An automatic correction system and method for a conveyor

Abstract

The application discloses a conveyor automatic deviation correction system and method, and relates to the technical field of intelligent control. The system comprises a driving system, a deviation sensing module, an intelligent control module, an adaptive execution module, a working condition adaptation module and a fault early warning module. The deviation sensing module adopts a multi-source fusion structure of laser displacement, infrared profile and tension sensor, and cooperates with a pressure bearing control mechanism to collect displacement deviation, profile deformation and tension data. The intelligent control module fuses a convolutional neural network and an adaptive PID algorithm to accurately identify the deviation type, amplitude and cause. The adaptive execution module realizes the switching of the roller and the adjusting shaft and the coordinated adjustment of the angle and tension through the control mechanism, and the auxiliary component provides buffer damping protection for the belt. The application solves the problems of single deviation correction detection, low precision, poor adaptability, no intelligent early warning and the like in the prior art, has the advantages of strong anti-interference, accurate deviation correction, full working condition adaptation, intelligent operation and maintenance and the like, and is suitable for the stable operation of the conveyor under complex working conditions such as mines, metallurgy and ports.

Description

Technical Field

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

[0002] Belt conveyors, as core equipment for continuous bulk material transport, are widely used in mining, metallurgy, ports, grain processing, and other industrial sectors. Their stable operation directly affects production line efficiency and equipment safety. During long-term continuous operation, conveyor belts are prone to deviation due to factors such as installation accuracy, material eccentricity, frame deformation, temperature changes, and wear and aging. Currently, the mainstream deviation correction methods in the industry still mainly rely on mechanical deviation correction rollers, manual adjustment, and simple photoelectric switch limit control. Some automated solutions use a single sensor and a conventional PID controller to achieve deviation detection and correction, forming the main technical system for conveyor deviation management at present.

[0003] Existing mechanical belt alignment devices rely on a purely mechanical structure for passive response, and cannot dynamically adjust the alignment force and angle according to working conditions such as load, belt speed, and environment. They can only play a limited role in suppressing slight belt deviation. When there is uneven material loading, uneven belt tension, or environmental changes, the alignment accuracy drops rapidly, and problems such as alignment lag, over-adjustment, or adjustment failure are prone to occur. This leads to continuous wear and tear on the conveyor belt edges, damage to idlers, and even shutdown accidents. Moreover, it is impossible to predict and provide graded warnings of potential belt deviation problems in advance.

[0004] Conventional automated deviation correction systems typically use a single type of sensor to collect data, resulting in insufficient detection dimensions and weak anti-interference capabilities. They are prone to signal distortion and malfunctions under harsh conditions such as dust, humidity, and vibration. Furthermore, these systems often use fixed-parameter PID control without integrating intelligent recognition algorithms, making it impossible to accurately determine the type, magnitude, and cause of deviation. This makes them ill-suited for complex conditions such as varying loads, gradients, and long distances. In addition, the systems lack module-level self-diagnosis and component fault protection functions. If sensors or actuators malfunction, deviation correction can easily fail, leading to difficulties in operation and maintenance, high maintenance costs, and an inability to meet the continuous, intelligent, and highly reliable conveying requirements of modern industry.

[0005] Therefore, an automatic conveyor correction system and method are proposed to solve the above problems. Summary of the Invention

[0006] 1. The technical problem to be solved by the present invention

[0007] The purpose of this invention is to provide an automatic conveyor correction system and method to solve the following problems existing in the prior art: (1) This solution addresses the problems of the existing conveyor correction system having a single detection dimension and weak anti-interference capability. It solves the technical defects of signal distortion, frequent malfunctions, and inability to accurately identify the type, magnitude and cause of deviation under harsh working conditions. At the same time, it overcomes the pain points of the traditional mechanical correction system, such as passive response, low correction accuracy, and easy lag or adjustment failure.

