An automatic cleaning system for a roll of a material

Abstract

This invention relates to the field of conveying machinery technology and discloses an automatic cleaning system for sticky materials on idlers. The system includes an idler with a mounting plate underneath. A photoelectric detection mechanism is mounted on the axial end of the idler and adjacent to its outer circumference via a bracket. A detection beam is emitted axially along the outer surface of the idler. When sticky material is present on the idler surface, the diffuse reflection of the detection light causes a change in light intensity at the receiving end, generating a foreign object detection signal. An angle adjustment mechanism and a waste collection mechanism are fixed on both sides of the mounting plate, respectively. The waste collection mechanism is located below the working path of the cleaning mechanism, and the angle adjustment mechanism is connected to the cleaning mechanism to adjust its angle. After the photoelectric detection mechanism detects the foreign object signal, it triggers a solenoid valve to start the cleaning mechanism to remove the sticky material. This invention integrates automatic detection, directional triggering, precise cleaning, and waste collection of sticky material on idlers, avoiding manual cleaning downtime and improving the operational stability and automation level of the conveying system.

Description

Technical Field

[0001] This invention relates to the field of conveying machinery technology, and more specifically to an automatic system for cleaning material adhering to idlers. Background Technology

[0002] In the gypsum board production process, the primary forming belt rollers and the secondary open roller conveyor are key conveying components, and their operational stability directly affects product quality. Because gypsum raw materials have strong adhesive properties, fine gypsum powder easily adheres to the roller surface and gradually accumulates, leading to a decrease in roller cylindricity and increased running vibration. This, in turn, causes unstable operation of the forming belt and stains on the product surface, severely impacting the appearance quality of the gypsum board and the continuity of production.

[0003] Currently, the issue of material adhesion on idler rollers mainly relies on regular manual inspections and cleaning on production sites. However, manual cleaning is significantly delayed, often only being discovered and addressed after the material has already impacted production. Furthermore, online cleaning poses safety hazards, and frequent shutdowns for cleaning reduce production efficiency. Some companies have attempted to use fixed scraper devices for online cleaning, but due to the lack of a precise detection trigger mechanism, the scraper needs to run continuously, resulting in unnecessary energy consumption and component wear, and making it difficult to effectively remove material in the first instance. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide an automatic cleaning system for cleaning material stuck to idler rollers.

[0005] To solve the above-mentioned technical problems, the present invention specifically provides the following technical solution:

[0006] An automatic cleaning system for removing adhesive residue from idler rollers includes an idler roller with a mounting plate disposed below it. A photoelectric detection mechanism is mounted on the axial end of the idler roller and adjacent to the outer circumferential surface of the idler roller via a bracket on the mounting plate. The detection beam of the photoelectric detection mechanism is emitted along the axial direction of the idler roller and close to the outer circumferential surface of the idler roller.

[0007] When there is material adhering to the surface of the idler roller, the material will diffusely reflect the detection light, causing a change in the light intensity received by the receiver, thereby generating a foreign object detection signal;

[0008] An angle adjustment mechanism and a waste collection mechanism are fixedly installed on both sides of the mounting plate, wherein the waste collection mechanism is located below the working path of the cleaning mechanism; the angle adjustment mechanism is connected to the cleaning mechanism to adjust the angle of the cleaning mechanism.

[0009] When the photoelectric detection mechanism detects a foreign object signal, it triggers the solenoid valve to start the cleaning mechanism to remove the sticky material.

[0010] Furthermore, the angle adjustment mechanism includes a base plate, on which a slide groove is installed. A slider and a screw are installed in the slide groove. The screw is arranged parallel to the slide groove and threadedly engaged with the slider. Rotating the screw can drive the slider to reciprocate linearly along the extension direction of the slide groove. Connecting rods are hinged to both ends of the slider. The other end of the two connecting rods is hinged to one side of a receiving plate. The other side of the receiving plate is hinged to the base plate.

[0011] Rotating the screw drives the slider to move linearly within the groove, which is then converted into the swinging motion of the receiving plate around its hinge point via the connecting rod, thereby adjusting the pitch angle of the cleaning mechanism.

