limit point, selects the idler with the smallest straight-line distance as the priority adjustment idler, adds its number to the first-level correction command, generates the first-level correction command containing the idler's adjustment angle and direction, and sends it to the hydraulic actuator of the corresponding idler, causing the idler to tilt for the first time. Subsequent steps include the second-level correction and feedback verification. The system's processor communicates with the pressure sensor array, laser displacement sensor array, and hydraulic actuator controller via industrial Ethernet or fieldbus, enabling real-time data acquisition and command issuance.

[0072] The foregoing has provided a detailed description of one embodiment of the present invention, but this description is merely a preferred embodiment and should not be construed as limiting the scope of the invention. All equivalent variations and modifications made within the scope of the claims of this invention should still fall within the patent coverage of this invention.

Claims

1. A method for automatic belt alignment on a conveyor belt machine, characterized in that, Includes the following steps: Collect real-time pressure data of multiple idler rollers and real-time offset distance data of multiple belt edges during the operation of the conveyor belt; Compare the real-time pressure data of each set of idlers with the corresponding preset reference pressure range to generate a pressure deviation flag. Compare the real-time offset distance data of each belt edge with the corresponding preset safety offset threshold to generate a distance over-limit flag. When at least one pressure deviation indicator and at least one distance limit violation indicator exist, the comprehensive correction start coefficient is calculated based on the idler positions corresponding to all pressure deviation indicators and the belt edge positions corresponding to all distance limit violation indicators. The specific steps are as follows: Obtain the number of positive idlers with positive deviation direction from all pressure deviation indicators, and the number of negative idlers with negative deviation direction from all pressure deviation indicators; Get the number of left-edge exceedances where the exceedance side is on the left, and the number of right-edge exceedances where the exceedance side is on the right, among all distance exceedance signs; The idler pressure deviation weight is calculated based on the number of positive and negative idlers. This idler pressure deviation weight is equal to the absolute value of the difference between the number of positive and negative idlers divided by the sum of the number of positive and negative idlers. When the sum of the number of positive and negative idlers is zero, the processor directly resets the idler pressure deviation weight to zero. The belt edge over-limit weight is calculated based on the number of over-limits on the left and right edges. This belt edge over-limit weight is equal to the absolute value of the difference between the number of over-limits on the left and right edges divided by the sum of the number of over-limits on the left and right edges. When the sum of the number of over-limits on the left and right edges is zero, the processor directly resets the belt edge over-limit weight to zero. The roller pressure deviation weight and the belt edge over-limit weight are multiplied by a preset proportional coefficient and then added together to obtain the comprehensive correction start coefficient. When the overall correction start coefficient is greater than the preset start threshold, a first-level correction instruction containing the idler roller adjustment angle and direction is generated. The specific steps are as follows: Obtain the first set of idlers corresponding to the positive pressure deviation indicator and the second set of idlers corresponding to the negative pressure deviation indicator; Select the roller with the largest real-time pressure difference from the first set of rollers as the first target roller, and select the roller with the smallest real-time pressure difference from the second set of rollers as the second target roller; The first adjustment angle is calculated based on the real-time pressure difference of the first target idler roller, and the first adjustment angle is proportional to the absolute value of the real-time pressure difference of the first target idler roller. The second adjustment angle is calculated based on the real-time pressure difference of the second target idler roller, and the second adjustment angle is proportional to the absolute value of the real-time pressure difference of the second target idler roller. The larger value between the first adjustment angle and the second adjustment angle is determined as the idler roller adjustment angle; The adjustment direction is determined based on the deviation direction of the roller with the larger adjustment angle among the first target roller and the second target roller. The adjustment angle, adjustment direction, and number of the idler roller with a large adjustment angle are encapsulated as the first layer of correction instructions; The first layer of correction command is sent to the hydraulic actuator of the corresponding idler roller, causing the idler roller to tilt for the first time according to the adjustment angle and direction.

2. The automatic belt alignment method for a conveyor belt machine according to claim 1, characterized in that, The specific steps for comparing the real-time pressure data of each set of idlers with the corresponding preset reference pressure range and generating a pressure deviation flag are as follows: Extract the current left and right pressure values ​​of the idler from the real-time pressure data of the idler; Calculate the real-time pressure difference between the pressure values ​​on the left and right sides; Obtain the preset reference pressure range corresponding to the current idler roller. The preset reference pressure range includes the lower limit of the reference pressure difference and the upper limit of the reference pressure difference. Determine whether the real-time pressure difference is less than the lower limit of the reference pressure difference or greater than the upper limit of the reference pressure difference; If the real-time pressure difference is less than the lower limit of the reference pressure difference, a negative pressure deviation flag is generated. This negative pressure deviation flag includes the current idler roller number and the direction of deviation as negative. If the real-time pressure difference is greater than the upper limit of the reference pressure difference, a positive pressure deviation flag is generated. This positive pressure deviation flag includes the current idler roller number and the deviation direction as positive.

3. The automatic belt alignment method for a conveyor belt machine according to claim 2, characterized in that, The preset reference pressure range is calibrated based on the pressure difference of the idler rollers during the no-load operation of the conveyor belt.

4. The automatic belt alignment method for a conveyor belt machine according to claim 1, characterized in that, The specific steps for comparing each set of real-time belt edge offset distance data with the corresponding preset safety offset threshold to generate a distance exceedance flag are as follows: Extract the real-time left edge offset distance and real-time right edge offset distance of the current detection point from the real-time offset distance data of the belt edge; Obtain the preset safety offset threshold corresponding to the current detection point. The preset safety offset threshold includes the left edge safety offset limit value and the right edge safety offset limit value. Determine whether the real-time left edge offset distance is greater than the left edge safe offset limit; If the real-time left edge offset distance is greater than the left edge safety offset limit, a left edge over-limit flag is generated. This left edge over-limit flag includes the position coordinates of the current detection point and the over-limit side being the left side. Determine whether the real-time right edge offset distance is greater than the right edge safe offset limit; If the real-time right edge offset distance is greater than the right edge safety offset limit, a right edge over-limit flag is generated. This right edge over-limit flag includes the position coordinates of the current detection point and the over-limit side as the right side.

5. The automatic belt alignment method for a conveyor belt machine according to claim 1, characterized in that, The preset safety offset threshold is calculated and determined based on the belt width and the idler roller trough angle.

6. The automatic belt alignment method for a conveyor belt machine according to claim 1, characterized in that, The adjustment angle of the idler roller is limited to a preset maximum single adjustment angle range.

7. An automatic belt correction system for a conveyor belt machine, comprising a memory, a processor, and a computer program stored in the memory and running on the processor, characterized in that, When the processor executes the computer program, it implements the steps of the automatic belt correction method for a conveyor belt as described in any one of claims 1 to 6.

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