Intelligent deviation rectifying control device for belt dryer mesh belt deviation and tension state

Abstract

This invention discloses an intelligent belt misalignment and tension control device for a belt dryer, comprising a conveyor base frame, a conveyor top frame fixedly mounted on the top of the conveyor base frame, and two symmetrically rotating conveyor roller structures mounted inside the conveyor base frame. The outer sides of the two conveyor roller structures are connected to the same conveyor belt, and a first servo motor is mounted on the outer side of the conveyor base frame. This device adopts an integrated structural design combining high-precision visual detection, AI trend prediction, thermal deformation graded correction, and drying support. It uses dual industrial cameras to acquire real-time images of the belt edge and obtains accurate offset data through sub-pixel positioning. It uses a Kalman filter algorithm to predict the misalignment trend, triggers graded heating expansion of the thermal deformation ring, and pushes the belt back to its original position through radial thrust. The multi-stage drying box not only supports the belt against sagging but also achieves graded heating and drying. The camera spacing is adjustable to adapt to different belt widths.

Description

Technical Field

[0001] This invention relates to the field of industrial vision technology, and in particular to an intelligent correction and control device for belt misalignment and tension status of belt dryers. Background Technology

[0002] A belt dryer is a continuous drying equipment widely used for drying granular, flaky, and strip-shaped materials. Its core component is a conveyor belt (either stainless steel or PTFE). Material is laid on the belt and passes through the drying chamber, where hot air passes through the material layer to achieve drying. The belt is driven by a drive roller, tensioned by a driven roller, and equipped with a tensioning device to maintain appropriate belt tension.

[0003] During long-term operation, due to factors such as uneven material distribution, roller parallelism deviation, uneven elongation of the conveyor belt itself, and changes in ambient temperature, the conveyor belt is prone to deviation (offset from the center line) and uneven tension. Severe deviation can lead to wear and tear on the edges of the conveyor belt, or even detachment from the roller, causing production accidents; uneven tension can cause localized loosening and wrinkling of the conveyor belt, affecting the stability of material conveying and the uniformity of drying.

[0004] Patent CN221987308U discloses an automatic belt alignment device for a belt dryer. This device controls the amount of air entering the alignment cylinder via a control valve group, further controlling the pulling force of the cylinder on the bearing housing to adjust the bearing housing's position and achieve the alignment function. This alignment device uses a cylinder to pull on the bearing housing to adjust its position, thus achieving the alignment function. However, this mechanical alignment method suffers from drawbacks such as slow response, low alignment accuracy, and easy damage to the conveyor belt. Summary of the Invention

[0005] To overcome the shortcomings of existing technologies, this invention provides an intelligent correction control device for the belt misalignment and tension status of a belt dryer, which solves one of the following technical problems: achieving high-precision visual misalignment detection, early trend prediction, and active correction of graded thermal deformation; and integrating graded drying and belt support functions to improve the operating stability and drying efficiency of the dryer.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution:

[0007] An intelligent belt misalignment and tension control device for a belt dryer includes a conveyor base frame. A conveyor top frame is fixedly mounted on the top of the conveyor base frame. Two conveyor roller structures are symmetrically rotated and mounted inside the conveyor base frame. The outer sides of the two conveyor roller structures are driven by the same conveyor belt. A first servo motor is mounted on the outer side of the conveyor base frame. The output shaft of the first servo motor is fixedly connected to one of the conveyor roller structures. The device also includes:

[0008] Two visual sensing mechanisms are symmetrically fixedly installed at the bottom of the conveyor top frame, above the conveyor belt, to collect the edge graphics of the conveyor belt;

[0009] The drying mechanism is fixedly installed inside the conveyor base frame, located on the upper and lower sides of the conveyor belt, and is used to support the upper part of the conveyor belt.

[0010] An integrated intelligent belt deviation correction and drying system for belt dryers is constructed, which integrates belt conveying, edge visual detection, intelligent deviation correction, and multi-stage drying functions. This system enables real-time monitoring, early warning, and precise deviation correction of belt deviation, while ensuring material drying effect and improving the operational stability and drying efficiency of the belt dryer.

[0011] Preferably, the conveyor roller structure includes a conveyor roller body, on which a hollow conveyor shaft is fixedly mounted. The hollow conveyor shaft is rotatably mounted on a conveyor base frame via bearings. Multiple offset correction annular grooves are evenly distributed on the outer side of the conveyor roller body. Each offset correction annular groove contains an offset correction thermal deformation ring. Under normal circumstances, the side of the offset correction thermal deformation ring is flush with the outer side of the offset correction annular groove. After being heated and deformed, the offset correction thermal deformation ring can push the conveyor belt to offset and reset. The offset correction annular groove provides installation and deformation space for the thermal deformation ring, ensuring that the operation of the conveyor belt is not affected during normal conveying.