[0008] (2) This solution also solves the problems that conventional correction systems cannot adapt to complex working conditions such as variable load and variable slope, as well as the lack of functions for predicting potential deviations, graded early warning and module-level self-diagnosis. It eliminates the technical shortcomings of sensor and actuator abnormalities that easily lead to correction failure, difficult operation and maintenance positioning and high maintenance costs. 2. Technical Solution To achieve the above objectives, the present invention provides the following technical solution: an automatic conveyor correction system, comprising a drive system, a transmission platform mounted on the drive system, a conveyor belt mounted on the transmission platform, and a deviation sensing module, an intelligent control module, an adaptive execution module, a working condition adaptation module, and a fault early warning module respectively mounted on the transmission platform, wherein the deviation sensing module, the adaptive execution module, the working condition adaptation module, and the fault early warning module are all electrically connected to the intelligent control module; The belt misalignment sensing module includes a monitoring module, which has a multi-source sensor fusion structure, including a laser displacement sensor, an infrared profile sensor, and a tension sensor. The belt misalignment sensing module also includes a pressure control mechanism, which is used to collect the displacement deviation and profile deformation data of the conveyor belt edge in real time. The intelligent control module incorporates a convolutional neural network algorithm and an adaptive PID control algorithm, which can fuse and analyze the displacement deviation, profile deformation, and tension distribution data collected by the belt misalignment sensing module to identify the belt misalignment type, misalignment amplitude, and cause. The adaptive execution module is equipped with a control mechanism for adjusting the conveyor belt's deviation; the belt edge buffer adjustment mechanism is used to buffer the force on the belt edge during the deviation correction process, reducing belt wear. The operating condition adaptation module is used to collect data on conveyor operating speed, material load, ambient temperature and humidity, and dust concentration, providing operating condition parameter support for the intelligent control module and realizing dynamic adaptation of the correction strategy. The fault early warning module, based on real-time data from the belt misalignment sensing module and the operating condition adaptation module, uses a trend analysis algorithm to predict potential belt misalignment hazards and system component failures, and issues tiered early warning signals.

[0009] Preferably, the pressure regulating mechanism includes a support plate, with both ends of the support plate fixedly mounted on a transmission table. A drive disk is mounted on the upper surface of the middle part of the support plate, and a U-shaped frame is fixedly mounted in the middle of the drive disk. Connecting plates are rotatably mounted on both ends of the U-shaped frame, with a roller mounted on one end of the connecting plate and an adjusting shaft mounted on the other end of the connecting plate.

[0010] Preferably, auxiliary components are symmetrically installed at both ends of the roller. The auxiliary components include guide plates, and a square limiting groove is opened in the middle of the guide plate. A sliding block is slidably installed in the square limiting groove of the guide plate. A compression spring is symmetrically fixedly installed on the lower surface of the sliding block. The end of the compression spring away from the sliding block is fixedly installed on the guide plate. Both ends of the roller are rotatably installed on the sliding block, and the end of the sliding block away from the roller is rotatably installed on the connecting plate.

[0011] Preferably, the control mechanism includes guide grooves symmetrically formed on the outer surfaces of both ends of the connecting plate. A guide post is slidably installed in the middle of the guide groove. Inner support plates are fixedly installed at both ends of the U-shaped frame. Arc-shaped grooves are symmetrically formed on the inner support plates. An outer sliding plate is slidably installed on the outer surface of the inner support plates. Positioning grooves are symmetrically formed on both sides of the outer sliding plate. The outer surface of the guide post is slidably installed through the arc-shaped groove and the positioning groove, respectively. The diameter of the arc center of the arc-shaped groove is the same as the diameter of the connecting plate. A monitoring module is installed on the upper surface of the inner support plate. One side of the outer sliding plate is L-shaped. A threaded screw is threadedly installed on the L-shaped side of the outer sliding plate. A drive motor is fixedly installed at one end of the threaded screw, and the drive motor is installed in the middle of one end of the inner support plate. A guide rod is symmetrically slidably installed on the L-shaped end of the outer sliding plate, and the guide rod is fixedly installed on the inner support plate.

