A belt conveyor idler replacement device and method of use thereof

Abstract

The application discloses a belt conveyor roller replacement device and a use method thereof, and relates to the technical field of conveying equipment. The belt conveyor roller replacement device is designed through a modular quick-release locking mechanism and a first mechanical arm, a second mechanical arm and a self-power supply system in an intelligent replacement robot, so that automatic replacement of the roller under a non-stop state and self-provision of energy in a working process are realized. A maintenance temporary lifting arm at the front end of the first mechanical arm can lift and temporarily support a maintenance temporary roller and a conveying belt, so that the faulty roller is unloaded. The second mechanical arm is combined with the modular quick-release locking mechanism through a clamping mechanism and an unlocking mechanism to complete dismounting and mounting. The whole replacement process does not need manual intervention and does not need to stop the whole machine. Meanwhile, a micro generator integrated in the maintenance temporary roller generates electric energy when the micro generator contacts and rotates with the conveying belt. After treatment, the electric energy is used to charge an internal battery assembly, so that the endurance problem is solved.

Description

Technical Field

[0001] This invention relates to the field of transportation equipment technology, specifically to a belt conveyor idler roller replacement device and its usage method. Background Technology

[0002] Belt conveyors (also known as belt conveyors) are equipment used in bulk material conveying systems in coal preparation plants, mines, ports, etc. Idler rollers are components that support the conveyor belt and materials. They are numerous and are subjected to alternating loads and material impacts over a long period of time, making them vulnerable parts. Currently, idler roller replacement mainly relies on manual operation: maintenance personnel need to carry tools to the site, stop the machine, and manually remove the fixing bolts or clamps of the faulty idler roller using pry bars, wrenches, etc., before moving the new idler roller for installation. Some more advanced scenarios use semi-automatic auxiliary devices, such as mobile trolleys with simple clamping functions or pneumatic lifting devices, which can reduce the burden of manual handling to a certain extent. However, core steps such as unlocking, positioning, and status judgment still need to be completed manually. In addition, to ensure the safety of replacement operations, it is usually necessary to stop the belt conveyor and wait for the replacement to be completed before restarting. Some existing technologies also have idler roller brackets with quick-locking structures that achieve boltless installation through buckles or wedges. However, such structures are mostly independently designed and have not yet been integrated with automated replacement equipment.

[0003] Existing technologies have the following shortcomings in practical applications: Firstly, the replacement speed of idlers is slow, especially for coal preparation plant transport lines with long distances and high-density idler arrangements. A single fault handling often leads to a long downtime of the production line, directly affecting coal preparation capacity. At the same time, on-site personnel face high labor intensity and safety risks. Secondly, existing semi-automatic auxiliary devices lack the ability to detect the rotational resistance and vibration status of idlers in real time. If newly replaced idlers have processing defects or transportation damage (such as bearing jamming or cylinder eccentricity), these defects are only discovered during the initial trial run after installation, requiring a second shutdown for rework, further extending the fault handling cycle. In addition, existing semi-automatic auxiliary devices mostly rely on external power cables or frequent battery pack replacements. In the complex environment of coal preparation plants, cables are easily damaged by material crushing or pulling, and the battery endurance is insufficient to support long-distance, multi-point continuous replacement operations. To address the shortcomings of existing technologies, this invention provides a belt conveyor idler replacement device and its usage method to solve the above problems. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a belt conveyor idler roller replacement device and its usage method, thereby solving the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a conveyor belt roller replacement device, comprising:

[0006] A modular quick-release locking mechanism is installed on the frame of the belt conveyor for detachable installation of the idler frame and idler rollers;

[0007] Intelligent replacement robot, the intelligent replacement robot includes:

[0008] A traveling mechanism for moving along the belt conveyor;

[0009] The lifting platform is installed on the traveling mechanism;

[0010] The first robotic arm is installed on the lifting platform, and a temporary maintenance lifting arm is provided at its front end. The temporary maintenance lifting arm is equipped with a temporary maintenance roller for lifting the conveyor belt of the belt conveyor.

[0011] The second robotic arm is installed on the lifting platform. Its front end is equipped with a clamping mechanism and an unlocking mechanism. The clamping mechanism is used to clamp the roller frame, and the unlocking mechanism is used to cooperate with the modular quick-release locking mechanism to unlock or lock.

[0012] Internal battery components are used to provide power to the intelligent replacement robot;

[0013] A controller is used to control the actions of the intelligent replacement robot;

[0014] The sensor detection component, integrated into the gripping mechanism of the second robotic arm, includes an acceleration sensor and a torque sensor, used to detect the rotational resistance of the roller and its operating status after installation during the replacement process;

[0015] The self-powered system includes a micro generator integrated inside the maintenance temporary idler. The micro generator generates electrical energy when the maintenance temporary idler comes into contact with and is driven to rotate by the running conveyor belt. The electrical energy is then processed to charge the internal battery assembly.

[0016] Preferably, the modular quick-release locking mechanism includes:

[0017] A fixed seat is fixedly installed on the roller frame mounting positions on both sides of the belt conveyor frame. The fixed seat is provided with guide rails and guide grooves.

[0018] Guide sliders are located at both ends of the roller frame and slide in cooperation with the guide rail;

[0019] A linkage lock is provided between the fixed seat and the guide slider, which is used to automatically engage and lock when the roller frame is pushed into the installation position;

[0020] The anti-detachment safety hook is linked to the linkage lock. The anti-detachment safety hook is released only when two unlocking actions in different directions are applied simultaneously. The two unlocking actions in different directions include: pulling the unlocking handle to disengage the anti-detachment safety hook, and pushing the linkage lock to release the lock.