[0012] Preferably, a heating resistor coil is embedded inside the offset correction thermal deformation ring. A branch wire is electrically connected to the heating resistor coil, and a main wire is connected to the branch wire. The main wire is embedded inside the hollow transmission shaft. When the heating resistor coil is energized, it generates heat, which drives the offset correction thermal deformation ring to expand and deform. The branch wire and the main wire realize the transmission of electrical energy. The hollow transmission shaft protects the wire from wear and ensures stable power supply.

[0013] Preferably, a rotary electrical connector is installed on the outer side of the conveyor base, the rotary electrical connector is electrically connected to the main guide line, and a branch temperature controller is electrically connected to the rotary electrical connector. The two branch temperature controllers are connected to the same main controller, which is installed on the outer side of the conveyor base. The rotary electrical connector ensures continuous power transmission when the conveyor roller structure rotates, the branch temperature controllers precisely control the heating temperature and time of the heating resistance coil, and the main controller coordinates the entire correction and drying system to achieve intelligent regulation.

[0014] Preferably, the vision sensing mechanism includes a slide rail, which is fixedly installed on the bottom inner wall of the conveyor top frame. A bidirectional screw is rotatably installed inside the slide rail, and sliders are threaded to both sides of the bidirectional screw. An industrial camera is installed at the bottom of each slider. The two industrial cameras are used to capture the edge image of the conveyor belt. A second servo motor is fixedly installed on the outside of the slide rail, and the output shaft of the second servo motor is fixedly installed with the bidirectional screw. The industrial cameras capture the edge image of the conveyor belt in real time, providing data support for correction. The second servo motor drives the bidirectional screw to rotate, thereby driving the sliders to adjust the spacing between the industrial cameras to adapt to conveyor belts of different widths.

[0015] Preferably, the optical axis of the industrial camera is perpendicular to the surface of the conveyor belt, and a ring light source is provided on the outside of the industrial camera to provide uniform illumination; the ring light source ensures that the image captured by the industrial camera is clear and shadow-free, and the vertical setting of the optical axis ensures the edge positioning accuracy and avoids image distortion from affecting the correction judgment.

[0016] Preferably, the drying mechanism includes a multi-stage support drying box, which is fixedly installed inside the conveyor base frame. The multi-stage support drying box is located on the upper and lower sides of the conveyor belt, with its top contacting the upper edge of the conveyor belt. Three sets of drying holes are provided on the top of the multi-stage support drying box. Two heating isolation plates are installed inside the multi-stage support drying box, dividing the three sets of drying holes into three heating zones. The multi-stage support drying box provides stable support to the conveyor belt, preventing it from sagging or shifting due to gravity. The three heating zones separated by the heating isolation plates enable graded drying of materials, improving drying uniformity.

[0017] Preferably, the multi-stage support drying box is equipped with three sets of heating resistance rods, which are located in three heating zones. All three sets of heating resistance rods are electrically connected to the main controller. The heating resistance rods generate heat when energized, which is conducted to the surface of the conveyor belt through the drying holes. The main controller controls the heating power to achieve precise control of the drying temperature and adapt to the drying needs of different materials.

[0018] Preferably, the main controller is internally equipped with an image processing module and a trend prediction module, both of which are electrically connected to the industrial camera.

[0019] The image processing module is used to perform edge detection and subpixel localization on the acquired images to obtain the real-time position, offset velocity, and offset acceleration of the conveyor belt edge;

[0020] The trend prediction module is used to calculate the predicted offset for future moments based on the real-time position and offset speed of the conveyor belt edge, combined with a time series prediction model.

[0021] The functions include an image processing module to achieve high-precision positioning of the conveyor belt edge, providing accurate data for correction; and a trend prediction module to predict the deviation trend, provide early warning and trigger correction, and avoid serious deviation of the conveyor belt that could damage the equipment.

[0022] Preferably, the image processing module includes an edge coarse positioning submodule and a subpixel positioning submodule. The edge coarse positioning submodule is used to extract the pixel-level contour of the conveyor belt edge using the Canny operator or the Sobel operator.

[0023] The subpixel positioning submodule is used to improve the edge positioning accuracy to the 0.1 pixel level through grayscale moment method or interpolation method, corresponding to the actual physical size accuracy;

[0024] The function is to quickly extract the edge contour of the mesh belt by the coarse edge positioning submodule, thereby improving the detection efficiency; and to improve the edge positioning accuracy by the subpixel positioning submodule, thereby ensuring accurate correction and avoiding over- or under-correction.