[0012] Furthermore, guide rails are respectively provided on both sides of the bottom surface of the base plate, and two guide rail grooves are provided on the upper surface of the mounting plate along the length direction of the guide rails. The cross-sections of the two guide rail grooves match the cross-sections of the guide rails, and the guide rails can slide within the guide rail grooves.

[0013] Furthermore, at least two bolts are provided on both sides of the base plate, and bolt holes that mate with the bolts are opened on the base plate. Tightening the bolts locks the position of the base plate.

[0014] Furthermore, the cleaning mechanism includes a cylinder, the bottom end of which is connected to the receiving plate, and a scraper connected to the output end of the cylinder, the scraper being tangential to the surface of the idler roller.

[0015] Furthermore, a wear-resistant layer is embedded on the working surface of the scraper that contacts the idler roller, and the scraper is detachably connected to the output end of the cylinder.

[0016] Furthermore, the photoelectric detection mechanism is a diffuse reflection photoelectric switch, which integrates a transmitter and a receiver;

[0017] When there is no material adhering to the surface of the idler roller, the detection beam propagates in a straight line along the surface of the idler roller and cannot be reflected back to the receiving end; when there is material adhering to the surface of the idler roller, the surface of the material will diffusely reflect the detection beam back to the receiving end, causing the light intensity received by the receiving end to change, thereby generating a foreign object detection signal.

[0018] Furthermore, a dust cover is installed on the outside of the transmitter and the receiver. The dust cover is a transparent structure and surrounds the transmitter and the receiver.

[0019] Furthermore, the waste collection mechanism includes a waste trough, in which a push-pull rod is installed and a drain outlet is provided on both sides of the bottom.

[0020] Furthermore, it also includes a control unit, which is electrically connected to the photoelectric detection mechanism and the solenoid valve respectively, for receiving the foreign object detection signal and controlling the opening and closing of the solenoid valve according to the signal.

[0021] Compared with the prior art, the present invention has the following advantages:

[0022] By arranging the photoelectric detection mechanism near the outer circumference of the idler roller, its detection beam is emitted axially close to the roller surface. Combined with the principle of diffuse reflection of the beam by the sticky material, foreign object identification is achieved. At the same time, the cleaning mechanism and the angle adjustment mechanism work together to adjust the scraper pitch angle to adapt to different working conditions. The waste collection mechanism takes over the cleaning of the dropped material to avoid secondary pollution. The whole system realizes the integration of automatic detection, triggering, cleaning and collection of sticky material, improving the stability of idler roller operation and the level of system automation. Attached Figure Description

[0023] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0024] Figure 1 This is an overall structural diagram of the present invention.

[0025] Figure 2 This is a top view of the structure of the present invention.

[0026] Figure 3 This is a side view of the present invention.

[0027] Figure 4 This is a front view structural diagram of the present invention.

[0028] Figure 5 For the present invention Figure 1 Enlarged view of the structure of part A.

[0029] Figure 6 A schematic diagram showing the addition of a protective cover to the photoelectric detection mechanism of the present invention.

[0030] Figure 7 For the present invention Figure 6 Enlarged view of the structure of part B.

[0031] The labels in the diagram represent the following:

[0032] 1. Idler roller; 2. Mounting plate; 3. Cleaning mechanism; 4. Photoelectric detection mechanism; 5. Waste collection mechanism; 6. Angle adjustment mechanism;

[0033] 301. Scraper; 302. Cylinder; 401. Transmitter; 402. Receiver; 403. Dust cover; 501. Waste trough; 502. Push-pull rod; 601. Screw; 602. Slider; 603. Slide groove; 604. Connecting rod; 605. Receiving plate; 606. Guide rail groove; 607. Guide rail; 608. Bolt; 609. Base plate. Detailed Implementation

[0034] 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.

[0035] During gypsum board production, due to the strong adhesive properties of gypsum raw materials, fine gypsum powder easily adheres to the surface of the rollers and gradually accumulates, severely affecting the appearance quality of the gypsum board and the continuity of production. Existing manual cleaning methods are slow and inefficient, while fixed scrapers require continuous operation, resulting in high energy consumption and easy wear of components.