[0021] Preferably, the gripping mechanism of the second robotic arm includes:

[0022] Grippers are used to hold and position features on the roller frame.

[0023] An accelerometer, installed inside the gripper, is used to detect the vibration response of the idler roller when it is driven to rotate.

[0024] A torque sensor, installed inside the gripper, is used to detect the rotational torque applied by the gripper to the idler roller;

[0025] The unlocking push rod, located beside the gripper, is driven by a miniature drive element and is used to dock with the anti-disengagement safety hook and the linkage lock to perform unlocking or locking actions.

[0026] The gripper, unlocking push rod, and micro-drive element are integrated, so that while the gripper is holding the roller frame, the unlocking push rod simultaneously enters the ready position to dock with the locking mechanism.

[0027] Preferably, the controller is configured to perform the following operations:

[0028] During the process of the clamping mechanism gripping the new idler frame and idler and pushing it to the installation position, the gripper is controlled to apply a preset rated rotational torque, and the rotational response curve of the idler is obtained in real time through the acceleration sensor and torque sensor.

[0029] The rotation response curve is compared with a pre-stored qualified response template to determine whether the rotation resistance of the idler roller is qualified.

[0030] If the result is deemed unqualified, the second robotic arm is controlled to move the current idler frame and idler to the designated inspection area, and another new idler frame and idler are retrieved from the spare parts warehouse for re-pre-assembly inspection.

[0031] If the result is deemed satisfactory, the push and locking actions will continue.

[0032] During the temporary lifting arm descent and reset process of the first robotic arm, the vibration and temperature response of the newly replaced idler roller after bearing the conveyor belt load are continuously monitored by the acceleration sensor and torque sensor, and compared with the fault data before replacement to confirm whether the abnormality has been eliminated.

[0033] Preferably, the temporary maintenance idler roller includes:

[0034] The idler roller body has a wear-resistant layer on its surface, which is used to contact the conveyor belt and rotate with the movement of the conveyor belt;

[0035] The rotating shaft is located inside the roller cylinder and its two ends are connected to the bearing seats of the temporary maintenance lifting arm.

[0036] A micro generator is integrated inside the roller drum or at the end of the shaft, and its rotor is linked with the roller drum or shaft.

[0037] The rectifier and voltage regulator module is electrically connected to the micro generator and is used to convert the AC power generated by the micro generator into stable DC power.

[0038] The charging management module is electrically connected to the rectifier and voltage regulator module and the internal battery assembly, respectively, and is used to control the charging current and voltage.

[0039] When the temporary maintenance lifting arm raises the temporary maintenance idler to contact the conveyor belt, the movement of the conveyor belt drives the idler cylinder to rotate, thereby driving the micro generator to generate electricity. The generated electricity is processed by the rectifier and voltage regulator module and the charging management module to charge the internal battery components.

[0040] Preferably, the self-powered system further includes:

[0041] Multiple wireless charging transmitters are respectively set at the preset power supply roller nodes on the frame of the belt conveyor;

[0042] A wireless charging receiver is mounted on the intelligent battery replacement robot and is electrically connected to the internal battery assembly.

[0043] The controller, based on the remaining power status of the internal battery components and the task queue, instructs the staff to dynamically schedule the robot to move to the nearest power supply roller node for wireless charging.

[0044] When the remaining power of the internal battery pack of the robot is lower than the preset threshold and the replacement work point has not been reached during the robot's walking path, the controller controls the temporary maintenance lifting arm to descend, so that the temporary maintenance roller contacts the conveyor belt. The movement of the conveyor belt drives the micro generator to generate electricity to recharge the internal battery pack midway.

[0045] Preferably, the maintenance temporary lifting arm of the first robotic arm is equipped with a pressure sensor to detect the contact pressure between the conveyor belt and the maintenance temporary idler; the controller controls the lifting height of the maintenance temporary lifting arm according to the feedback signal of the pressure sensor, and automatically stops lifting when it detects that the conveyor belt has lost contact with the faulty idler.

[0046] The device is also equipped with a positioning detection sensor to detect the clamping, unlocking, and locking positions. If any position is not detected, the controller will automatically alarm and pause the operation.

[0047] Preferably, the intelligent replacement robot is also equipped with a first storage box and a second storage box. The first storage box is used to store the disassembled faulty idler frame and idler. The second storage box is divided into a spare parts storage area and an inspection area. The inspection area is used to store idler frames and idler that fail the pre-installation inspection.

[0048] Preferably, the controller is communicatively connected to the remote monitoring system of the belt conveyor and is used to receive idler roller fault alarm signals, the fault alarm signals including the position coordinates of the faulty idler roller; the controller automatically plans the robot's travel path according to the received alarm signals and the operator moves to the target position; when the alarm signal contains multiple fault points, the controller automatically sorts and plans according to the severity of the faults and executes the replacement task in sequence.

[0049] This invention also discloses a method for using a conveyor belt roller replacement device, which includes the following steps:

[0050] Step S1: The remote monitoring system monitors the operating status of each idler roller of the belt conveyor in real time. When the vibration, noise or temperature of a certain idler roller exceeds the preset threshold, an alarm signal containing the location coordinates of the faulty idler roller is generated and sent to the controller.