[0025] Preferably, the trend prediction module uses a Kalman filter algorithm or an autoregressive moving average model to predict the offset after a future time Δt based on the edge position data of the current time and the past N time points. When the predicted offset exceeds the first preset threshold of 0.5mm, an early warning signal is output; when the predicted offset exceeds the second preset threshold of 1.5mm, a correction action is triggered.

[0026] The algorithm accurately predicts the belt deviation trend, provides early warnings for operators to pay attention to, and automatically triggers correction when the deviation exceeds the threshold, realizing a closed-loop control of "prediction-early warning-correction" to improve the timeliness and effectiveness of correction.

[0027] Compared with the prior art, the beneficial effects that this invention can achieve are:

[0028] 1. Subpixel-level high-precision visual inspection: Abandoning the traditional coarse inspection method of photoelectric switches, it adopts a combination of Canny edge coarse positioning and grayscale moment subpixel fine positioning, with an edge positioning accuracy of 0.01mm. It can capture the slight deviation of the conveyor belt and completely solve the problems of low detection accuracy, easy misjudgment and missed detection in traditional inspection.

[0029] 2. Trend prediction-based proactive correction: For the first time, the Kalman filter / autoregressive moving average model is introduced into the conveyor belt correction system. Based on historical offset data, the future deviation amount is predicted, realizing early warning and proactive correction, rather than traditional passive and delayed correction, thus avoiding serious conveyor belt deviation, tearing and jamming from the root.

[0030] 3. Roller-embedded heat-deformation flexible graded correction: The innovative roller surface is embedded with a heat-deformation ring structure. Graded correction is achieved by linearly matching the amount of heating expansion with the amount of offset. The correction thrust is gentle and has no mechanical impact, so it does not damage the conveyor belt. Under normal conditions, the deformation ring is flush with the roller surface and does not interfere with the normal operation of the conveyor belt, which is different from the rigid extrusion structure of traditional mechanical correction.

[0031] 4. Integrated drying support and belt alignment: The multi-stage heating and drying mechanism and the mesh belt support structure are combined into one. The drying box not only achieves zoned gradient drying, but also provides planar support for the mesh belt to prevent sagging and deviation, solving the technical defects of traditional equipment where the drying and belt alignment structures are separated and the mesh belt is prone to loosening and deviation.

[0032] 5. Adaptive adjustable vision sensing mechanism; adopts a bidirectional screw to drive the synchronous sliding of dual cameras, which can freely adjust the detection spacing and adapt to different width mesh belts. One device is compatible with multiple specifications of dryers, breaking through the limitations of traditional correction sensors that are fixed and have poor adaptability.

[0033] 6. Rotary conductive and closed-loop feedback intelligent control: The problem of continuous power supply to the rotating roller is solved by a rotary electrical connector. Combined with real-time image feedback, it forms a closed-loop control of detection, prediction, correction and reset. The correction process is dynamically adjusted and automatically terminated without manual operation. The level of intelligence is significantly higher than that of traditional mechanical / semi-automatic correction.

[0034] 7. The drying and belt alignment are controlled independently in stages without interference. The heating isolation plate divides the drying mechanism into three independent temperature control zones, which can be adjusted according to the material characteristics. At the same time, it does not affect the belt alignment action, achieving a dual improvement in drying efficiency and alignment stability. Its functional synergy is superior to that of single-function equipment.

[0035] This invention employs an integrated structural design combining high-precision visual detection, AI trend prediction, graded thermal deformation correction, and drying support. It uses dual industrial cameras to acquire real-time images of the conveyor belt edges and obtains precise offset data through sub-pixel positioning. A Kalman filter algorithm is used to predict deviation trends, triggering graded heating expansion of the thermal deformation ring, which then pushes the conveyor belt back to its original position via radial thrust. The multi-stage drying box both supports the conveyor belt against sagging and enables graded heating and drying. The camera spacing is adjustable to accommodate different conveyor belt widths, forming a closed-loop intelligent control system encompassing detection, prediction, correction, support, and drying. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the main structure of the present invention;

[0037] Figure 2 This is a side view of the structure of the present invention;

[0038] Figure 3 This is a bottom-view structural diagram of the present invention;

[0039] Figure 4 This is a bottom view schematic diagram of the conveying top frame and visual sensing mechanism of the present invention;

[0040] Figure 5 This is a schematic diagram of the structure of the conveyor base, conveyor belt, first servo motor, and drying mechanism of the present invention;

[0041] Figure 6 This is a schematic diagram of the structure of the conveyor base, the first servo motor, and the drying mechanism of the present invention;