[0036] To address the aforementioned issues, this paper proposes an automatic system for cleaning material adhering to idler rollers.

[0037] Example 1

[0038] Please see Figures 1 to 7 As shown, the device includes an idler roller 1, with a mounting plate 2 positioned below the idler roller 1. A photoelectric detection mechanism 4 is mounted on the axial end of the idler roller 1 and adjacent to its outer circumferential surface via a bracket on the mounting plate 2. The detection beam of the photoelectric detection mechanism 4 is emitted along the axial direction of the idler roller 1, closely adhering to its outer circumferential surface. By placing the detection point at the axial end of the idler roller rather than directly above it, the area covered by the belt is avoided, preventing false detections.

[0039] When there is material adhering to the surface of roller 1, the material will diffusely reflect the detection light, causing a change in the light intensity received by the receiver, thereby generating a foreign object detection signal.

[0040] Furthermore, such as Figure 6 and Figure 7 As shown, the photoelectric detection mechanism 4 is a diffuse reflection photoelectric switch, which integrates a transmitter 401 and a receiver 402. A dust cover 403 is installed outside the transmitter 401 and the receiver 402. The dust cover 403 is a transparent structure and surrounds the transmitter 401 and the receiver 402.

[0041] Specifically, when there is no material adhering to the surface of the idler roller 1, the detection beam propagates in a straight line along the surface of the idler roller and cannot be reflected back to the receiving end 402; when there is material adhering to the surface of the idler roller 1, the surface of the material will diffusely reflect the detection beam back to the receiving end 402, causing the light intensity received by the receiving end 402 to change, thereby generating a foreign object detection signal.

[0042] The rough surface of the adhesive creates diffuse reflection, causing some light to return along its original path or be captured by the receiver. This change in light intensity is the basis for system startup.

[0043] When the photoelectric detection mechanism 4 detects a foreign object signal, it triggers the solenoid valve to start the cleaning mechanism 3 to clean the sticky material. Specifically, when the photoelectric detection mechanism 4 detects a foreign object signal, the control unit immediately outputs a drive command to the solenoid valve. After the solenoid valve is energized, it extends the piston rod of the cylinder 302 outward at a preset speed and thrust, driving the scraper 301 to move quickly from the standby position to the working position, so that the scraper blade edge is in contact with the surface of the idler roller 1.

[0044] To achieve automated control, a control unit is also included. The control unit is electrically connected to the photoelectric detection mechanism 4 and the solenoid valve, respectively, and is used to receive foreign object detection signals and control the opening and closing of the solenoid valve according to the signals.

[0045] The specific electrical connection method can be as follows: the signal output terminal of the photoelectric detection mechanism 4 is connected to the signal input terminal of the control unit via a signal line, and the control signal output terminal of the control unit is connected to the coil of the solenoid valve via a control line. The control unit integrates a signal processing module and a logic judgment module.

[0046] When the receiver 402 of the photoelectric detection mechanism 4 receives the light intensity change signal generated by the diffuse reflection of the adhesive material, it converts it into an electrical signal and sends it to the control unit. Upon receiving the foreign object detection signal, the control unit processes the signal and performs logical judgment. If the presence of adhesive material is confirmed, it outputs a switching control signal to the solenoid valve, energizing or de-energizing the solenoid valve coil. This enables the cylinder 302 to automatically extend and retract, driving the scraper 301 to clean the surface of the roller 1. Through the aforementioned control unit configuration, fully automated control from adhesive detection to the cleaning action is achieved, requiring no manual intervention.

[0047] This embodiment is further analyzed in detail: Because the detection beam is emitted axially close to the outer circumference of the idler roller, the beam path maintains only a very small gap with the roller surface. Under normal circumstances, the beam propagates almost parallel to the smooth roller surface, with very little reflection back to the receiving end. When adhesive material adheres to the roller surface, its protrusion will interrupt the straight-line propagation of the beam. The adhesive material surface usually has an irregular porous or granular microstructure, which produces a strong diffuse reflection effect on the incident light.