[0051] Step S2: The controller automatically plans the travel path based on the received alarm signal, and the staff controls the intelligent replacement robot to move to the target position, and accurately locates the faulty roller frame through the vision sensor;

[0052] Step S3: The controller controls the first robotic arm to extend the temporary maintenance lifting arm and lift the temporary maintenance idler to below the conveyor belt, so that the conveyor belt rises to a preset height until the pressure sensor detects that the faulty idler frame and the idler are in an unloaded state detached from the conveyor belt; during this process, the movement of the conveyor belt drives the temporary maintenance idler to rotate, and the micro generator integrated inside it starts to generate electricity. The generated electricity is rectified, regulated and charged to charge the internal battery components.

[0053] Step S4: The controller controls the second robotic arm to move to the position of the faulty roller frame, the clamping mechanism clamps the faulty roller frame, and at the same time the unlocking push rod connects with the modular quick-release locking mechanism to perform the unlocking action, the anti-detachment safety hook disengages and the linkage lock is released, and the second robotic arm takes out the faulty roller frame and roller and transfers them to the first storage box.

[0054] Step S5: The controller controls the second robotic arm to pick up the new idler frame and idler from the spare parts storage area of ​​the second storage box. During the gripping process, the gripper applies the rated rotational torque. The acceleration sensor and torque sensor detect the rotational response curve. The controller compares the curve with the qualified response template to determine whether the rotational resistance of the new idler is qualified.

[0055] Step S6: If the result is qualified, the second robotic arm pushes the new idler frame and idler to the installation position. The guide rail and guide slider cooperate to guide the idler, the linkage lock automatically engages, the anti-detachment safety hook returns to its position to complete the locking, and the clamping mechanism releases. If the result is unqualified, the second robotic arm moves the current idler to the inspection area and clamps another new idler, repeating step S5.

[0056] Step S7: The controller controls the temporary lifting arm of the first robotic arm to descend and reset, and the conveyor belt resumes contact with the new idler after replacement. During this process, the acceleration sensor and torque sensor continuously monitor the vibration and temperature response of the new idler. The controller compares the detection data with the fault data before replacement to confirm whether the abnormality has been eliminated.

[0057] Step S8: The controller records the completion information of this replacement operation and uploads it to the remote monitoring system. At the same time, it detects the remaining power of the internal battery components. If it is lower than the preset threshold, it selects the following based on the current working condition: If the robot is in the lifting state of the replacement operation, it continues to use the maintenance temporary idler to rotate to charge the internal battery components; if the robot is in standby or walking state, it controls the robot to move to the nearest power supply idler node for wireless charging, or controls the maintenance temporary lifting arm to descend so that the maintenance temporary idler contacts the conveyor belt for mid-way supplementary charging.

[0058] The technical effects and advantages of this invention are as follows:

[0059] 1. This conveyor belt roller replacement device, through the design of a modular quick-release locking mechanism and the first and second robotic arms and self-powered system in the intelligent replacement robot, achieves automated roller replacement without stopping the machine and energy self-sufficiency during operation. The maintenance temporary lifting arm at the front end of the first robotic arm can lift the maintenance temporary roller and temporarily support the conveyor belt, allowing the faulty roller to be unloaded. The second robotic arm, through the clamping and unlocking mechanisms, cooperates with the modular quick-release locking mechanism to complete the disassembly and installation. The entire replacement process requires no manual intervention and no machine shutdown. At the same time, the micro generator integrated inside the maintenance temporary roller generates electricity when it comes into contact with and rotates with the conveyor belt. After processing, the electricity charges the internal battery pack, solving the problem of the robot's endurance during long-distance operation.

[0060] 2. This conveyor belt roller replacement device, through the acceleration and torque sensors integrated on the second robotic arm clamping mechanism and the pre-installation inspection logic of the controller, automatically determines the rotational resistance and vibration status of the new roller before installation. During the process of clamping the new roller and pushing it to the installation position, the controller controls the gripper to apply the rated rotational torque and collects the rotational response curve in real time, comparing it with the qualified template. Locking and installation are only performed when the result is qualified; if it is unqualified, it is automatically moved to the inspection area and a spare part is re-clamped, thereby avoiding secondary failures caused by installing defective rollers into the equipment and improving the first-time success rate of replacement operations.

[0061] 3. This conveyor roller replacement device, through the modular quick-release locking mechanism with its dual-action unlocking design of the linkage lock and anti-detachment safety hook, combined with the precise drive of the second robotic arm's unlocking push rod, achieves highly reliable rapid locking and anti-accidental detachment. This mechanism requires the simultaneous application of forces in two different directions—pulling the unlocking handle and pushing the linkage lock—to release the roller frame, effectively preventing accidental loosening caused by equipment vibration or robot malfunction. With the status feedback from the positioning detection sensor, the controller can confirm the completion of the unlocking or locking action in real time. If any step is not completed, an automatic alarm will sound and the process will pause, improving the safety of automated replacement operations under the harsh conditions of a coal preparation plant. Attached Figure Description

[0062] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0063] Figure 1 This is a front view of the overall structure of the device of the present invention;

[0064] Figure 2 This is a diagram showing the overall structural architecture of the device of the present invention;

[0065] Figure 3 This is a schematic diagram of the modular quick-release locking mechanism of the present invention;

[0066] Figure 4 This is a diagram of the self-powered system architecture of the present invention;

[0067] Figure 5 This is a pre-installed test logic diagram for the controller of the present invention;

[0068] Figure 6 This is a logic diagram for sorting multiple fault points in the controller of the present invention;

[0069] Figure 7This is a flowchart of the idler roller replacement method of the present invention.