[0012] Preferably, the fault early warning module includes a hazard classification unit and an early warning output unit. The hazard classification unit classifies belt deviation hazards into three levels: minor, moderate, and severe. Minor hazards correspond to belt deviation of 5-10mm, moderate hazards correspond to belt deviation of 10-20mm, and severe hazards correspond to belt deviation ≥20mm. The early warning output unit adopts both audible and visual alarms and wireless communication alarms, which can transmit early warning signals to the field control terminal and remote monitoring platform, while recording hazard data to provide support for subsequent operation and maintenance.

[0013] Preferably, the intelligent control module also has a built-in self-diagnostic unit, which can perform real-time self-checks on the operating status of the deviation sensing module, adaptive execution module, working condition adaptation module and fault early warning module. When a component fault is detected, the power supply of the corresponding component is automatically cut off, a fault alarm signal is issued, and the fault type and fault location are recorded.

[0014] A method for correcting the deviation of an automatic conveyor belt deviation system includes the following steps: S1: After the system starts, the working condition adaptation module collects working condition data such as conveyor running speed, material load, ambient temperature and humidity and dust concentration, and transmits them to the intelligent control module; the belt deviation sensing module collects the displacement deviation, profile deformation and tension distribution data of the conveyor belt through the monitoring module and the pressure control mechanism, and transmits them to the intelligent control module. S2: The intelligent control module uses a built-in convolutional neural network algorithm and an adaptive PID control algorithm to fuse and analyze the collected working condition data and belt misalignment data, identify the belt misalignment type, misalignment amplitude and misalignment cause, generate targeted correction control commands and transmit them to the adaptive execution module. S3: After receiving the correction control command, the adaptive execution module adjusts the rotation angle of the connecting plate through the control mechanism to switch between the roller and the adjustment shaft, and performs precise correction adjustment of the conveyor belt; at the same time, the belt edge buffer adjustment mechanism buffers the force on the belt edge and reduces belt wear. S4: During the correction process, the fault early warning module uses real-time data from the deviation sensing module and the working condition adaptation module to predict deviation hazards and system component failures through trend analysis algorithms. The hazard classification unit classifies the hazards and issues corresponding warning signals through the early warning output unit. S5: The self-diagnostic unit of the intelligent control module checks the operating status of each module in real time. If a component fault is detected, it automatically cuts off the power supply to the corresponding component, issues a fault alarm signal, and records the fault information. S6: The working condition adaptation module continuously collects working condition data, and the intelligent control module dynamically adapts the correction strategy according to changes in working conditions to ensure the correction effect under different working conditions; when the conveyor belt resumes normal operation, the system maintains real-time monitoring and executes the above steps in a loop.

[0015] Preferably, the specific operating steps of the control mechanism in S3 are as follows: start the drive motor at one end of the inner support plate to drive the threaded screw to rotate, and the threaded screw drives the outer slide plate to slide smoothly under the guidance of the guide rod; when the outer slide plate slides, it drives the guide column to squeeze the guide groove, adjust the rotation angle of the connecting plate, and at the same time realize the tension adjustment between the roller and the conveyor belt, as well as the switching between the roller and the adjustment shaft.

[0016] Preferably, in S3, the auxiliary component uses the cooperation of a sliding block and a compression spring to achieve buffering and damping control of the roller, offsetting the impact of falling materials and vibration of the conveyor belt, buffering and relieving instantaneous impact force, and reducing the tensile wear of the conveyor belt and the stress load on the roller shaft and bearings.

[0017] Preferably, in step S3, the roller angle is finely adjusted by the control mechanism according to the on-site conveying slope requirements to adapt to different conveying conditions such as horizontal, slightly uphill, and slightly downhill. When the conveyor belt becomes loose or deformed after long-term use, the roller angle is finely adjusted to restore the conveyor belt to normal operation.