[0042] Figure 7 This is a schematic diagram of the conveyor roller structure of the present invention;

[0043] Figure 8 This is an internal structural schematic diagram of the conveyor roller structure of the present invention;

[0044] Figure 9 This is a schematic diagram of the internal structure of the offset correction thermal deformation ring and heating resistance coil of the present invention;

[0045] Figure 10 This is a schematic diagram of the structure of the visual sensing mechanism of the present invention;

[0046] Figure 11 This is a schematic diagram of the drying mechanism, multi-stage support drying box, and drying holes of the present invention;

[0047] Figure 12 This is a perspective structural diagram of the drying mechanism, multi-stage support drying box, drying hole, heating isolation plate, and heating resistance rod of the present invention;

[0048] Figure 13 This is a diagram showing the normal operating state of the conveyor belt of the present invention;

[0049] Figure 14 This is a diagram showing the working state of the conveyor belt correction system according to the present invention.

[0050] The components include: 1. Conveyor base frame; 11. Conveyor top frame; 2. Main controller; 21. Branch temperature controller; 22. Rotary electrical connector; 3. Conveyor roller structure; 31. Conveyor roller body; 32. Hollow conveyor shaft; 33. Offset correction annular groove; 34. Offset correction thermal deformation ring; 341. Heating resistance coil; 35. Branch conductor; 36. Main conductor; 4. Conveyor belt; 5. First servo motor; 6. Vision sensing mechanism; 61. Slide rail; 62. Bidirectional screw; 63. Slider; 64. Second servo motor; 65. Industrial camera; 7. Drying mechanism; 71. Multi-stage support drying box; 72. Drying hole; 73. Heating isolation plate; 74. Heating resistance rod. Detailed Implementation

[0051] To make the technical means, creative features, and achieved objectives and effects of this invention easier to understand, the invention is further described below with reference to specific embodiments. However, the following embodiments are merely preferred embodiments of this invention and not all of them. Other embodiments obtained by those skilled in the art based on the embodiments described herein without creative effort are all within the protection scope of this invention. Unless otherwise specified, the experimental methods in the following embodiments are conventional methods, and the materials and reagents used in the following embodiments are commercially available unless otherwise specified.

[0052] Example 1

[0053] like Figures 1-12 As shown, this invention provides an intelligent belt misalignment and tension control device for a belt dryer, comprising a conveyor base frame 1, a conveyor top frame 11, a conveyor belt 4, a drive mechanism, an intelligent control mechanism, and two vision sensing mechanisms 6. The conveyor top frame 11 is fixedly installed on the top of the conveyor base frame 1. Two conveyor roller structures 3 are symmetrically rotated and installed inside the conveyor base frame 1. The conveyor belt 4 is driven and connected to the outside of the two conveyor roller structures 3. The drive mechanism is installed on the outside of the conveyor base frame 1 and connected to one of the conveyor roller structures 3, for driving the conveyor belt 4 to circulate and transport materials. The two vision sensing mechanisms 6 are symmetrically fixed at the bottom of the conveyor top frame 11 and above the conveyor belt 4. The two vision sensing mechanisms 6 are used to collect images of the belt edge in real time to monitor the misalignment status. The intelligent control mechanism is electrically connected to the vision sensing mechanisms 6 and the conveyor roller structures 3 respectively, for image processing, misalignment trend prediction, and automatic and accurate correction. The whole device achieves high-precision visual detection of belt misalignment, early prediction and warning, graded thermal deformation correction, and integrated drying support, eliminating belt misalignment and jamming, and improving the operating stability of the dryer.

[0054] like Figures 6-9As shown, in this embodiment, the driving mechanism includes a first servo motor 5, which is fixedly installed on the outside of the conveyor base 1 and its output shaft is fixedly connected to the conveyor roller structure 3. This provides stable conveying power to the conveyor belt 4, ensuring uniform material conveying and providing a stable operating basis for deviation monitoring and correction. The conveyor roller structure 3 includes a conveyor roller body 31, a hollow conveyor shaft 32, a deviation correction annular groove 33, a deviation correction thermal deformation ring 34, and a heating assembly. The hollow conveyor shaft 32 is fixed to the end of the conveyor roller body 31 and rotatably mounted on the conveyor base 1 via bearings. Multiple deviation correction rings are evenly spaced on the outside of the conveyor roller body 31. An annular groove 33 is provided, and a deviation correction thermal deformation ring 34 is installed inside the deviation correction annular groove 33 and is flush with the outer radial side of the deviation correction annular groove 33. The deviation correction thermal deformation ring 34 expands and deforms due to heat, generating radial thrust, which pushes the misaligned mesh belt to reverse and reset. The deviation correction annular groove 33 provides installation and deformation space for the deviation correction thermal deformation ring 34 to avoid interfering with the normal conveying of the mesh belt. The conveyor mesh belt 4 is sleeved on the outside of the two conveyor roller bodies 31 and is used to convey the conveyor mesh belt 4. The deviation correction thermal deformation ring 34 expands and squeezes the conveyor mesh belt 4 outward due to thermal deformation. Under the expansion and squeezing, the conveyor mesh belt 4 becomes conical and will slide to the other side.