[0048] The transmitter 401 uses modulated infrared light, and the receiver 402 has a built-in bandpass filter to demodulate only light signals of the same frequency, thus eliminating ambient light interference. The system sets a light intensity threshold—when the instantaneous light intensity detected by the receiver 402 exceeds three times the standard deviation of the background noise without material, it is considered a valid foreign object signal. This threshold can be adaptively adjusted via a potentiometer or software parameters in the control unit to accommodate differences in the reflectivity of different viscous materials.

[0049] In this embodiment, an angle adjustment mechanism 6 and a waste collection mechanism 5 are fixedly installed on both sides of the mounting plate 2. The waste collection mechanism 5 is located below the working path of the cleaning mechanism 3 and is used to receive the scraped adhesive material to prevent it from scattering and polluting the environment. The angle adjustment mechanism 6 is connected to the cleaning mechanism 3 to adjust the angle of the cleaning mechanism 3. The connection method is usually bolt fastening.

[0050] Among them, such as Figure 5 The angle adjustment mechanism 6 includes a base plate 609, on which a slide groove 603 is installed. A slider 602 and a screw 601 are installed in the slide groove 603. The screw 601 is arranged parallel to the slide groove 603 and is threadedly engaged with the slider 602. Rotating the screw 601 can drive the slider 602 to reciprocate linearly along the extension direction of the slide groove 603. The two ends of the slider 602 are hinged to connecting rods 604. The other end of the two connecting rods 604 is hinged to one side of a receiving plate 605. The other side of the receiving plate 605 is hinged to the base plate.

[0051] The rotating screw 601 drives the slider 602 to move linearly within the groove 603, and then through the connecting rod 604, it is converted into the swing of the receiving plate 605 around its hinge point, thereby adjusting the pitch angle of the cleaning mechanism 3.

[0052] To better adjust the distance to the idler roller 1, guide rails 607 are respectively provided on both sides of the bottom surface of the base plate 609. Two guide rail grooves 606 are provided on the upper surface of the mounting plate 2 along the length of the guide rails 607. The cross-sections of the two guide rail grooves 606 match the cross-sections of the guide rails 607. The guide rails 607 can slide in the guide rail grooves 606. At least two bolts 608 are provided on both sides of the base plate 609, and bolt holes that mate with the bolts 608 are opened on the base plate 609. Tightening the bolts locks the position of the base plate 609.

[0053] In addition, such as Figure 5 The cleaning mechanism 3 includes a cylinder 302, the bottom end of which is connected to a receiving plate 605. A scraper 301 is connected to the output end of the cylinder 302, and the scraper 301 is tangential to the surface of the idler roller 1. Under the thrust of the cylinder, the scraper blade forms a line contact or narrow band contact with the cylindrical surface of the idler roller to generate sufficient shearing force to peel off the sticky material.

[0054] Furthermore, a wear-resistant layer is embedded on the working surface of the scraper 301 that contacts the idler roller 1, and the scraper 301 is detachably connected to the output end of the cylinder 302 for easy and quick replacement. The wear-resistant layer can be made of hard alloy or ceramic material to resist erosion; the detachable connection is usually achieved by bolt fastening or quick-pin structure.

[0055] like Figure 2 The waste collection mechanism 5 includes a waste trough 501, in which a push-pull rod 502 is installed and drain ports are provided on both sides of the bottom. The push-pull rod 502 can prevent sticky materials from bridging and clogging in the trough. Its working principle is to manually move the push-pull rod back and forth in the trough to discharge the material from the drain ports at the bottom.

[0056] In this embodiment, the working steps are as follows:

[0057] Step S1: The photoelectric detection mechanism 4 detects in real time whether there is any sticky material on the surface of the idler roller 1;

[0058] Step S2: When sticky material is detected, the photoelectric detection mechanism 4 generates a foreign object detection signal and sends it to the control unit. The control unit triggers the solenoid valve to start the cleaning mechanism 3.