[0070] In the diagram, 10 is the modular quick-release locking mechanism; 20 is the intelligent replacement robot; 21 is the walking mechanism; 22 is the lifting platform; 23 is the first robotic arm; 231 is the temporary maintenance roller; 24 is the second robotic arm; 25 is the internal battery assembly; 26 is the controller; 27 is the sensor detection assembly; and 28 is the self-powered system. Detailed Implementation

[0071] 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.

[0072] This embodiment discloses a belt conveyor idler replacement device, which is particularly suitable for belt conveyors in mining environments such as coal preparation plants. According to the attached... Figure 1 To be continued Figure 7 As shown, the device mainly includes: a modular quick-release locking mechanism 10 installed on the frame of the conveyor belt, and one or more intelligent replacement robots 20.

[0073] Furthermore, the intelligent replacement robot 20 includes the following components:

[0074] Walking mechanism 21: Installed at the bottom of the robot, it can take various forms such as track wheel, tracked, or Mecanum wheel, and is used to move along the preset track or ground path of the belt conveyor. It can have autonomous navigation and obstacle avoidance capabilities, and can also be towed by the staff, and can be designed according to the actual situation.

[0075] Lifting platform 22: Installed above the walking mechanism 21, it adopts a scissor lift, screw lift, or hydraulic structure and is used to adjust the working height of the upper mechanism of the robot according to the target position of the operation.

[0076] First robotic arm 23: Installed on lifting platform 22, with a maintenance temporary lifting arm at its front end. The lifting arm is equipped with a specially designed maintenance temporary idler 231, whose main function is to lift and temporarily support the conveyor belt of the belt conveyor from below when replacing the faulty idler, so that the faulty idler can be unloaded.

[0077] The second robotic arm 24 is also installed on the lifting platform 22. Its front end is integrated with a clamping mechanism and an unlocking mechanism. The clamping mechanism is used to firmly clamp the roller frame, and the unlocking mechanism is specifically designed to interact mechanically or electromagnetically with the modular quick-release locking mechanism 10 to achieve quick unlocking or locking actions.

[0078] Internal battery assembly 25: Serves as the robot's primary energy source, providing power to the walking mechanism 21, robotic arm, controller 26, and all other power-consuming units.

[0079] Controller 26: Can be an industrial-grade PLC or embedded industrial computer, used to receive sensor signals, plan paths, control all action sequences of the robot, and exchange data with the remote monitoring system.

[0080] Sensor detection component 27: integrated on the gripping mechanism of the second robotic arm 24, including at least an acceleration sensor (for detecting vibration) and a torque sensor (for detecting rotational resistance), used to detect the rotational resistance, vibration status and other operating parameters of the new and old idlers in real time during the replacement process.

[0081] Specifically disclosed, as attached Figure 4 As shown in the architecture diagram of the self-powered system 28, the device of this invention is equipped with a unique self-powered system 28 to solve the problem of robot endurance in long-distance, high-concentration dust environments. The self-powered system 28 includes:

[0082] Integrated micro generator: A micro generator is integrated inside the maintenance temporary idler 231, such as on the inner wall of the idler cylinder or at the end of the shaft. Its working principle is as follows: When the maintenance temporary lifting arm lifts the maintenance temporary idler 231 to contact the lower surface of the running conveyor belt, the friction of the conveyor belt drives the idler cylinder to rotate at high speed, which in turn drives the rotor of the micro generator to rotate, thereby generating electrical energy.

[0083] Energy processing module: including rectification and voltage regulation unit and charging management unit. The AC power output by the micro generator is first converted into stable DC power by rectification and voltage regulation unit, and then charged to the internal battery assembly 25 by the charging management unit with appropriate voltage and current.

[0084] Wireless charging assistance system: To further ensure energy supply, multiple wireless charging transmitters are pre-set at specific nodes on the conveyor belt frame (such as every 100 meters or at key turns), and corresponding wireless charging receivers are set on the robot, which can automatically go to the receiving end for non-contact charging when in standby or when the power is low.

[0085] It is particularly important to emphasize that the modular quick-release locking mechanism 10 is the key mechanical interface for enabling rapid replacement of the idler rollers. Its structure includes:

[0086] Fixed seat: It is firmly installed on the roller frame mounting position on both sides of the belt conveyor frame by bolts or welding. The fixed seat is precision machined with horizontal guide rails and positioning guide grooves.

[0087] Guide sliders: Fixed at both ends of the roller frame, their shape matches the guide rail, and are used to achieve precise sliding guidance when the roller frame is pushed in.

[0088] Linkage lock: Located between the fixed base and the guide slider, it adopts a spring reset mechanism. When the roller frame is pushed into the predetermined installation position along the guide rail, the guide slider touches and compresses the linkage lock, causing it to automatically engage and achieve rapid locking.

[0089] Anti-detachment safety hook: Linked with the linkage lock, it forms a double safety lock. The anti-detachment safety hook is designed to require the application of two forces in different directions at the same time to unlock: first, pull up a special unlocking handle to disengage the safety hook from the hook groove; second, push the unlocking paddle of the linkage lock inward to release the main locking force. This dual-action design can effectively prevent accidental loosening caused by vibration or accidental contact.