[0055] like Figures 13-14 As shown, more specifically, when the conveyor belt 4 deviates to the right: the control system sends a command to the thermal deformation ring on the right roller. The heating resistance coil 341 inside the conveyor roller body 31 is energized to generate heat, causing the thermal deformation ring 34 to expand and increase in volume. The thermal deformation ring 34 is confined in the annular groove 33 and can only bulge outwards. By controlling the degree of heating, the deformation of the thermal deformation ring 34 increases from the middle to the right. Under the deformation of the thermal deformation ring 34, the conveyor roller body 31 forms a cone shape that is larger on the right and smaller on the left. This unidirectional cone shape creates a "cone" effect and correction: the bulging thermal deformation ring 34 forms a tiny cone or drum shape on the surface of the conveyor roller body 31.

[0056] When the conveyor belt 4 comes into contact with the protrusion on the right, the tension of the conveyor belt 4 will naturally generate a component force pointing to the left. This force will gently push the conveyor belt 4 to the left, thereby correcting its original deviation to the right.

[0057] The principle is to heat up a temporary, tiny tapered guide ring to "grow" on the surface of the roller, and then use the tension of the conveyor belt 4 itself to guide it back to the correct position.

[0058] like Figure 3 , Figure 8 , Figure 9As shown, in this embodiment, the heating assembly includes a heating resistance coil 341, a branch wire 35, a main wire 36, a rotary electrical connector 22, and a branch temperature controller 21. The heating resistance coil 341 is embedded inside the offset correction thermal deformation ring 34. The branch wire 35 connects the heating resistance coil 341 to the main wire 36 embedded in the hollow conveyor shaft 32. The rotary electrical connector 22 is installed on the outside of the conveyor base 1 and electrically connected to the main wire 36. The branch temperature controller 21 connects the rotary electrical connector 22 to the intelligent control mechanism. The branch temperature controller 21 is used to precisely control the heating temperature and duration of the heating resistance coil 341. The rotary electrical connector 22 ensures continuous power supply to the heating resistance coil 341 when the roller rotates, thereby achieving precise control of thermal deformation correction.

[0059] like Figure 10 As shown, in this embodiment, the visual sensing mechanism 6 includes a slide rail 61, a bidirectional screw 62, a slider 63, a second servo motor 64, and an industrial camera 65 with a ring light source. The slide rail 61 is fixed to the inner wall of the bottom of the conveyor top frame 11. The bidirectional screw 62 is rotatably installed inside the slide rail 61. Two sliders 63 are threadedly connected to both sides of the bidirectional screw 62. The industrial camera 65 is installed at the bottom of the slider 63 with its optical axis perpendicular to the surface of the conveyor belt 4. The second servo motor 64 is installed on the outside of the slide rail 61 with its output shaft fixed to the bidirectional screw 62. The industrial camera 65 is used to acquire high-definition images of the conveyor belt edge in real time. The second servo motor 64 can adjust the distance between the two industrial cameras 65 to adapt to the deviation monitoring of conveyor belts of different widths. The ring light source eliminates image shadows and improves detection accuracy.

[0060] In this embodiment, the intelligent control mechanism includes a main controller 2, which has a built-in image processing module and a trend prediction module. The image processing module is electrically connected to an industrial camera 65 and is used to perform pixel-level coarse positioning and sub-pixel fine positioning on the edge image of the conveyor belt to obtain the real-time offset, offset speed and acceleration of the conveyor belt. The trend prediction module uses a Kalman filter or an autoregressive moving average model to predict the future deviation based on historical and real-time offset data, so as to realize early warning and active correction triggering.

[0061] Specifically, the image processing module includes a coarse edge positioning submodule and a subpixel positioning submodule; the coarse edge positioning submodule extracts the pixel-level contour of the mesh edge using the Canny / Sobel operator to quickly lock the position of the mesh edge; the subpixel positioning submodule improves the positioning accuracy to 0.1 pixel level using the gray-scale moment method / interpolation method, corresponding to a physical accuracy of 0.01 mm, to ensure ultra-high accuracy of deviation detection;

[0062] The trend prediction module presets a first warning threshold of 0.5mm and a second correction threshold of 1.5mm. When the predicted offset exceeds 0.5mm, it outputs a warning signal. When it exceeds 1.5mm, the main controller 2 triggers graded correction. According to the offset size, it controls the corresponding number of offset correction heat deformation rings 34 to heat and expand, so as to achieve precise reset of the conveyor belt. After the correction is completed, it automatically cuts off the power and cools down to reset.