[0059] Step S3: The cleaning mechanism 3 operates to scrape off the sticky material on the surface of the idler roller 1;

[0060] Step S4: The scraped-off adhesive material falls into the waste collection mechanism 5.

[0061] Once the sticky material is removed, the photoelectric detection mechanism 4 no longer receives diffuse reflection signals. The control unit then cuts off the solenoid valve, the cylinder 302 resets, the scraper 301 disengages from the surface of the idler roller 1, and the system enters standby monitoring mode. This intermittent working mode not only significantly reduces energy consumption and equipment wear, but more importantly, it avoids the ineffective wear caused by the scraper rubbing against the idler roller surface for a long time when there is no sticky material, reflecting the automation of "cleaning on demand".

[0062] In summary, this solution arranges the photoelectric detection mechanism near the outer circumference of the idler roller, allowing its detection beam to be emitted axially close to the roller surface. Combined with the principle of diffuse reflection of the beam by the sticky material, foreign object identification is achieved. At the same time, the cleaning mechanism and angle adjustment mechanism work together to adjust the scraper pitch angle to adapt to different working conditions. The waste collection mechanism takes over the cleaning of the dropped material, avoiding secondary pollution. Compared with the traditional method that relies on manual inspection or timed cleaning, this solution realizes the integration of automatic detection, triggering, cleaning and collection of sticky material, improving the stability of idler roller operation and the level of system automation.

[0063] Example 2

[0064] In this embodiment, the photoelectric detection mechanism 4 uses a through-beam photoelectric switch instead of a diffuse reflection photoelectric switch. The transmitting end and the receiving end are respectively located at both ends of the axial direction of the idler roller 1, and the detection beam also propagates axially along the outer circumferential surface of the idler roller 1. When there is no material adhering to the surface of the idler roller 1, the receiving end can stably receive the beam; when there is material adhering, the beam is blocked or deflected, the light intensity at the receiving end changes, and a foreign object detection signal is generated. Compared with the diffuse reflection type, the through-beam structure has higher anti-interference capability during long-distance detection.

[0065] Example 3

[0066] In this embodiment, the cylinder 302 in the cleaning mechanism 3 is replaced with an electric push rod. Simultaneously, a stepper motor is added to the end of the screw 601 of the angle adjustment mechanism 6, and is uniformly controlled by the control unit.

[0067] When the photoelectric detection mechanism 4 detects slight material adhesion, the control unit first instructs the stepper motor to fine-tune the screw 601, so that the scraper 301 lightly sweeps the surface with a very small contact angle; if the signal is not eliminated, the angle is increased or the electric push rod is activated for strong scraping.

[0068] By replacing the cylinder with an electric push rod and adding a stepper motor to the angle adjustment screw, when the photoelectric detector detects slight material adhesion, the system prioritizes driving the stepper motor to finely adjust the scraper angle for low-damage light sweeping. Only when the signal has not been cleared will the electric push rod be linked to apply constant force for strong scraping. This achieves closed-loop control that dynamically matches the cleaning force according to the thickness of the adhesive material, solving the problem of uneven force caused by air pressure fluctuations. While ensuring efficient decontamination, it minimizes roller wear and operating noise.

[0069] The above embodiments are merely exemplary embodiments of this application and are not intended to limit this application. The scope of protection of this application is defined by the claims. Those skilled in the art can make various modifications or equivalent substitutions to this application within its substance and scope of protection, and such modifications or equivalent substitutions should also be considered to fall within the scope of protection of this application.

Claims

1. An automatic system for cleaning material adhering to idler rollers, characterized in that, The device includes a roller (1), with a mounting plate (2) below the roller (1). The photoelectric detection mechanism (4) is mounted on the axial end of the roller (1) and adjacent to the outer circumferential surface of the roller (1) via a bracket on the mounting plate (2). The detection beam of the photoelectric detection mechanism (4) is emitted along the axial direction of the roller (1) and close to the outer circumferential surface of the roller. When there is sticky material on the surface of the roller (1), the sticky material will diffusely reflect the detection light, causing the light intensity received by the receiving end to change, thereby generating a foreign object detection signal. An angle adjustment mechanism (6) and a waste collection mechanism (5) are fixedly installed on both sides of the mounting plate (2), wherein the waste collection mechanism (5) is located below the working path of the cleaning mechanism (3); the angle adjustment mechanism (6) is connected to the cleaning mechanism (3) to adjust the angle of the cleaning mechanism (3); When the photoelectric detection mechanism (4) detects a foreign object signal, it triggers the solenoid valve to start the cleaning mechanism (3) to clean the sticky material.