[0090] Furthermore, the gripping mechanism of the second robotic arm 24 is a highly integrated multi-functional unit, the specific structure of which is as follows:

[0091] Grippers: Parallel pneumatic or electric grippers are used, and their inner contours are adapted to the special clamping and positioning features (such as bosses, grooves or pin holes) on the roller frame to ensure stable clamping and high positioning repeatability.

[0092] Accelerometer: Mounted on the inside of the gripper, used to pick up the three-dimensional vibration signal generated when the gripper drives the new or old idler roller to rotate.

[0093] Torque sensor: Also installed at the contact point between the gripper and the idler frame, it is used to accurately measure the rotational torque applied by the gripper to the idler shaft end, thereby calculating the starting resistance and running resistance of the idler.

[0094] Unlocking push rod: Located on the side of the gripper, driven by a miniature servo cylinder or electromagnet. When the gripper correctly holds the roller frame, the front end of the unlocking push rod is aligned with the unlocking handle and linkage lock tab of the modular quick-release locking mechanism 10. Under the command of the controller 26, it performs precise push and pull actions to complete the unlocking or locking.

[0095] It should be particularly emphasized that the controller 26 of this invention is internally configured with advanced intelligent control logic, as shown in the attached diagram. Figure 5 As shown, its core process includes:

[0096] Pre-installation inspection logic: During the process of clamping the new idler roller and pushing it to the installation position, the controller 26 first controls the gripper to apply a preset standard rated rotational torque (e.g., 5-10 Nm) to drive the idler roller to rotate idling. During this process, the controller 26 obtains the "rotation response curve" of the idler roller in real time through micro acceleration and torque sensors (including the starting peak torque, stable running torque, vibration spectrum, etc.). The controller 26 compares the curve with the "qualified response template" in the pre-stored database to determine whether the rotational resistance and vibration amplitude are within the qualified range.

[0097] Non-conforming handling: If the roller is determined to be non-conforming (e.g., excessive starting resistance or abnormal vibration), the controller 26 will control the second robotic arm 24 to move the problematic roller to the inspection area in the second storage box, and automatically pick up another new roller from the spare parts storage area, repeating the above inspection process.

[0098] Post-installation verification logic: After the temporary lifting arm of the first robotic arm 23 is lowered and reset, allowing the conveyor belt to be fully supported by the newly replaced idler, the controller 26 will again monitor the vibration and temperature response of the new idler under load through sensors, and compare it with the faulty idler data recorded before replacement to automatically confirm whether the abnormal indicators have been eliminated, ensuring maintenance quality.

[0099] Further details are attached. Figure 6 As shown, the controller 26 has the ability to intelligently sort and manage multiple fault points. The controller 26 communicates in real time with the remote monitoring system of the belt conveyor via industrial Ethernet or wireless bridge. When it receives an alarm signal containing the location coordinates of multiple faulty idlers and the severity of the fault (such as vibration amplitude and temperature rise rate), the controller 26 will execute the following algorithm:

[0100] Automatically planning the optimal walking path usually follows the principle of shortest distance.

[0101] Tasks are dynamically prioritized based on the severity of the fault (e.g., abnormal high temperature takes precedence over minor vibration).

[0102] Generate a detailed task queue to guide the robot to execute tasks sequentially, avoiding prolonged downtime of the transport vehicle due to suboptimal paths or sequences.

[0103] Specifically, to ensure operational reliability in the high humidity and high dust environment of a coal preparation plant, this device is also equipped with multiple safety and auxiliary functions:

[0104] Position detection sensor: Photoelectric or inductive proximity switches are integrated in key moving parts such as gripper, unlocking push rod, and lifting arm to detect the position of gripping, unlocking and locking. If any state is not detected within the set time, the controller 26 will immediately issue an audible and visual alarm and suspend all actions, waiting for manual intervention.

[0105] Pressure sensor: A pressure sensor is installed on the maintenance temporary lifting arm of the first robotic arm 23 to provide real-time feedback on the contact pressure between the conveyor belt and the temporary idler. The controller 26 uses this information to control the lifting height in a closed loop, ensuring that the lifting stops just when the faulty idler is unloaded, thus avoiding excessive lifting that could damage the conveyor belt or tensioning system.

[0106] Storage box system: The robot body is equipped with a first storage box and a second storage box. The first storage box is used to temporarily store the disassembled faulty idler rollers. The interior of the second storage box is divided into a "spare parts storage area" and an "inspection area" by a partition, which respectively store qualified spare parts and unqualified spare parts that failed the pre-assembly inspection, thus realizing the orderly management of materials.

[0107] The workflow of the present invention will be described in detail below with reference to specific embodiments:

[0108] Example 1: This example demonstrates the automatic replacement of a single faulty idler roller on the main conveyor belt of a coal preparation plant, triggered by a remote monitoring system. (See attached example.) Figure 1 To be continued Figure 7 The workflow is explained in detail below:

[0109] Fault Triggering and Response: The remote monitoring system of the belt conveyor detects that the vibration of the idler roller numbered "T-103" exceeds the threshold, generates an alarm signal containing its precise coordinates (e.g., at frame K+235 meters, on the left), and sends it to the controller 26 of the intelligent replacement robot 20.

[0110] Autonomous movement and positioning: After receiving the task, the controller 26 plans the shortest path and controls the walking mechanism 21 to automatically travel along the frame track to the target position. The faulty idler frame is accurately located by the onboard vision sensor (such as a 3D camera).