[0063] Image processing module 41: Using the OpenCV library, Gaussian filtering (5×5 kernels) and Otsu binarization are applied to each frame of the image. Then, the Canny operator (threshold 50 / 150) is used to extract the edge contours. Least square line fitting is performed on the point set on the edge contours to obtain the linear equation of the mesh edge. Subpixel interpolation (gray-level moment method) improves the edge positioning accuracy to 0.1 pixels. The camera calibration coefficient is 0.05mm / pixel, so the actual positional accuracy is 0.005mm. The processing time for each frame is <15ms.

[0064] Working method: Connect the power supply, place the material to be dried on the top of the conveyor belt 4, start the first servo motor 5, the first servo motor 5 drives one conveyor roller structure 3 to rotate, and through the cooperation of another conveyor roller structure 3, drives the conveyor belt 4 to smoothly convey the material.

[0065] Industrial cameras 65 are installed at each of the four corners of the conveyor belt 4. The industrial cameras 65 acquire images of the edges of the conveyor belt 4 in real time. The acquired images are transmitted to the image processing module of the main controller 2. The image processing module performs edge detection and sub-pixel positioning on the acquired images to obtain the real-time position, offset speed and offset acceleration of the edges of the conveyor belt 4. Real-time data on belt deviation is obtained through visual inspection, providing the main controller 2 with a precise basis for determining whether correction is needed.

[0066] The edge coarse localization submodule of the image processing module extracts the pixel-level contour of the conveyor belt 4 edge using the Canny or Sobel operator, and quickly locks the approximate position of the belt edge; its function is to quickly complete the edge coarse localization, improve detection efficiency, and avoid affecting the timeliness of correction due to excessive localization time.

[0067] The sub-pixel positioning submodule of the image processing module improves the edge positioning accuracy to the 0.1 pixel level through gray-scale moment method or interpolation method, corresponding to the actual physical size accuracy (assuming the correspondence between pixel and physical size is 1 pixel = 0.1 mm, that is, the positioning accuracy reaches 0.01 mm); the function is to improve the edge positioning accuracy, ensure the accurate detection of mesh belt offset, and provide reliable data support for subsequent correction actions.

[0068] When conveyor belt 4 deviates, the trend prediction module of the main controller 2, based on the real-time position (x0) and deviation velocity (v0) of the edge of conveyor belt 4, combines the Kalman filter algorithm or the autoregressive moving average model, and substitutes the edge position data (x1, x2...x0) from the past N time points (recommended N=5-10, time interval Δt0=0.1s) into the input. n It calculates the predicted offset x_pred after a future time Δt (recommended Δt=0.3s); its function is to accurately predict the belt deviation trend, realize early warning and active correction, and avoid the belt deviation from aggravating.

[0069] Automatic correction specific control logic and calculation

[0070] Offset determination: The normal position of the conveyor belt 4 is set as the baseline x=0. When the industrial camera 65 detects that the absolute value of the real-time offset x0, |x0|, is less than the first preset threshold of 0.5mm, it is determined to be normal and no correction is triggered; when 0.5mm≤|x0|<the second preset threshold of 1.5mm, an early warning signal is output; when |x0|≥1.5mm or the predicted offset x_pred≥1.5mm, the main controller 2 triggers the correction action.

[0071] Correction heating control: The main controller 2, based on the real-time offset |x0|, controls the corresponding side and corresponding group of heating resistance coils 341 to be energized and heated through the branch temperature controller 21. The offset correction thermal deformation ring 34 adopts a coefficient of thermal expansion of α (recommended α=1.2×10⁻). 5 The elastic metal material ( / ℃) has a linear relationship between heating temperature and offset. The calculation formula is: T=T0+|x0|×k (where T0 is the ambient temperature and k is the temperature coefficient, and it is recommended that k=50℃ / mm) to ensure that the degree of deformation and offset are accurately matched.

[0072] Graded correction control: Multiple offset correction annular grooves 33 are evenly distributed at 50mm intervals, corresponding to different degrees of offset.

[0073] 1. When 1.5mm≤|x0|<3mm, start heating of the set of offset correction heat deformation rings 34 near the offset side of the mesh belt. The thermal expansion ΔL=α×L×(T-T0) (L is the circumference of the heat deformation ring) pushes the mesh belt to offset and reset in the opposite direction.

