An upstream and downstream belt center line misalignment automatic adjusting material flow method, system, device and medium

Abstract

The present application belongs to the technical field of material conveying, and particularly relates to a method, system, device and medium for automatically adjusting material flow with center line misalignment of upstream and downstream belt conveyors, which acquires a center line deviation distance, determines parameters of an asymmetric curve baffle plate in combination with simulation analysis, and determines parameters of a funnel chute according to material flow calculation and simulation. The baffle plate is installed in the chute and can rotate, a hand wheel screw adjusting device is installed and connected with a PLC controller. A corresponding relationship between screw extension and deflection angle of the baffle plate and change of curvature is established and calibrated. Finally, the PLC controller controls the hand wheel screw device according to a signal of the upstream belt conveyor to adjust the baffle plate in real time and guide the material to fall onto the center line of the downstream belt conveyor. The present application solves the problems of material deviation and funnel blockage caused by center line misalignment of the belt conveyor, can adjust the baffle plate in real time, adapts to changes of material flow state under different working conditions, improves accuracy and stability of material conveying, and ensures efficient production operation.

Description

Technical Field

[0001] This invention belongs to the field of material transfer technology, specifically relating to a method, system, equipment, and medium for automatically adjusting material flow when the center lines of upstream and downstream belt conveyors are misaligned. Background Technology

[0002] In the field of bulk material handling and continuous conveying, belt conveyors are indispensable core equipment in industries such as mining, ports, power, metallurgy, and building materials. Their main function is to realize the continuous, long-distance transfer of materials such as coal, ore, sand, and grain.

[0003] Currently, to solve the problem of material transfer from upstream to downstream conveyor belts, transfer funnels are used as intermediate connecting components. However, transfer funnel designs are mostly based on the principle of symmetry, with the internal structure arranged symmetrically along the centerline. When faced with a large misalignment between the centerlines of the upstream and downstream conveyor belts, this symmetrical design causes the material thrown from the upstream belt to directly impact the inner wall of one side of the funnel, sliding down an irregular trajectory to the edge area of ​​the downstream conveyor belt. This causes the downstream conveyor belt to deviate. Due to the continuous unilateral loading of material, the belt experiences uneven stress, and the belt gradually shifts towards the receiving side during operation. Severe deviation not only wears down the belt edges, damages idlers and the frame, but can also cause material spillage, ultimately forcing the production line to stop for adjustments, affecting production efficiency and equipment lifespan.

[0004] To bring off-center material back to the center of the downstream conveyor belt, the size of the hopper outlet is reduced or internal baffles are added. However, this reduces the cross-sectional area for material flow, which can easily lead to bridging or wall-sticking of unevenly sized materials inside the hopper, causing frequent material blockages. Summary of the Invention

[0005] This invention provides a method for automatically adjusting material flow when the center lines of upstream and downstream belt conveyors are misaligned. This method can reduce the material deviation rate caused by center line misalignment, achieve automated adjustment, and improve production efficiency.

[0006] The methods include: S1: Obtain the centerline position information of the upstream and downstream belt conveyors and calculate the centerline deviation distance; S2: Based on the centerline deviation distance obtained in step S1, combined with the material movement trajectory and discrete element simulation analysis, determine the initial radius of curvature, initial deflection angle and asymmetric offset distance of the asymmetric curved baffle, so that the asymmetric curved baffle bends in the opposite direction of the centerline deviation direction. S3: Based on the material flow cross-sectional area calculation formula and minimum flow area requirement, combined with the structural parameters of the asymmetric curved baffle determined in step S2, the material flow trajectory is simulated through discrete element simulation to determine the minimum tilt angle and asymmetric cross-sectional shape of the funnel chute. S4: Install the asymmetric curved baffle plate inside the funnel chute and make the asymmetric curved baffle plate rotatably connected to the funnel chute. S5: Install a handwheel screw adjustment device on the back side of the asymmetrical curved baffle, and electrically connect the handwheel screw adjustment device to the PLC controller. The PLC controller drives the screw to extend and retract by controlling the rotation of the handwheel. S6: Establish the correspondence between the extension and retraction of the lead screw and the deflection angle and curvature change of the asymmetric curved baffle. Detect the extension and retraction stroke of the handwheel lead screw adjustment device in step S5 using an encoder, and match and calibrate the encoder feedback value with the preset position parameters in the PLC controller. S7: The PLC controller receives the operating status signal of the upstream belt conveyor and, according to the correspondence calibrated in step S6, controls the handwheel screw adjustment device to drive the asymmetric curved baffle to rotate around the shaft, adjusting the curvature and deflection angle of the asymmetric curved baffle so that the material flows along the surface of the asymmetric curved baffle and falls into the center line position of the downstream belt conveyor.

[0007] The present invention also provides an automatic material flow adjustment system for misalignment of the center lines of upstream and downstream belt conveyors. The system includes: a simulation design module, an asymmetric curved baffle, a funnel chute, a PLC controller, and a handwheel screw adjustment device. The simulation design module is used to obtain the centerline position information of the upstream and downstream belt conveyors and calculate the centerline deviation distance. Based on the obtained centerline deviation distance, combined with the material movement trajectory and discrete element simulation analysis, the initial radius of curvature, initial deflection angle, and asymmetric offset distance of the asymmetric curved baffle are determined, so that the asymmetric curved baffle bends in the opposite direction of the centerline deviation direction. According to the material flow cross-sectional area calculation formula and the minimum passing area requirement, combined with the determined structural parameters of the asymmetric curved baffle, the material flow trajectory is simulated through discrete element simulation to determine the minimum tilt angle and asymmetric cross-sectional shape of the funnel chute. An asymmetric curved baffle is installed inside the funnel chute, and the asymmetric curved baffle is rotatably connected to the funnel chute. A handwheel screw adjustment device is installed on the back side of the asymmetrical curved baffle. The handwheel screw adjustment device is electrically connected to the PLC controller. The PLC controller drives the screw to extend and retract by controlling the rotation of the handwheel. Establish the correspondence between the extension and retraction of the lead screw and the deflection angle and curvature change of the asymmetric curved baffle. Detect the extension and retraction stroke of the handwheel lead screw adjustment device in step S5 using an encoder, and match and calibrate the encoder feedback value with the preset position parameters in the PLC controller. The PLC controller receives the operating status signal of the upstream belt conveyor and, according to the correspondence calibrated in step S6, controls the handwheel screw adjustment device to drive the asymmetric curved baffle to rotate around the shaft, adjusting the curvature and deflection angle of the asymmetric curved baffle so that the material flows along the surface of the asymmetric curved baffle and falls into the centerline position of the downstream belt conveyor.

[0008] According to another embodiment of this application, an electronic device is provided, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the program to implement the steps of the automatic adjustment method for material flow caused by misalignment of the center lines of the upstream and downstream belt conveyors.