[0111] Temporary lifting and self-charging of conveyor belt: The controller 26 starts the first robotic arm 23, extends the temporary maintenance lifting arm, and precisely lifts the temporary maintenance idler 231 to the conveyor belt below the faulty idler. The controller 26 monitors the feedback from the pressure sensor. When the pressure value reaches the preset threshold (indicating that the conveyor belt has detached from the faulty idler), the lifting stops. During this process, the running conveyor belt drives the temporary maintenance idler 231 to rotate, and the micro generator inside it starts to generate electricity. After rectification and voltage stabilization, it trickle charges the internal battery assembly 25.

[0112] Old idler removal: The second robotic arm 24 moves into position, and the clamping mechanism clamps the clamping and positioning features of the faulty idler frame. At the same time, the unlocking push rod moves forward under the drive of the micro electric cylinder, and performs two actions in sequence: "lifting the unlocking handle" and "pushing the linkage lock inward", so that the anti-detachment safety hook is disengaged and the linkage lock is released. The second robotic arm 24 then smoothly pulls out the faulty idler frame and idler and transfers them to the first storage box.

[0113] New idler pre-installation inspection and installation: The second robotic arm 24 rotates to the second storage box and picks up a new idler frame and idler from the spare parts storage area. In the clamping state, the controller 26 instructs the gripper to apply the rated rotational torque to drive the new idler to rotate and collect its rotation response curve. After comparison with the qualified template, it is determined that the resistance is qualified. Subsequently, the second robotic arm 24 pushes the new idler to the installation position. The guide slider slides in along the fixed seat guide rail, the linkage lock automatically engages, and the anti-disengagement safety hook resets under the action of spring force, completing the locking. The gripper releases and retracts.

[0114] Reset and Verification: The controller 26 instructs the maintenance temporary lifting arm of the first robotic arm 23 to slowly descend and reset, and the conveyor belt falls back naturally to contact the newly replaced idler. During this process, the sensors on the clamping mechanism continuously monitor the vibration and temperature data of the new idler after it is loaded. The controller 26 compares the real-time data with the fault data before replacement to confirm that the vibration and temperature have returned to the normal range.

[0115] Closure and Reporting: The controller 26 records the completion time, replacement location, and new and old idler roller numbers of this replacement operation and uploads them to the remote monitoring system. At the same time, it detects that the internal battery pack 25 has sufficient power and does not need to be recharged, so the robot returns to the standby point.

[0116] Example 2: This example details the workflow of a coal preparation plant where two idler rollers of different severity simultaneously fail on a belt conveyor, and the robot runs out of power during its return trip.

[0117] Multi-fault task reception: Controller 26 received two alarms: Fault A (position +100m, temperature 85℃, severe high temperature, requires emergency handling) and Fault B (position +300m, slight vibration exceeding the standard, general fault).

[0118] Intelligent sorting and execution: According to the principle of priority based on severity, the controller 26 prioritizes fault A as the first task and fault B as the second task, and plans the path: first go to +100m to handle fault A, and execute the same disassembly, pre-installation inspection, installation and verification process as in Example 1, and successfully replace the faulty roller A.

[0119] Heading to the second fault point: After the robot completes the replacement of fault A, it moves to +300m. During the journey, the power monitoring module shows that the remaining power of the internal battery component 25 is less than 30%, which is lower than the preset safe operating threshold (40%).

[0120] Dynamic energy replenishment: The controller 26 assesses the current operating conditions: the transport vehicle is running and there are no wireless charging nodes on the current route. The controller 26 immediately makes a decision and actively controls the first robotic arm 23 to lower the temporary maintenance lifting arm so that the temporary maintenance idler 231 contacts the running conveyor belt. The conveyor belt drives the idler to rotate, driving the micro generator to perform mid-journey supplementary charging. When the power recovers to more than 45%, the controller 26 retracts the temporary maintenance lifting arm and continues to travel.

[0121] Complete the second fault replacement: The robot arrives at +300m, executes the standard replacement procedure, and successfully replaces the faulty roller B. After the operation is completed, the battery level drops to 35% again. The controller 26 guides the robot to the nearest (+280m) preset wireless charging node for fast wireless charging until the battery is fully charged and then returns.

[0122] Example 3: This example details the workflow when a pre-installation inspection during replacement reveals that the new idler roller has unacceptable rotational resistance.

[0123] Perform the standard disassembly procedure: As in Example 1, the robot successfully disassembled the faulty idler and placed it into the first storage box.

[0124] Pre-assembly inspection revealed a defect: the second robotic arm 24 picked up a new idler roller (number N-01) from the spare parts storage area. During the pre-assembly inspection, the controller 26 controlled the gripper to apply the rated torque to drive the N-01 idler roller to rotate. The peak resistance detected by the torque sensor was 30% higher than that of the qualified template. At the same time, the acceleration sensor detected obvious periodic low-frequency vibration.

[0125] Automatic sorting and re-retrieval: The controller 26 determines that roller N-01 is a "non-conforming product". The second robotic arm 24 does not install it, but moves it to the "inspection area" in the second storage box. Then, the robotic arm picks up another new roller (number N-02) from the spare parts storage area.

[0126] Secondary inspection and successful installation: The controller 26 performs the same pre-installation inspection process on the N-02 idler roller. The rotation response curve detected this time is completely matched with the qualified template, and it is judged to be qualified. The second robotic arm 24 then pushes it to the installation position to complete the locking and reset operation.