[0074] 2. When 3mm≤|x0|<5mm, start the synchronous heating of the two sets of offset correction thermal deformation rings 34 near the offset side of the mesh belt to increase the correction thrust;

[0075] 3. When |x0|≥5mm, start heating of the offset correction heat deformation ring 34 near the offset side of the conveyor belt to quickly achieve the correction.

[0076] Correction feedback adjustment: Industrial camera 65 collects the position of the conveyor belt edge in real time during the correction process. The main controller 2 dynamically adjusts the heating temperature and heating time of the heating resistor coil 341 according to the feedback offset x1. When |x1| < 0.5mm, the heating resistor coil 341 is de-energized, the offset correction thermal deformation ring 34 cools and shrinks naturally, and returns to the state of being flush with the offset correction annular groove 33, and the correction stops until the conveyor belt 4 is stable in the normal transmission position. The function is to achieve accurate, graded, and closed-loop correction of the conveyor belt deviation, avoid over-correction or under-correction, and ensure the smooth operation of the conveyor belt.

[0077] The spacing between the industrial cameras 65 positioned on the same slide rail 61 is adjustable. Activating the second servo motor 64 rotates the bidirectional screw 62, which in turn drives the two industrial cameras 65 to move synchronously in opposite directions via two sliders 63. Adjusting the spacing between the two industrial cameras 65 allows for alignment of conveyor belts 4 with different widths (500-2000mm is recommended). This enhances equipment adaptability and can be used with belt dryers of different specifications, expanding the equipment's application range.

[0078] Example 2

[0079] like Figures 6-14 As shown, this embodiment is a further optimization based on Embodiment 1. The parts that are the same as those described above will not be repeated here. Figure 2 , Figure 3 As shown, in order to better realize the present invention, the following arrangement is adopted: a drying mechanism 7 is fixedly installed inside the conveyor base 1, and the drying mechanism 7 is located between the upper and lower sides of the conveyor belt 4;

[0080] The drying mechanism 7 includes a multi-stage support drying box 71, drying holes 72, heating isolation plates 73, and heating resistance rods 74. The multi-stage support drying box 71 is fixed inside the conveyor base frame 1 and its top contacts the conveyor belt 4. The two heating isolation plates 73 divide the multi-stage support drying box 71 into three independent heating zones. Each zone has a drying hole 72 and a built-in heating resistance rod 74. The heating resistance rod 74 is electrically connected to the intelligent control mechanism. The drying mechanism 7 is used to stably support the conveyor belt 4 to prevent sagging and deviation, and at the same time realizes graded heating and drying of materials, improving drying uniformity and efficiency.

[0081] Specifically, the main controller 2 independently controls the heating resistance rods 74 of the three-stage heating zone to be energized and heated. The heat is evenly conducted to the mesh belt and the material surface through the drying holes 72 of the multi-stage support drying box 71, realizing the partitioned gradient drying of the material. The heating temperature can be independently adjusted according to the material characteristics, which ensures the drying effect without affecting the mesh belt correction and conveying. After drying is completed, the first servo motor 5 and the heating components are turned off, and the mesh belt stops conveying.

[0082] The drying mechanism 7 provides stable support for the conveyor belt 4 through the multi-stage support drying box 71, preventing the belt from sagging or shifting due to material weight or running vibration. On the other hand, the multi-stage support drying box 71 is divided into three independent heating zones by the heating isolation plate 73. The main controller 2 controls the three sets of heating resistance rods 74 to generate heat, which is then evenly conducted to the surface of the conveyor belt 4 through the three sets of drying holes 72, thus classifying and uniformly drying the material on the conveyor belt 4. The function is to balance belt support and material drying, ensuring the stability of belt operation while improving the uniformity and efficiency of material drying.

[0083] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An intelligent deviation control device for belt dryer mesh belt deviation and tension state, characterized in that: The system includes a conveyor base (1), on which a conveyor top frame (11) is fixedly installed. Two conveyor roller structures (3) are symmetrically rotated inside the conveyor base (1). The outer sides of the two conveyor roller structures (3) are connected to the same conveyor belt (4). A first servo motor (5) is installed on the outer side of the conveyor base (1). The output shaft of the first servo motor (5) is fixedly connected to one of the conveyor roller structures (3). The system also includes: Two visual sensing mechanisms (6) are symmetrically fixedly installed at the bottom of the conveyor top frame (11) and above the conveyor belt (4) to collect the edge graphics of the conveyor belt (4); The drying mechanism (7) is fixedly installed inside the conveyor base frame (1) and located on the upper and lower sides of the conveyor belt (4).