[0009] According to another embodiment of this application, a storage medium is also provided, on which a computer program is stored, wherein when the computer program is executed by a processor, the steps of the automatic adjustment method for material flow by misalignment of the center lines of the upstream and downstream belt conveyors are implemented.

[0010] As can be seen from the above technical solutions, the present invention has the following advantages: This invention employs a laser positioning device to precisely locate the center lines of upstream and downstream conveyor belts. Multiple measurements are taken and the average value is used to determine the deviation distance. Combined with material motion trajectory analysis and EDEM discrete element simulation, an asymmetric curved baffle is designed. Its initial radius of curvature, initial deflection angle, and asymmetric offset distance are determined, causing the baffle to bend in the opposite direction of the deviation. This allows the baffle to provide targeted lateral guiding force, effectively counteracting material deviation. After being guided by the baffle, the material points towards the downstream conveyor belt center line, preventing one-sided belt wear, material spillage, and belt derailment, thus ensuring continuous production.

[0011] This invention designs an asymmetric curved baffle. Optimal initial parameters are selected through simulation, and a handwheel and screw adjustment device is installed and electrically connected to a PLC controller. A correspondence is established between the screw extension / retraction and the baffle adjustment parameters. Precise feedback and calibration are achieved through an encoder, allowing for flexible adjustment based on the conveyor's operating status and material flow changes, adapting to different material characteristics and operating condition fluctuations. The minimum cross-sectional area is calculated using the material flow cross-sectional area formula Qm=ρ×A×v, with a minimum passage area reserved at 5-6 times the minimum cross-sectional area. Multiple sets of asymmetric expansion cross-sections are designed based on the baffle parameters, and the optimal tilt angle and cross-sectional shape are selected through EDEM simulation. The effect is that the tilt angle and cross-sectional shape of the funnel chute perfectly match the material flow characteristics and the baffle structure, ensuring smooth material flow within the chute, eliminating material accumulation and solving blockage problems. The asymmetric cross-section further guides the material flow, improving anti-deviation effects. This ensures that material accurately falls onto the downstream conveyor centerline, reducing belt wear, material spillage, and equipment downtime risks, thus improving production continuity. Attached Figure Description

[0012] To more clearly illustrate the technical solution of the present invention, the accompanying drawings used in the description will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0013] Figure 1 Flowchart of a method for automatically adjusting material flow when the center lines of upstream and downstream belt conveyors are misaligned; Figure 2 A schematic diagram of an automatic material flow adjustment system for misalignment of the center lines of upstream and downstream belt conveyors; Figure 3 This is a schematic diagram of the upstream and downstream belt conveyors; Figure 4 This is a schematic diagram of an embodiment of the cooperation between an asymmetrical curved baffle and a funnel chute. Figure 5 This is a schematic diagram of an embodiment of an asymmetric curved baffle. Figure 6 This is a schematic diagram of the side of an asymmetrical curved baffle. Figure 7 A simulation diagram of the misalignment of the center lines of the upstream and downstream belt conveyors, created using 3D modeling software; Figure 8 This is a schematic diagram of an electronic device. Detailed Implementation

[0014] The following describes in detail the automatic material flow adjustment method for misalignment of the centerlines of upstream and downstream belt conveyors involved in this application. Specific details, such as particular system structures and technologies, are presented for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application can also be implemented in other embodiments without these specific details.

[0015] It should be understood that, when used in this specification, the term "comprising" indicates the presence of the described feature, integral, step, operation, element, and / or component, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or collections thereof. The terms "comprising," "including," "having," and variations thereof all mean "including but not limited to," unless otherwise specifically emphasized.

[0016] The terms "one embodiment" or "some embodiments" used in this application mean that one or more embodiments of this application include the specific features, structures, or characteristics described in that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this application do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized.

[0017] 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.

[0018] Please see Figure 1 The diagram shows a flowchart of a method for automatically adjusting material flow by misaligning the center lines of upstream and downstream belt conveyors in a specific embodiment. The method includes: S1: Obtain the centerline position information of the upstream and downstream belt conveyors, calculate the centerline deviation distance, and the centerline deviation distance is greater than 500mm.

[0019] In some embodiments, a laser positioning device is used to locate the center lines of the upstream and downstream belt conveyors respectively. During positioning, the laser positioning device is fixed at both ends of the belt conveyor frame to ensure that the laser beam is parallel to the running direction of the belt conveyor, and the projection points of the center lines of the upstream and downstream belt conveyors on the frame are marked respectively.

[0020] Measure the horizontal distance between the projected centerline points of the upstream and downstream conveyor belts in the direction perpendicular to the belt conveyor's running direction. Repeat the measurement multiple times and take the average of the multiple measurements as the final centerline deviation distance. After the measurement is completed, check the measurement results to ensure that the absolute value of the deviation distance is not less than 500mm. If the measurement result is less than 500mm, recheck the positioning points and measurement method to eliminate measurement errors until the deviation distance requirement is met.

[0021] S2: Based on the centerline deviation distance obtained in step S1, combined with the material movement trajectory and discrete element simulation analysis, determine the initial radius of curvature, initial deflection angle and asymmetric offset distance of the asymmetric curved baffle, so that the asymmetric curved baffle bends in the opposite direction of the centerline deviation direction.

[0022] This invention provides one implementation of step S2, such as... Figure 2 As shown, the specific steps include the following: S21: In the 3D modeling software, establish a right-handed rectangular coordinate system with the width direction of the belt conveyor as the X-axis, the material flow direction as the Y-axis, and the vertical height direction as the Z-axis. Input the centerline deviation distance value obtained in step S1 into the coordinate system origin offset parameter column. Retrieve the bulk density, static friction coefficient, and particle size distribution data of the material under the preset working conditions from the material attribute database to establish the constitutive model of the material particles.

[0023] In some embodiments, the positional relationship of the belt conveyor is transformed into a calculable positional relationship by establishing a spatial coordinate system. The numerical input of the centerline deviation distance provides a reference for the spatial positioning of the subsequent asymmetric curved baffle. The establishment of the material constitutive model enables the simulation calculation to reflect the actual material flow characteristics and ensures the physical authenticity of the simulation boundary conditions.

[0024] The constitutive model of the material particles in this embodiment is a set of models and parameters that describe the contact and mechanical behavior between particles and between particles and geometry in discrete element simulation.

[0025] The discrete element simulation parameters in this embodiment are mainly divided into two categories: density, Poisson's ratio, shear modulus, and material contact parameters, such as coefficient of restitution, static friction coefficient, and rolling friction coefficient. These parameters together constitute the constitutive model.

[0026] Taking coal particles as the constitutive model setting as an example, the Hertz-Mindlin model is selected as the contact model.