[0127] Anomaly Report: In the final uploaded work report, controller 26 specifically marked the test data of roller N-01 and the information "Pre-installation inspection failed, and has been transferred to the inspection area". This prompted maintenance personnel to re-verify or return the roller to the warehouse, thereby avoiding the installation of unqualified spare parts on the equipment and improving maintenance quality.

[0128] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A roller replacement device for a conveyor belt, characterized in that, include: A modular quick-release locking mechanism (10) is installed on the frame of the belt conveyor for detachable installation of the idler frame and idler; Intelligent replacement robot (20), the intelligent replacement robot (20) includes: The traveling mechanism (21) is used to move along the belt conveyor; The lifting platform (22) is installed on the traveling mechanism (21); The first robotic arm (23) is installed on the lifting platform (22), and a temporary maintenance lifting arm is provided at its front end. A temporary maintenance roller (231) is installed on the temporary maintenance lifting arm. The second robotic arm (24) is installed on the lifting platform (22). Its front end is provided with a clamping mechanism and an unlocking mechanism. The clamping mechanism is used to clamp the roller frame, and the unlocking mechanism is used to cooperate with the modular quick-release locking mechanism (10) to unlock or lock. An internal battery assembly (25) is used to provide power to the intelligent replacement robot (20); Controller (26) is used to control the actions of the intelligent replacement robot (20); The sensor detection component (27) is integrated on the gripping mechanism of the second robotic arm (24) and includes an acceleration sensor and a torque sensor; The self-powered system (28) includes a micro generator integrated inside the maintenance temporary idler (231) for charging the internal battery assembly (25).

2. The conveyor belt roller replacement device according to claim 1, characterized in that, The modular quick-release locking mechanism (10) includes: A fixed seat is fixedly installed on the roller frame mounting positions on both sides of the belt conveyor frame. The fixed seat is provided with guide rails and guide grooves. Guide sliders are located at both ends of the roller frame and slide in cooperation with the guide rail; A linkage lock is provided between the fixed seat and the guide slider, which is used to automatically engage and lock when the roller frame is pushed into the installation position; The anti-detachment safety hook is linked to the linkage lock. The anti-detachment safety hook is released only when two unlocking actions in different directions are applied simultaneously. The two unlocking actions in different directions include: pulling the unlocking handle to disengage the anti-detachment safety hook, and pushing the linkage lock to release the lock.

3. The conveyor belt roller replacement device according to claim 2, characterized in that, The gripping mechanism of the second robotic arm (24) includes: Grippers are used to hold and position features on the roller frame. An accelerometer, installed inside the gripper, is used to detect the vibration response of the idler roller when it is driven to rotate. A torque sensor, installed inside the gripper, is used to detect the rotational torque applied by the gripper to the idler roller; The unlocking push rod, located beside the gripper, is driven by a miniature drive element and is used to dock with the anti-disengagement safety hook and the linkage lock to perform unlocking or locking actions. The gripper, unlocking push rod, and micro-drive element are integrated, so that while the gripper is holding the roller frame, the unlocking push rod simultaneously enters the ready position to dock with the locking mechanism.

4. The conveyor belt roller replacement device according to claim 3, characterized in that, The controller (26) is configured to perform the following operations: During the process of the clamping mechanism gripping the new idler frame and idler and pushing it to the installation position, the gripper is controlled to apply a preset rated rotational torque, and the rotational response curve of the idler is obtained in real time through the acceleration sensor and torque sensor. The rotation response curve is compared with a pre-stored qualified response template to determine whether the rotation resistance of the idler roller is qualified. If it is determined to be unqualified, the second robotic arm (24) is controlled to move the current idler frame and idler to the designated inspection area, and another new idler frame and idler are picked up from the spare parts warehouse for pre-assembly inspection again; If the result is deemed satisfactory, the push and locking actions will continue. During the maintenance temporary lifting arm descent and reset process of the first robotic arm (23), the vibration and temperature response of the newly replaced idler after bearing the conveyor belt load are continuously monitored by the acceleration sensor and torque sensor, and compared with the fault data before replacement to confirm whether the abnormality has been eliminated.

5. The conveyor belt roller replacement device according to claim 1, characterized in that, The temporary maintenance idler (231) includes: The idler roller body has a wear-resistant layer on its surface, which is used to contact the conveyor belt and rotate with the movement of the conveyor belt; The rotating shaft is located inside the roller cylinder and its two ends are connected to the bearing seats of the temporary maintenance lifting arm. A micro generator is integrated inside the roller drum or at the end of the shaft, and its rotor is linked with the roller drum or shaft. The rectifier and voltage regulator module is electrically connected to the micro generator and is used to convert the AC power generated by the micro generator into stable DC power. The charging management module is electrically connected to the rectifier and voltage regulator module and the internal battery assembly (25) respectively, and is used to control the charging current and voltage; When the maintenance temporary lifting arm lifts the maintenance temporary idler (231) to contact the conveyor belt, the movement of the conveyor belt drives the idler cylinder to rotate, thereby driving the micro generator to generate electricity. The generated electrical energy is processed by the rectifier and voltage regulator module and the charging management module to charge the internal battery assembly (25).