2. The intelligent belt misalignment and tension control device for a belt dryer according to claim 1, characterized in that: The conveyor roller structure (3) includes a conveyor roller body (31), a hollow conveyor shaft (32) is fixedly installed on the conveyor roller body (31), the hollow conveyor shaft (32) is rotatably installed on the conveyor base frame (1) through bearings, and multiple offset correction annular grooves (33) are evenly opened on the outer side of the conveyor roller body (31), and offset correction thermal deformation rings (34) are provided in the multiple offset correction annular grooves (33). Under normal circumstances, the side of the offset correction thermal deformation ring (34) is flush with the outer side of the offset correction annular groove (33) in the radial direction.

3. The intelligent belt misalignment and tension control device for a belt dryer according to claim 2, characterized in that: The offset correction thermal deformation ring (34) has a heating resistance coil (341) embedded inside. A branch wire (35) is electrically connected to the heating resistance coil (341). A main wire (36) is connected to the branch wire (35). The main wire (36) is embedded inside the hollow transmission shaft (32).

4. The intelligent belt misalignment and tension control device for a belt dryer according to claim 3, characterized in that: A rotary electrical connector (22) is installed on the outside of the conveyor base (1). The rotary electrical connector (22) is electrically connected to the main line (36). A branch temperature controller (21) is electrically connected to the rotary electrical connector (22). The same main controller (2) is connected to the two branch temperature controllers (21). The main controller (2) is installed on the outside of the conveyor base (1).

5. The intelligent belt misalignment and tension control device for a belt dryer according to claim 4, characterized in that: The visual sensing mechanism (6) includes a slide rail (61), which is fixedly installed on the bottom inner wall of the conveyor top frame (11). A bidirectional screw (62) is rotatably installed inside the slide rail (61). Slider (63) is threadedly connected to both sides of the bidirectional screw (62). An industrial camera (65) is provided at the bottom of each of the two sliders (63). The two industrial cameras (65) are used to collect the edge graphics of the conveyor belt (4). A second servo motor (64) is fixedly installed on the outside of the slide rail (61). The output shaft of the second servo motor (64) is fixedly installed with the bidirectional screw (62).

6. The intelligent belt misalignment and tension control device for a belt dryer according to claim 5, characterized in that: The optical axis of the industrial camera (65) is perpendicular to the surface of the conveyor belt (4), and a ring light source is provided on the outside of the industrial camera (65) to provide uniform illumination.

7. The intelligent belt misalignment and tension control device for a belt dryer according to claim 6, characterized in that: The drying mechanism (7) includes a multi-stage support drying box (71), which is fixedly installed inside the conveyor base frame (1). The multi-stage support drying box (71) is located on the upper and lower sides of the conveyor belt (4). The top of the multi-stage support drying box (71) is in contact with the upper side of the conveyor belt (4). The top of the multi-stage support drying box (71) is provided with three sets of drying holes (72). The multi-stage support drying box (71) is provided with two heating isolation plates (73). The two heating isolation plates (73) divide the three sets of drying holes (72) into three heating zones.

8. The intelligent belt misalignment and tension control device for a belt dryer according to claim 7, characterized in that: The multi-level support drying box (71) is fixedly equipped with three sets of heating resistance rods (74), which are located in three heating zones. All three sets of heating resistance rods (74) are electrically connected to the main controller (2).

9. The intelligent belt misalignment and tension control device for a belt dryer according to claim 8, characterized in that: The main controller (2) is equipped with an image processing module and a trend prediction module, both of which are electrically connected to the industrial camera (65). The image processing module is used to perform edge detection and subpixel localization on the acquired image to obtain the real-time position, offset speed and offset acceleration of the edge of the conveyor belt (4); The trend prediction module is used to calculate the predicted offset at future times based on the real-time position and offset speed of the edge of the conveyor belt (4) and the time series prediction model. The image processing module enables high-precision positioning of the conveyor belt edge, providing accurate data for correction; the trend prediction module enables prediction of deviation trends, provides early warning and triggers correction, and avoids serious deviation of the conveyor belt from damaging the equipment.

10. The intelligent belt misalignment and tension control device for a belt dryer according to claim 9, characterized in that: The image processing module includes an edge coarse positioning submodule and a subpixel positioning submodule. The edge coarse positioning submodule is used to extract the pixel-level contour of the edge of the conveyor belt (4) using the Canny operator or the Sobel operator. The subpixel positioning submodule is used to improve the edge positioning accuracy to the 0.1 pixel level through grayscale moment method or interpolation method, corresponding to the actual physical size accuracy.

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