[0027] The intrinsic material parameters of the constitutive model are: coal particle density set to 1400 kg / m³, Poisson's ratio set to 0.25, and shear modulus set to 100 MPa. The particle-to-particle contact parameters are: coefficient of restitution set to 0.5 (indicating half the velocity recovery after particle collision), static friction coefficient set to 0.55, and rolling friction coefficient set to 0.15. These two coefficients were obtained through physical experiments on the angle of repose of coal particles on a steel plate, combined with discrete element method (DEM) simulation calibration.

[0028] The contact parameters between the particles and the geometry in the constitutive model are also set to a restitution coefficient of 0.5. The static friction coefficient is set to 0.45, lower than the static friction coefficient between particles, because the steel surface is smoother than the coal particle surface. The rolling friction coefficient is set to 0.10, also lower than the rolling friction coefficient between particles. All these parameters together constitute the constitutive model of coal particles in discrete element simulation. After being input into the simulation software, it can be used to simulate the complete motion process of coal being thrown from the upstream conveyor belt, impacting the asymmetric curved baffle, and sliding down to the downstream conveyor belt.

[0029] S22: Import the 3D solid models of the head roller of the upstream conveyor and the tail roller of the downstream conveyor into the discrete element simulation software. Set the linear velocity of the head roller to the actual running speed of the upstream conveyor and the linear velocity of the tail roller to the actual running speed of the downstream conveyor. Generate a particle group at the outlet of the head roller with a thickness equal to the thickness of the material layer on the conveyor. The horizontal width of the particle group generation area is equal to the width of the conveyor belt. The particle group falls into the funnel chute area under the action of gravity. Monitor the horizontal offset trajectory of the center point of the particle group in the simulation interface.

[0030] In some embodiments, discrete element simulation software is used to numerically reproduce the parabolic trajectory of the material after it leaves the upstream conveyor belt. The speed parameters of the head roller and tail roller are set to ensure the authenticity of the initial velocity conditions of the material. The generation method of the particle group simulates the distribution state of the material layer on the actual conveyor belt. By monitoring the trajectory of the center point of the particle group, the natural landing position of the material under the condition of no baffle plate intervention can be obtained. The deviation of the natural landing position from the center line of the downstream conveyor belt is the offset that needs to be compensated.

[0031] S23: Based on the monitored horizontal offset trajectory of the particle group center point, calculate the horizontal displacement of the particle group when it reaches the theoretical receiving height of the downstream conveyor belt. Vector superimpose the horizontal displacement with the centerline deviation distance from step S1 to obtain the horizontal guiding compensation amount required by the asymmetric curved baffle. Using the origin of the coordinate system as the reference, translate the installation reference surface of the asymmetric curved baffle in the opposite direction of the centerline deviation direction by the horizontal guiding compensation amount multiplied by a reduction factor. The reduction factor is determined by parameter scanning in the discrete element simulation by changing the installation position of the baffle. The value is a coefficient that minimizes the deviation between the material drop point distribution centerline and the downstream conveyor belt centerline. The coefficient value is between 0.6 and 0.8. The translation distance is used as the asymmetric offset distance of the asymmetric curved baffle.

[0032] In some embodiments, the offset of the material's natural parabolic trajectory and the deviation of the belt conveyor centerline are geometrically synthesized using the principle of vector superposition to determine the total compensation amount that the baffle plate needs to bear.

[0033] It should be noted that when the installation reference surface is shifted in the opposite direction, the bending starting point of the baffle plate is set eccentrically relative to the center line of the funnel. The reduction factor is based on the inertia of the material during flight; the baffle plate does not need to completely offset the entire offset, but only needs to provide a partial guiding force to gradually deflect the material trajectory. The optimal reduction factor, determined by discrete element simulation parameter scanning, ensures that the material is guided to the vicinity of the downstream center line.

[0034] S24: Based on the determined asymmetric offset distance d and the working height H of the baffle plate along the material flow direction, calculate the initial installation tilt angle α=arctan(d / H). With the initial installation tilt angle as the tangent direction, establish a spatial curve in the coordinate system that passes through the coordinate point corresponding to the asymmetric offset distance. Calculate the radius of curvature of the spatial curve projected onto the horizontal plane. Use the radius of curvature as the initial radius of curvature of the asymmetric curved baffle plate. Import the surface model corresponding to the initial radius of curvature into the discrete element simulation software. Adjust the deflection angle of the surface model so that the surface normal and the average velocity direction of the particle group center point trajectory are at an angle of 15 degrees to 25 degrees.

[0035] In some embodiments, the asymmetric offset distance and the height of the baffle plate are converted into an installation tilt angle through geometric relationships. The tilt angle determines the overall inclination of the baffle plate relative to the vertical plane. Establishing a spatial curve with this tilt angle as the tangent direction ensures a smooth transition between the baffle plate and the material inflow direction of the upstream conveyor belt. The radius of curvature is calculated based on a horizontal projection rather than a three-dimensional spatial curve, simplifying the template layout process during manufacturing.

[0036] S25: Run material flow simulation in discrete element simulation software, monitor the distribution range of the landing points of the material on the downstream conveyor after being guided by the asymmetric curved baffle, calculate the horizontal distance between the center point of the landing point distribution range and the center line of the downstream conveyor, if the horizontal distance is greater than 5% of the belt bandwidth, adjust the curvature radius value in step S24, increase the curvature radius to make the baffle more gentle or decrease the curvature radius to make the baffle more steep, until the horizontal distance between the center point of the landing point distribution range and the center line of the downstream conveyor is less than or equal to 5% of the belt bandwidth, record the current curvature radius as the final curvature radius, and also record the deflection angle as the final deflection angle, and output the final curvature radius, final deflection angle and the asymmetric offset distance determined in step S23 as the structural parameters of the asymmetric curved baffle.

[0037] This embodiment uses a combination of material trajectory analysis and discrete element simulation to determine the initial structural parameters of the baffle plate, ensuring that the bending direction, curvature, deflection angle, and centerline deviation of the baffle plate are precisely matched.

[0038] S3: Based on the material flow cross-sectional area calculation formula and minimum flow area requirement, combined with the structural parameters of the asymmetric curved baffle determined in step S2, the material flow trajectory is simulated through discrete element simulation to determine the minimum tilt angle and asymmetric cross-sectional shape of the funnel chute. The asymmetric cross-sectional shape gradually expands along the material flow direction.

[0039] This invention provides one implementation of step S3, such as... Figures 3 to 6 As shown, the specific steps include the following: S31. Based on the three-dimensional model and spatial position of the upstream conveyor unloading point, the downstream conveyor receiving point, and the determined asymmetric curved baffle, construct an initial funnel chute shell model in the three-dimensional design software that connects the upstream and downstream and includes the baffle; input the design volumetric flow rate QV and the bulk density ρ of the material, and estimate the initial velocity v of the material when it enters the chute based on the upstream conveyor belt speed and the drop height.