2. The automatic cleaning system for removing adhesive residue from idler rollers according to claim 2, characterized in that, The angle adjustment mechanism (6) includes a base plate (609), on which a slide groove (603) is installed. A slider (602) and a screw (601) are installed in the slide groove (603). The screw (601) is arranged parallel to the slide groove (603) and threadedly engaged with the slider (602). Rotating the screw (601) can drive the slider (602) to reciprocate linearly along the extension direction of the slide groove (603). The slider (602) is hinged to two ends with connecting rods (604). The other ends of the two connecting rods (604) are hinged to one side of a receiving plate (605). The other side of the receiving plate (605) is hinged to the base plate. Rotating the screw (601) causes the slider (602) to move linearly within the groove (603), and then through the connecting rod (604) it is converted into the swing of the receiving plate (605) around its hinge point, thereby adjusting the pitch angle of the cleaning mechanism (3).

3. The automatic cleaning system for removing adhesive residue from idler rollers according to claim 1, characterized in that, Guide rails (607) are respectively provided on both sides of the bottom surface of the base plate (609). Two guide rail grooves (606) are provided on the upper surface of the mounting plate (2) along the length direction of the guide rails (607). The cross-sections of the two guide rail grooves (606) match the cross-sections of the guide rails (607). The guide rails (607) can slide in the guide rail grooves (606).

4. The automatic cleaning system for removing adhesive residue from idler rollers according to claim 3, characterized in that, At least two bolts (608) are provided on both sides of the base plate (609), and bolt holes that mate with the bolts (608) are opened on the base plate (609). Tighten the bolts to lock the position of the base plate (609).

5. An automatic cleaning system for removing adhesive residue from idler rollers according to claim 1, characterized in that, The cleaning mechanism (3) includes a cylinder (302), the bottom end of which is connected to the receiving plate (605), and a scraper (301) is connected to the output end of the cylinder (302), the scraper (301) being tangential to the surface of the idler roller (1).

6. An automatic cleaning system for removing adhesive residue from idler rollers according to claim 5, characterized in that, The working surface of the scraper (301) in contact with the idler roller (1) is inlaid with a wear-resistant layer, and the scraper (301) is detachably connected to the output end of the cylinder (302).

7. The automatic cleaning system for removing adhesive residue from idler rollers according to claim 1, characterized in that, The photoelectric detection mechanism (4) is a diffuse reflection photoelectric switch, which integrates a transmitter (401) and a receiver (402). When there is no sticky material on the surface of the idler (1), the detection beam propagates in a straight line along the surface of the idler and cannot be reflected back to the receiver (402); when there is sticky material on the surface of the idler (1), the sticky surface diffusely reflects the detection beam back to the receiver (402), causing the light intensity received by the receiver (402) to change, thereby generating a foreign object detection signal.

8. An automatic cleaning system for removing adhesive residue from idler rollers according to claim 7, characterized in that, A dust cover (403) is installed on the outside of the transmitter (401) and the receiver (402). The dust cover (403) is a transparent structure and surrounds the transmitter (401) and the receiver (402).

9. An automatic cleaning system for removing adhesive residue from idler rollers according to claim 1, characterized in that, The waste collection mechanism (5) includes a waste trough (501), in which a push-pull rod (502) is installed and a drain outlet is provided on both sides of the bottom.

10. An automatic cleaning system for removing adhesive residue from idler rollers according to claim 1, characterized in that, It also includes a control unit, which is electrically connected to the photoelectric detection mechanism (4) and the solenoid valve respectively, and is used to receive the foreign object detection signal and control the opening and closing of the solenoid valve according to the signal.

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