[0018] Compared with the prior art, the automatic conveyor correction system and method provided by the present invention have the following advantages: (1) This solution solves the problem of multi-source fusion sensing, and fundamentally solves the problems of inaccurate detection and poor anti-interference. This solution employs a multi-source sensor fusion structure combining laser displacement, infrared contour, and tension sensors, working in conjunction with a pressure control mechanism to simultaneously acquire three-dimensional data on displacement deviation, contour deformation, and tension distribution, replacing the traditional single-sensor detection method. It maintains signal stability under harsh conditions such as dust, humidity, and strong vibration, avoiding signal distortion and malfunctions, achieving full-dimensional, high-precision real-time perception of deviation status, and overcoming the core shortcomings of existing technologies such as insufficient detection dimensions and weak anti-interference capabilities.

[0019] (2) This scheme sets up intelligent algorithm collaborative control to achieve accurate identification and dynamic correction; The system incorporates a dual algorithm of convolutional neural network and adaptive PID control, which integrates and analyzes multi-source data to accurately identify the type, magnitude, and cause of belt misalignment, unlike traditional fixed-parameter PID control. It can automatically adjust the correction force and angle based on changes in load, belt speed, and gradient, eliminating problems such as correction lag, over-adjustment, or failure. It is adaptable to complex operating conditions with varying loads, long distances, and varying gradients, solving the problems of traditional systems' inability to intelligently determine belt misalignment and low correction accuracy.

[0020] (3) This scheme adopts an adaptive mechanical structure design to balance adjustment accuracy and equipment protection; The adaptive execution module employs a control mechanism that combines a screw rod, guide column, and arc groove, along with a switchable structure for rollers and adjusting shafts, to achieve coordinated adjustment of conveyor belt angle and tension. Simultaneously, auxiliary components provide buffering and damping through sliding blocks and compression springs to counteract material impact and running vibration, buffering the force on the belt edges, significantly reducing conveyor belt wear and idler jamming / breakage. This balances correction accuracy with equipment lifespan, outperforming traditional purely mechanical passive correction structures.

[0021] (4) This solution is dynamically adaptable to all working conditions, covering multiple scenarios and the entire life cycle of use; The operating condition adaptation module collects real-time data on belt speed, load, temperature, humidity, and dust concentration, providing parameter support for the intelligent control module and enabling automatic dynamic adaptation of the correction strategy according to the operating conditions. It can flexibly adapt to conveyor slopes such as horizontal, slightly uphill, and slightly downhill. When the conveyor belt becomes loose or deformed, only a slight adjustment of the roller angle is needed to restore operation, without the need to replace parts, reducing maintenance costs and solving the problems of traditional devices being unable to adapt to changing operating conditions and having poor versatility.

[0022] (5) Hierarchical early warning and self-diagnosis to achieve proactive protection and convenient operation and maintenance; The fault early warning module uses trend analysis algorithms to predict potential deviations in advance, classifying them into three levels: 5-10mm, 10-20mm, and ≥20mm. It employs a dual alarm system combining sound and light, along with wireless communication, simultaneously uploading data to the terminal and platform. The intelligent control module has a built-in self-diagnostic unit that checks the status of each module in real time. In case of component failure, it automatically cuts off power and alarms to pinpoint the location, shifting from "passive maintenance" to "proactive early warning," reducing downtime risks, simplifying maintenance processes, and filling the functional gaps of traditional systems lacking early warning and self-diagnostic capabilities. Attached Figure Description

[0023] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is an auxiliary schematic diagram of the three-dimensional structure of the present invention; Figure 3 This is a schematic diagram of the structural connection relationship of the pressure control mechanism of the present invention; Figure 4 For the present invention Figure 3 Enlarged view of point A in the middle; Figure 5 This is a schematic diagram of the connection relationship of the control mechanism structure of the present invention; Figure 6 For the present invention Figure 5 Enlarged view of section B in the middle.