[0040] In some embodiments, within a 3D CAD environment, a pre-designed asymmetric curved baffle model is retrieved. Using the baffle model as a reference, a preliminary shell is drawn that can enclose the baffle model and smoothly connect the upstream discharge port and the downstream outlet. This shell is the initial funnel chute model. At this stage, the funnel chute model primarily defines the central flow channel and basic orientation of the chute.

[0041] Furthermore, the design conveying capacity is obtained from the production process and converted into volumetric flow rate QV. The bulk density ρ is looked up or measured from the material properties table. Based on the upstream conveyor speed and the parabolic trajectory of the material after leaving the conveyor, the average velocity v of the material entering the chute opening is estimated.

[0042] S32. Calculate the minimum cross-sectional area Amin required for the theoretical material flow according to the formula Qm=ρ×QV=ρ×A×v; multiply Amin by a safety factor of 5 to 6 to obtain the minimum flow area Adesign of the funnel chute under the design conditions.

[0043] In some embodiments, the formula Qm = ρ × QV = ρ × A × v is used, where Qm is the mass flow rate. Substituting the known ρ, QV, and estimated v into the formula, the minimum cross-sectional area Amin required for material flow under theoretical minimum conditions can be directly calculated. To ensure absolute reliability and prevent blockages in actual operation, an empirical safety factor is introduced. Based on engineering practice, for the design of such transfer points, the theoretical minimum area Amin is increased by 5 to 6 times to obtain the minimum flow area Adesign.

[0044] S33. In the initial funnel chute shell model, select the section with the narrowest internal space as the control section. According to the formula A = ½ × B × h or A = ¼ B²tanα, where B is the width of the control section, determined by the effective width of the downstream conveyor belt and the installation space for the baffle plate, and h is the effective height of the control section. Using Adesign as a constraint, derive the minimum required height hmin of the control section, or the minimum required inclination angle αmin of the chute wall. Adjust the wall inclination angle of the initial shell model based on hmin or αmin to generate the preliminary chute model.

[0045] In some embodiments, in the initial 3D model of the chute established in step S31, the internal flow channel is analyzed to find the narrowest cross-section in space. The width B of the cross-section is preset and is limited by the effective width of the downstream conveyor belt and the installation width of the internal baffle. If the chute cross-section is designed as rectangular or approximately rectangular, then the area A = width B × effective height h.

[0046] If the design is an inverted isosceles triangle or trapezoid with a bottom inclination angle of α, the area can be expressed as A = ¼B²tanα. Using A ≥ Adesign as a constraint, substituting Adesign and the known width B into the corresponding area formula allows for the reverse calculation of the minimum effective height hmin or the minimum wall inclination angle αmin required for this control section. Based on the calculated hmin or αmin, the relevant dimensional parameters of the initial chute shell are modified in the 3D model, the inclination of the sidewalls is adjusted, and a preliminary chute model is generated.

[0047] S34. In the discrete element method (DEM) simulation software, assemble the preliminary chute model obtained in step S33 with the determined asymmetric curved baffle model. Set the same initial material conditions as in step S22 and run the material flow simulation within the combined model. By observing the flow pattern of the material particle group in the simulation, increase the angle between the sidewall and the horizontal plane on the side where the material flow is deflected by the asymmetric baffle, forming an asymmetric cross-section that gradually expands along the material flow direction. Through iterative simulation, observation, and local modifications, until the simulation shows that the material flows smoothly in the chute without continuous accumulation, the final asymmetric cross-sectional shape and overall tilt angle of the funnel chute are determined.

[0048] In some embodiments, a virtual transfer system is established in discrete element simulation software, including an optimized preliminary model of a baffle and a chute. Material flow simulation is run, and it is observed whether material particles accumulate on one side wall of the preliminary chute model, especially on the side aligned with the guiding force of the baffle, or form a significant low-velocity zone. The overall material flow pattern is also observed to determine if it is biased to one side, resulting in extremely low space utilization on the other side.

[0049] Furthermore, based on these observations, the initial chute model was modified in a targeted manner within the 3D CAD model. On the side where the material flow is dense and prone to collisions and accumulation, the inclination angle of the sidewall was appropriately increased, or the sidewall was designed as an outwardly convex curved surface, thereby providing greater expansion and buffer space for the material flow on that side.

[0050] Correspondingly, on the other side where the material flow is relatively sparse, its expansion angle can be maintained or slightly reduced to control the overall structural dimensions. This iterative process of modifying the shape in the model and then re-simulating and verifying it ultimately yields the final model of the asymmetric funnel chute.

[0051] S4: Install the asymmetric curved baffle plate inside the funnel chute and make the asymmetric curved baffle plate rotatably connected to the funnel chute. The asymmetric curved baffle plate can rotate relative to the funnel chute around a horizontal axis.

[0052] In some embodiments, the funnel chute designed in S3 is fixedly installed on a preset bracket between the upstream and downstream belt conveyors to ensure that the inclination angle of the chute is consistent with the determined minimum inclination angle and the chute outlet is aligned with the feed end of the downstream belt conveyor.

[0053] Furthermore, the asymmetrical curved baffle plate designed in S2 is hoisted into the chute. The height and horizontal position of the baffle plate are adjusted according to the preset installation position to ensure that the surface of the baffle plate is tangent to the natural trajectory of the material flow. A shaft seat is connected to the corresponding position inside the chute, and the rotating shaft is passed through the preset mounting hole on the back side of the baffle plate. The two ends of the rotating shaft are fixed to the shaft seat with bolts to ensure that the rotating shaft is perpendicular to and coaxial with the baffle plate. The baffle plate is rotated for adjustment to ensure that the baffle plate can rotate around the rotating shaft, and the rotation angle range covers the determined initial deflection angle and the range required for subsequent adjustments.

[0054] S5: Install a handwheel and screw adjustment device on the back side of the asymmetrical curved baffle. Connect the handwheel and screw adjustment device to the PLC controller. The handwheel and screw adjustment device includes a handwheel and a screw. The PLC controller drives the screw to extend and retract by controlling the rotation of the handwheel.

[0055] In some embodiments, an adjustment bracket is welded to the back side of the asymmetrical curved baffle to ensure that the bracket position does not affect the rotation of the baffle and the material flow. One end of the screw of the handwheel screw adjustment device is hinged to the adjustment bracket via a pin, and the other end of the screw is fixedly connected to the handwheel. The handwheel is installed on the outside of the chute in a convenient operating position. The drive module of the handwheel screw adjustment device is connected to the PLC controller.