6. The conveyor belt roller replacement device according to claim 5, characterized in that, The self-powered system (28) also includes: Multiple wireless charging transmitters are respectively set at the preset power supply roller nodes on the frame of the belt conveyor; The wireless charging receiver is mounted on the intelligent replacement robot (20) and electrically connected to the internal battery assembly (25); The controller (26) instructs the staff to dynamically schedule the robot to move to the nearest power supply roller node for wireless charging based on the remaining power status of the internal battery assembly (25) and the task queue. When the remaining power of the internal battery assembly (25) of the robot is lower than the preset threshold and the replacement work point has not been reached during the robot's walking path, the controller (26) controls the temporary maintenance lifting arm to descend, so that the temporary maintenance roller (231) contacts the conveyor belt, and the movement of the conveyor belt drives the micro generator to generate electricity to recharge the internal battery assembly (25) midway.

7. The conveyor belt roller replacement device according to claim 4, characterized in that, The maintenance temporary lifting arm of the first robotic arm (23) is equipped with a pressure sensor to detect the contact pressure between the conveyor belt and the maintenance temporary idler (231); the controller (26) controls the lifting height of the maintenance temporary lifting arm according to the feedback signal of the pressure sensor, and automatically stops lifting when it detects that the conveyor belt has lost contact with the faulty idler. The device is also equipped with a positioning detection sensor to detect the clamping, unlocking and locking states. When any state is not detected as being in position, the controller (26) will automatically alarm and suspend the operation.

8. The conveyor belt roller replacement device according to claim 4, characterized in that, The intelligent replacement robot (20) is also equipped with a first storage box and a second storage box. The first storage box is used to store the disassembled faulty idler frame and idler. The second storage box is divided into a spare parts storage area and an inspection area. The inspection area is used to store idler frames and idler that fail the pre-installation inspection.

9. A conveyor belt roller replacement device according to claim 1, characterized in that, The controller (26) is connected to the remote monitoring system of the belt conveyor and is used to receive the fault alarm signal of the idler roller. The fault alarm signal includes the position coordinates of the faulty idler roller. The controller (26) automatically plans the robot's travel path according to the received alarm signal and the staff moves to the target position. When the alarm signal contains multiple fault points, the controller (26) automatically sorts and plans according to the severity of the fault and executes the replacement task in sequence.

10. A method of using a conveyor belt roller changing device, characterized in that, The conveyor belt roller replacement device according to any one of claims 1 to 9 includes the following steps: Step S1: The remote monitoring system monitors the operating status of each idler of the belt conveyor in real time. When the vibration, noise or temperature of a certain idler exceeds the preset threshold, an alarm signal containing the location coordinates of the faulty idler is generated and sent to the controller (26). Step S2: The controller (26) automatically plans the travel path according to the received alarm signal, and the staff controls the intelligent replacement robot (20) to move to the target position and accurately locate the faulty roller frame through the vision sensor; Step S3: The controller (26) controls the first robotic arm (23) to extend the temporary maintenance lifting arm and lift the temporary maintenance idler (231) to the bottom of the conveyor belt, so that the conveyor belt rises to a preset height until the pressure sensor detects that the faulty idler frame and the idler are in an unloaded state detached from the conveyor belt; during this process, the movement of the conveyor belt drives the temporary maintenance idler (231) to rotate, and the micro generator integrated inside it starts to generate electricity. The generated electricity is rectified, regulated and charged to charge the internal battery assembly (25); Step S4: The controller (26) controls the second robotic arm (24) to move to the position of the faulty roller frame, the clamping mechanism clamps the faulty roller frame, and at the same time the unlocking push rod connects with the modular quick-release locking mechanism (10) to perform the unlocking action, the anti-detachment safety hook disengages and the linkage lock is released, and the second robotic arm (24) takes out the faulty roller frame and roller and transfers them to the first storage box. Step S5: The controller (26) controls the second robotic arm (24) to pick up the new idler frame and idler from the spare parts storage area of ​​the second storage box. During the gripping process, the gripper applies the rated rotational torque, and the acceleration sensor and torque sensor detect the rotational response curve. The controller (26) compares the curve with the qualified response template to determine whether the rotational resistance of the new idler is qualified. Step S6: If the result is qualified, the second robotic arm (24) pushes the new idler frame and idler to the installation position. The guide rail and guide slider cooperate to guide, the linkage lock automatically engages, the anti-detachment safety hook returns to its position to complete the locking, and the clamping mechanism is released. If the result is unqualified, the second robotic arm (24) moves the current idler to the inspection area and clamps another new idler to repeat step S5. Step S7: The controller (26) controls the maintenance temporary lifting arm of the first robotic arm (23) to descend and reset, and the conveyor belt resumes contact with the new idler after replacement. During this process, the acceleration sensor and torque sensor continuously monitor the vibration and temperature response of the new idler. The controller (26) compares the detection data with the fault data before replacement to confirm whether the abnormality has been eliminated. Step S8: The controller (26) records the completion information of this replacement operation and uploads it to the remote monitoring system. At the same time, it detects the remaining power of the internal battery component (25). If it is lower than the preset threshold, it selects according to the current working condition: if the robot is in the lifting state of the replacement operation, it continues to use the maintenance temporary roller (231) to rotate to charge the internal battery component (25); if the robot is in standby or walking state, it controls the robot to move to the nearest power supply roller node for wireless charging, or controls the maintenance temporary lifting arm to descend so that the maintenance temporary roller (231) contacts the conveyor belt for mid-way supplementary charging.

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