[0056] S6: Establish the correspondence between the extension and retraction of the lead screw and the deflection angle and curvature change of the asymmetric curved baffle. Detect the extension and retraction stroke of the handwheel lead screw adjustment device in step S5 using an encoder, and match and calibrate the encoder feedback value with the preset position parameters in the PLC controller.

[0057] S7: The PLC controller receives the operating status signal of the upstream belt conveyor and, according to the correspondence calibrated in step S6, controls the handwheel screw adjustment device to drive the asymmetric curved baffle to rotate around the shaft, adjusting the curvature and deflection angle of the asymmetric curved baffle so that the material flows along the surface of the asymmetric curved baffle and falls into the center line position of the downstream belt conveyor.

[0058] In some specific embodiments, based on step S6, establishing the correspondence between the lead screw extension / retraction amount and the deflection angle and curvature change of the asymmetric curved baffle, the following will provide a possible embodiment based on a field application scenario, and its specific implementation will be described in a non-limiting manner. Of course, the correspondence can also be calibrated using simulation software in a simulation environment. The specific calibration method is not limited.

[0059] S61. Set a displacement measurement reference point on the exposed part of the lead screw of the handwheel lead screw adjustment device; set a reference surface for measuring angle on the asymmetrical curved baffle plate.

[0060] In some embodiments, the reference point for the extension and retraction of the lead screw is set at a convenient location for observation and measurement at the nut of the lead screw and the end of the push rod fixed to the nut. For the angle of the asymmetrical curved stop plate, a calibration plate can be welded to the back as an angle reference surface for measuring the posture.

[0061] S62. Taking the starting point of the full stroke of the lead screw in the handwheel lead screw adjustment device as the initial position, the lead screw is driven to move towards the endpoint position gradually at fixed displacement intervals using the PLC controller in a jogging mode. Each time the lead screw reaches a predetermined interval position, it is kept stationary, and the deflection angle of the reference surface on the asymmetrical curved baffle relative to the initial installation position is measured using an angle measuring instrument. The corresponding data pairs of the lead screw displacement and the measured baffle deflection angle are recorded simultaneously. The above process is repeated to traverse the full stroke of the lead screw, obtaining the lead screw displacement and baffle angle data pairs.

[0062] In some embodiments, after the reference is set, the lead screw is electrically driven to an extreme position of its mechanical stroke, such as fully retracted or fully extended, where the displacement L=0 and the angle θ=θ0 is defined. The PLC controller sends pulses to control the motor, causing the lead screw to extend by a fixed interval ΔL. After the lead screw stops and stabilizes, the absolute displacement of the reference point on the lead screw relative to its initial position is measured and recorded as L1. The measuring end of the electronic inclinometer is attached to the reference surface of the baffle plate, and the angle value displayed by the inclinometer is read and recorded as θ1. This yields the first set of valid data (L1, θ1).

[0063] Further, continue driving the lead screw to extend by ΔL, and measure and record the second set of data (L2, θ2). Repeat this process until the lead screw reaches another limit stroke position. A list containing N sets of data will be obtained, describing the corresponding continuous change in the angle of the stop plate as the lead screw moves from one end to the other.

[0064] S63. Plot all the lead screw displacement and baffle angle data pairs collected in step S62 on a coordinate system, where the horizontal axis represents the lead screw displacement L and the vertical axis represents the baffle spatial deflection angle θ. Observe the distribution trend of the data points to obtain a continuous function curve θ=f(L) that characterizes the relationship between the lead screw displacement L and the baffle spatial deflection angle θ. Store the continuous function curve in memory to complete the calibration.

[0065] In some embodiments, the data points (Li, θi) can be plotted with the lead screw displacement L as the horizontal axis and the baffle angle θ as the vertical axis. A data fitting tool is used to fit the data points, making the function curve closely approximate all data points. The fitting process calculates the specific values ​​of coefficients a, b, and c. This yields a calculation method f(L) for θ from L. All node data (Li, θi) of the fitted polynomial coefficients are compiled into a table and stored in memory. Control is then implemented based on the calibrated correspondence, ensuring accurate and reliable automatic adjustment.

[0066] In one embodiment of the present invention, based on step S6, the extension and retraction stroke of the handwheel screw adjustment device in step S5 is detected by the encoder, and the feedback value of the encoder is matched and calibrated with the preset position parameters in the PLC controller. The following will provide a possible embodiment and describe its specific implementation in a non-limiting manner.

[0067] S611: Fix the encoder to the end of the lead screw of the handwheel lead screw adjustment device, so that the detection shaft of the encoder is coaxial with the lead screw axis, and connect the encoder to the PLC controller.

[0068] S612: Based on the correspondence between deflection angle and curvature change, the values ​​of the lead screw extension and retraction at all calibrated positions are used as preset position parameters and entered into the PLC controller one by one. Each preset position parameter is assigned an identifier to ensure that the preset parameters are compatible with the lead screw extension and retraction range and the encoder detection range.

[0069] S613: Manually rotate the handwheel to drive the lead screw to extend and retract, stopping sequentially at each lead screw extension position corresponding to each preset position parameter. After the lead screw and encoder are stable, read the real-time extension value fed back by the encoder, compare the feedback value with the corresponding preset position parameter in the PLC controller, and calculate the difference between the two. If the difference exceeds the lead screw extension deviation corresponding to the preset difference, adjust the encoder installation position and detection sensitivity, repeat the comparison operation until the feedback value of all preset positions meets the requirements of the preset parameter difference, save the calibration parameters, and complete the matching calibration.

[0070] In some embodiments, the encoder detects the extension and retraction displacement of the lead screw, converts the mechanical displacement into an electrical signal, and feeds it back to the PLC controller. Through installation and wiring debugging, it can be ensured that the encoder can detect the extension and retraction stroke of the lead screw. In step S612, based on the parameter setting interface of the PLC controller, the lead screw extension and retraction values ​​of all calibrated positions in the correspondence between the lead screw extension and retraction amount and the deflection angle and curvature change of the stop plate established in step S6 can be entered into the PLC controller. Manually rotate the handwheel to drive the lead screw to extend and retract to the extension and retraction amount corresponding to the first preset position parameter. Stop rotating the handwheel and wait for the lead screw extension and retraction state to stabilize and the encoder detection signal to stabilize. Then, read the real-time extension and retraction value fed back by the encoder on the PLC controller interface. By comparing the real-time extension and retraction value fed back by the encoder with the preset position parameter, errors can be found and corrected, so that the encoder feedback value can accurately correspond to the actual lead screw extension and retraction amount, ensuring that the PLC controller can control the adjustment of the stop plate according to the feedback value.

[0071] In one embodiment of the present invention, based on step S7, the PLC controller receives the operating status signal of the upstream belt conveyor and controls the handwheel screw adjustment device to drive the asymmetric curved baffle to rotate around the shaft according to the correspondence calibrated in step S6. The following will give a possible embodiment and describe its specific implementation in a non-limiting manner.

[0072] S711: The PLC controller obtains the inverter frequency value and motor current value from the upstream belt conveyor control system. It divides the frequency value by the inverter's rated frequency and multiplies it by the belt conveyor's rated speed to obtain the linear speed value of the current belt speed. It divides the motor current value by the current transformer ratio to obtain the actual current value. It establishes a piecewise linear correspondence table between current and load rate in the PLC controller. It uses the actual current value as input to look up the table to obtain the load rate and then multiplies it by the belt conveyor's rated conveying capacity to obtain the current mass flow rate value.

[0073] In some embodiments, the belt speed of the conveyor is related to the initial velocity of the material thrown from the head roller. The initial velocity affects the parabolic trajectory of the material in the air and the lateral offset distance of the landing point. By reading the inverter parameters, and taking advantage of the positive correlation between the motor current and the conveyor load, when the belt speed is constant, the current reflects the amount of material on the belt. By estimating the flow rate through the current, material load information can be obtained without adding flow meter hardware, providing working condition input for the real-time adjustment of the baffle.

[0074] S712: The obtained linear velocity value is used as the v value in the formula Qm=ρ×A×v, the mass flow rate value is used as the Qm value, the current material bulk density ρ is retrieved from the material database, the material flow cross-sectional area A is calculated by the formula A=Qm / (ρ×v), the corresponding baffle plate target deflection angle is obtained based on the cross-sectional area, and the target extension amount of the lead screw is obtained.

[0075] In some embodiments, the mass flow rate Qm and linear velocity v calculated in step S711 are called in the PLC program. The bulk density ρ constant of the current conveyed material is read from the data block. Qm is divided by ρ and then by v to obtain the cross-sectional area A of the current material on the belt conveyor, which reflects the thickness of the material layer. In the continuous function relationship curves established in steps S61 to S63, reference values ​​of the deflection angle of the baffle plate corresponding to different cross-sectional areas are stored. The calculated value of A is compared with the reference value of the deflection angle of the baffle plate. If there is an equal value, the corresponding deflection angle is directly used.

[0076] If no equal value exists, find the closest baffle deflection angle reference value A1 and its corresponding angle θ1 that is smaller than A, and the closest baffle deflection angle reference value A2 and its corresponding angle θ2 that is larger than A. Calculate the target deflection angle θ using the linear interpolation formula θ=θ1+(θ2-θ1)×(A-A1) / (A2-A1). Based on the angle θ, obtain the lead screw extension amount, and then obtain the target position coordinates that the lead screw needs to reach.

[0077] S713: The calculated target extension / retraction amount of the lead screw is analyzed with the current actual extension / retraction amount to obtain the stroke deviation value. Based on the stroke deviation value, the PLC controller drives the handwheel to run and reads the current extension / retraction amount checked by the encoder in real time. When the absolute value of the difference between the current value and the target value meets the set allowable error limit, the drive handwheel is stopped.

[0078] In some embodiments, the stroke deviation is based on the distance difference between the current and desired baffle postures. Multiplying the deviation by a pulse conversion coefficient establishes a quantitative conversion relationship between mechanical displacement and electrical pulse count. Directional signals control the motor's forward and reverse rotation, thus determining whether the lead screw extends or retracts. The pulse frequency determines the motor's speed, thereby determining the adjustment speed of the baffle. Real-time comparison control ensures the final position. The entire control process is executed automatically based on the operating status of the upstream conveyor belt, achieving automated material flow regulation.

[0079] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

[0080] The following are embodiments of the automatic material flow adjustment system for misaligned centerlines of upstream and downstream belt conveyors provided in this disclosure. This system and the automatic material flow adjustment method for misaligned centerlines of upstream and downstream belt conveyors in the above embodiments belong to the same inventive concept. For details not described in detail in the embodiments of the automatic material flow adjustment system for misaligned centerlines of upstream and downstream belt conveyors, please refer to the embodiments of the automatic material flow adjustment method for misaligned centerlines of upstream and downstream belt conveyors.

[0081] like Figures 2 to 6 As shown, the system includes: a simulation design module, an asymmetric curved baffle plate 2, a funnel chute 3, a PLC controller, and a handwheel screw adjustment device 5.

[0082] The simulation design module is used to obtain the centerline position information of the upstream conveyor belt 1 and the downstream conveyor belt 4, and calculate the centerline deviation distance A. Figure 3 For example, the centerline deviation distance A is 600mm. Based on the obtained centerline deviation distance, combined with the material movement trajectory and discrete element simulation analysis, the initial radius of curvature, initial deflection angle, and asymmetric offset distance of the asymmetric curved baffle 2 are determined, so that the asymmetric curved baffle 2 bends in the opposite direction of the centerline deviation direction; according to the material flow cross-sectional area calculation formula and the minimum passing area requirement, combined with the determined structural parameters of the asymmetric curved baffle 2, the material flow trajectory is simulated through discrete element simulation to determine the minimum tilt angle and asymmetric cross-sectional shape of the funnel chute 3; the asymmetric curved baffle 2 is installed inside the funnel chute 3, and the asymmetric curved baffle 2 is rotatably connected to the funnel chute 3.

[0083] A handwheel screw adjustment device 5 is installed on the back side of the asymmetrical curved baffle 2. The handwheel screw adjustment device 5 is electrically connected to the PLC controller. The PLC controller drives the screw to extend and retract by controlling the rotation of the handwheel.

[0084] Establish the correspondence between the extension and retraction of the lead screw and the deflection angle and curvature change of the asymmetric curved baffle 2. Detect the extension and retraction stroke of the handwheel lead screw adjustment device 5 in step S5 using an encoder, and match and calibrate the encoder feedback value with the preset position parameters in the PLC controller.

[0085] The PLC controller receives the operating status signal of the upstream belt conveyor 1 and, according to the correspondence calibrated in step S6, controls the handwheel screw adjustment device 5 to drive the asymmetric curved baffle 2 to rotate around the shaft, adjusting the curvature and deflection angle of the asymmetric curved baffle 2 so that the material flows along the surface of the asymmetric curved baffle 2 and falls into the centerline position of the downstream belt conveyor 4.

[0086] like Figure 7 As shown, this application also provides an electronic device, including a display module 103, a memory 102, a processor 101, a communication module 104, and a computer program stored in the memory and executable on the processor 101. When the processor 101 executes the program, it implements the steps of an automatic adjustment method for material flow based on the misalignment of the center lines of the upstream and downstream belt conveyors.

[0087] In embodiments of the present invention, electronic devices include, but are not limited to, laptop computers, desktop computers, workstations, personal digital assistants, servers, blade servers, mainframe computers, and other suitable computers. Electronic devices may also represent various forms of mobile devices, such as personal digital assistants, cellular phones, smartphones, wearable devices, and other similar computing devices. The components shown herein, their connections and relationships, and their functions are merely illustrative and are not intended to limit the implementation of the embodiments described and / or claimed herein.

[0088] In this embodiment, processor 101 may be implemented using at least one of an application-specific integrated circuit, a programmable logic device, a field-programmable gate array, a processor, a controller, a microcontroller, a microprocessor, or an electronic unit designed to perform the functions described herein. In some cases, such an implementation may be implemented within a controller. For software implementation, implementations such as processes or functions may be implemented with separate software modules that allow the performance of at least one function or operation. Software code may be implemented by a software application (or program) written in any suitable programming language, and the software code may be stored in memory and executed by the controller.

[0089] The display module 103 is used to display information input by the user or information provided to the user. The display module 103 may include a display panel, which may be configured in the form of a liquid crystal display, an organic light-emitting diode, or the like.

[0090] The memory 102 can be used to store software programs and various data. The memory 102 may include high-speed random access memory, and may also include non-volatile memory, such as at least one disk storage device, flash memory device, or other volatile solid-state storage device.

[0091] The communication module 104 transmits radio signals to and / or receives radio signals from at least one of a base station, an external terminal, and a server. Such radio signals may include voice call signals, video call signals, or various types of data sent and / or received according to text and / or multimedia messages.

[0092] The present invention also provides a storage medium storing a computer program thereon, wherein the computer program, when executed by a processor, implements the steps of the automatic adjustment method for material flow by misalignment of the center lines of the upstream and downstream belt conveyors.

[0093] The storage medium may be any combination of one or more readable media. A readable medium may be a readable signal medium or a readable storage medium. A readable storage medium may be, for example,, but not limited to, an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any combination thereof. More specific examples of readable storage media include: an electrical connection having one or more wires, a portable disk, a hard disk, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), optical fiber, portable compact disk read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination thereof.

[0094] The storage medium stores a program product capable of implementing the methods described above in this specification. In some possible implementations, various aspects of this disclosure may also be implemented as a program product comprising program code that, when run on a terminal device, causes the terminal device to perform the steps described in the "Exemplary Methods" section of this specification according to various exemplary embodiments of this disclosure.

[0095] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for automatically adjusting material flow by misalignment of the center lines of upstream and downstream belt conveyors, characterized in that the method... include: S1: Obtain the centerline position information of the upstream and downstream belt conveyors and calculate the centerline deviation distance; S2: Based on the centerline deviation distance obtained in step S1, combined with the material movement trajectory and discrete element simulation analysis, determine the initial radius of curvature, initial deflection angle and asymmetric offset distance of the asymmetric curved baffle, so that the asymmetric curved baffle bends in the opposite direction of the centerline deviation direction. S3: Based on the material flow cross-sectional area calculation formula and minimum flow area requirement, combined with the structural parameters of the asymmetric curved baffle determined in step S2, the material flow trajectory is simulated through discrete element simulation to determine the minimum tilt angle and asymmetric cross-sectional shape of the funnel chute. S4: Install the asymmetric curved baffle plate inside the funnel chute and make the asymmetric curved baffle plate rotatably connected to the funnel chute. S5: Install a handwheel screw adjustment device on the back side of the asymmetrical curved baffle, and electrically connect the handwheel screw adjustment device to the PLC controller. The PLC controller drives the screw to extend and retract by controlling the rotation of the handwheel. S6: Establish the correspondence between the extension and retraction of the lead screw and the deflection angle and curvature change of the asymmetric curved baffle. Detect the extension and retraction stroke of the handwheel lead screw adjustment device in step S5 using an encoder, and match and calibrate the encoder feedback value with the preset position parameters in the PLC controller. S7: The PLC controller receives the operating status signal of the upstream belt conveyor and, according to the correspondence calibrated in step S6, controls the handwheel screw adjustment device to drive the asymmetric curved baffle to rotate around the shaft, adjusting the curvature and deflection angle of the asymmetric curved baffle so that the material flows along the surface of the asymmetric curved baffle and falls into the center line position of the downstream belt conveyor.

2. The method for automatically adjusting material flow by misalignment of the center lines of upstream and downstream belt conveyors according to claim 1, characterized in that, In S2, the design of the asymmetric curved baffle plate specifically includes the following steps: S21: Establish a right-handed rectangular coordinate system with the width direction of the belt conveyor, the material flow direction, and the vertical height direction as coordinate axes. Input the centerline deviation distance and retrieve the material bulk density, static friction coefficient, and particle size distribution data to establish a constitutive model of the material particles. S22: Import the upstream and downstream belt conveyor roller models into the discrete element simulation software and set their respective linear velocities. Generate a particle group at the head roller outlet that matches the belt conveyor bandwidth and material layer thickness. Monitor the horizontal offset trajectory of the center point of the particle group when it falls into the funnel chute area under the action of gravity. S23: Calculate the horizontal displacement of the particle group at the theoretical receiving height of the downstream conveyor belt based on the horizontal offset trajectory. Vector superimpose the horizontal displacement with the centerline deviation distance to obtain the horizontal guiding compensation amount. Multiply the translation compensation amount of the installation reference surface of the asymmetric curved baffle in the opposite direction of the centerline deviation direction by the reduction coefficient and use the translation distance as the asymmetric offset distance of the asymmetric curved baffle. S24: Calculate the initial installation tilt angle based on the asymmetric offset distance and the working height of the baffle plate. Establish a spatial curve through the coordinate point corresponding to the asymmetric offset distance with the tilt angle as the tangent direction and calculate the radius of curvature projected on the horizontal plane as the initial radius of curvature. Import the corresponding surface model and adjust its deflection angle so that the surface normal and the average velocity direction of the particle group center point trajectory are at an angle of 15 degrees to 25 degrees. S25: Run material flow simulation and monitor the distribution range of the landing point after the material is guided by the baffle. When the horizontal distance between the center point of the landing point distribution range and the center line of the downstream belt conveyor is greater than 5% of the belt conveyor bandwidth, repeatedly adjust the radius of curvature until the horizontal distance is less than or equal to 5% of the belt conveyor bandwidth. Output the final radius of curvature, the final deflection angle and the asymmetric offset distance as the structural parameters of the asymmetric curved baffle.

3. The method for automatically adjusting material flow by misalignment of the center lines of upstream and downstream belt conveyors according to claim 1, characterized in that, S3 specifically includes the following steps: S31: Construct an initial hopper chute shell model containing an asymmetric curved baffle in 3D design software, and input the material volumetric flow rate, material bulk density, and the initial velocity of the material entering the chute estimated based on the upstream belt speed and drop height. S32: Based on the relationship that mass flow rate equals bulk density multiplied by volume flow rate, which in turn equals bulk density multiplied by cross-sectional area multiplied by velocity, calculate the minimum cross-sectional area, and then multiply the minimum cross-sectional area by a safety factor of 5 to 6 to obtain the minimum flow area of ​​the funnel chute. S33: Select the narrowest section inside the initial shell model as the control section. Utilize the geometric relationship between cross-sectional area and width, height, or tilt angle to solve for the minimum height or minimum tilt angle required for the control section, with the minimum flow area as the constraint. Adjust the shell wall tilt angle accordingly to generate the initial chute model. S34: After assembling the initial model of the chute with the model of the asymmetric curved baffle, perform discrete element simulation. Based on the flow pattern of the material on the baffle guide side in the simulation, gradually increase the angle between the side wall and the horizontal plane to form an asymmetric cross section that gradually expands along the material flow direction until the simulation shows that the material flow is smooth and there is no continuous accumulation, thereby determining the final asymmetric cross section shape and overall tilt angle of the funnel chute.

4. The method for automatically adjusting material flow by misalignment of the center lines of upstream and downstream belt conveyors according to claim 1, characterized in that, In S6, establishing the correspondence between the lead screw extension / retraction amount and the deflection angle and curvature change of the asymmetric curved baffle plate specifically includes the following steps: S61: Set a displacement measurement reference point on the screw of the handwheel screw adjustment device, and set a reference surface for measuring the deflection angle on the asymmetrical curved baffle plate. S62: Drive the lead screw to move gradually from the start of the stroke to the end at fixed displacement intervals. Measure the deflection angle of the reference surface at each interval position and record the corresponding lead screw displacement to form a corresponding data pair of lead screw displacement and deflection angle. S63: Plot the corresponding data of all lead screw displacement and deflection angle as a continuous function curve, and store the continuous function curve in the memory to complete the calibration between the lead screw displacement and the deflection angle of the baffle plate.

5. The method for automatically adjusting material flow by misalignment of the center lines of upstream and downstream belt conveyors according to claim 1, characterized in that, In step S6, the extension and retraction stroke of the handwheel screw adjusting device in step S5 is detected by the encoder, and the encoder feedback value is matched and calibrated with the preset position parameters in the PLC controller. The specific steps include the following: S611: Fix the encoder to the end of the lead screw of the handwheel lead screw adjustment device, so that the detection shaft of the encoder is coaxial with the lead screw axis, and connect the encoder to the PLC controller; S612: Based on the correspondence between the deflection angle and curvature change, the screw extension and retraction values ​​at all calibrated positions are used as preset position parameters, entered into the PLC controller, and an identifier is assigned to each preset position parameter; S613: Manually rotate the handwheel to drive the lead screw to extend and retract, stopping sequentially at each lead screw extension position corresponding to each preset position parameter. After the lead screw and encoder are stable, read the real-time extension value fed back by the encoder, compare the feedback value with the corresponding preset position parameter in the PLC controller, and calculate the difference between the two. If the difference exceeds the lead screw extension deviation corresponding to the preset difference, adjust the encoder installation position and detection sensitivity, repeat the comparison operation until the feedback value of all preset positions meets the requirements of the preset parameter difference, save the calibration parameters, and complete the matching calibration.

6. The method for automatically adjusting material flow by misalignment of the center lines of upstream and downstream belt conveyors according to claim 1, characterized in that, S7 specifically includes the following steps: S711: The PLC controller reads the inverter frequency value and motor current value from the upstream belt conveyor control system, converts the frequency value into the linear velocity value of the current belt speed, and converts the current value into the current mass flow rate value. S712: The PLC controller calculates the required cross-sectional area based on the linear velocity value, mass flow rate value and material bulk density, and then converts the cross-sectional area into the target deflection angle of the asymmetric curved baffle and the corresponding target extension amount of the lead screw. S713: The PLC controller compares the target extension amount of the lead screw with the current actual extension amount fed back by the encoder to obtain the stroke deviation. Based on the stroke deviation, it drives the handwheel to rotate and reads the encoder feedback value in real time until the difference between the current actual extension amount and the target extension amount of the lead screw is less than the allowable error limit, at which point the drive stops.

7. The method for automatically adjusting material flow by misalignment of the center lines of upstream and downstream belt conveyors according to claim 1, characterized in that, The handwheel and lead screw adjustment device includes a handwheel and a lead screw. The PLC controller drives the lead screw to extend or retract by controlling the rotation of the handwheel.

8. An automatic material flow adjustment system for misalignment of the center lines of upstream and downstream belt conveyors, characterized in that, The system is used to implement the automatic material flow adjustment method for misalignment of the center lines of upstream and downstream belt conveyors as described in any one of claims 1 to 7; The system includes: a simulation design module, an asymmetric curved baffle, a funnel chute, a PLC controller, and a handwheel and screw adjustment device; The simulation design module is used to obtain the centerline position information of the upstream and downstream belt conveyors and calculate the centerline deviation distance. Based on the obtained centerline deviation distance, combined with the material movement trajectory and discrete element simulation analysis, the initial radius of curvature, initial deflection angle, and asymmetric offset distance of the asymmetric curved baffle are determined, so that the asymmetric curved baffle bends in the opposite direction of the centerline deviation direction. According to the material flow cross-sectional area calculation formula and the minimum passing area requirement, combined with the determined structural parameters of the asymmetric curved baffle, the material flow trajectory is simulated through discrete element simulation to determine the minimum tilt angle and asymmetric cross-sectional shape of the funnel chute. An asymmetric curved baffle is installed inside the funnel chute, and the asymmetric curved baffle is rotatably connected to the funnel chute. A handwheel screw adjustment device is installed on the back side of the asymmetrical curved baffle. The handwheel screw adjustment device is electrically connected to the PLC controller. The PLC controller drives the screw to extend and retract by controlling the rotation of the handwheel. Establish the correspondence between the extension and retraction of the lead screw and the deflection angle and curvature change of the asymmetric curved baffle. Detect the extension and retraction stroke of the handwheel lead screw adjustment device in step S5 using an encoder, and match and calibrate the encoder feedback value with the preset position parameters in the PLC controller. The PLC controller receives the operating status signal of the upstream belt conveyor and, according to the correspondence calibrated in step S6, controls the handwheel screw adjustment device to drive the asymmetric curved baffle to rotate around the shaft, adjusting the curvature and deflection angle of the asymmetric curved baffle so that the material flows along the surface of the asymmetric curved baffle and falls into the centerline position of the downstream belt conveyor.

9. An electronic device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the program, it implements the steps of the automatic material flow adjustment method for misalignment of the center lines of upstream and downstream belt conveyors as described in any one of claims 1 to 7.

10. A storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by the processor, it implements the steps of the automatic adjustment method for material flow by misalignment of the center lines of the upstream and downstream belt conveyors as described in any one of claims 1 to 7.

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