[0024] In the picture: 1. Drive system; 11. Conveyor belt; 12. Transmission table; 2. Pressure regulating mechanism; 21. Support plate; 22. Drive disc; 23. U-shaped frame; 25. Connecting plate; 26. Roller; 27. Adjusting shaft; 3. Auxiliary components; 31. Guide plate; 32. Sliding block; 33. Compression spring; 4. Control mechanism; 41. Guide groove; 42. Guide column; 43. Inner support plate; 44. Arc groove; 45. Outer sliding plate; 46. Positioning groove; 47. Guide rod; 48. Threaded screw; 49. Monitoring module. Detailed Implementation

[0025] 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0026] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0027] Example 1, please refer to Figures 1 to 6 As shown: To address the problems mentioned in the technical solutions, this application provides an automatic conveyor correction system including a drive system 1, a transmission platform 12 mounted on the drive system 1, and a conveyor belt 11 laid on the transmission platform 12. The transmission platform 12 is also equipped with a deviation sensing module, an intelligent control module, an adaptive execution module, a working condition adaptation module, and a fault early warning module. The deviation sensing module, adaptive execution module, working condition adaptation module, and fault early warning module are all electrically connected to the intelligent control module, forming a complete closed-loop control system.

[0028] The misalignment sensing module has a built-in monitoring module 49, which adopts a multi-source sensor fusion structure, integrating a laser displacement sensor, an infrared contour sensor, and a tension sensor to achieve multi-dimensional data acquisition. At the same time, the misalignment sensing module is also equipped with a pressure control mechanism 2, which is used to collect the displacement deviation and contour deformation data of the edge of the conveyor belt 11 in real time, providing accurate data support for subsequent correction control.

[0029] The intelligent control module incorporates a convolutional neural network algorithm and an adaptive PID control algorithm. It can fuse and analyze the displacement deviation, profile deformation, and tension distribution data collected by the belt misalignment sensing module, accurately identify the belt misalignment type, misalignment amplitude, and cause, and output targeted correction control commands to the adaptive execution module.

[0030] The adaptive execution module is equipped with a control mechanism 4, which is mainly used to precisely adjust the conveyor belt 11. At the same time, a belt edge buffer adjustment mechanism is also provided to buffer the force on the belt edge during the correction process, effectively reduce belt wear, and extend the service life of the conveyor belt.

[0031] The operating condition adaptation module is responsible for collecting key operating condition data such as conveyor operating speed, material load, ambient temperature and humidity, and dust concentration. It provides comprehensive operating condition parameter support for the intelligent control module, realizes dynamic adaptation of the correction strategy, and ensures that the system can maintain good correction effect under different operating conditions.

[0032] The fault early warning module, based on real-time data collected by the belt misalignment sensing module and the working condition adaptation module, uses trend analysis algorithms to predict potential belt misalignment hazards and system component failures, and issues graded early warning signals to avoid equipment damage and production safety risks in advance.

[0033] The pressure regulating mechanism 2 specifically includes a support plate 21, with both ends of the support plate 21 fixedly installed on the transmission table 12. A drive disc 22 is mounted on the upper surface of the middle part of the support plate 21. A U-shaped frame 23 is fixedly installed in the middle of the drive disc 22. Connecting plates 25 are rotatably connected to both ends of the U-shaped frame 23. A roller 26 is installed at one end of the connecting plate 25, and an adjusting shaft 27 is installed at the other end.

[0034] In operation, after the drive disc 22 is started, it can drive the U-shaped frame 23 to rotate and adjust on the pallet 21. The auxiliary component 3 and the control mechanism 4 are respectively set at both ends of the U-shaped frame 23. By rotating and adjusting the U-shaped frame 23, the orientation of the roller 26 and the adjusting shaft 27 can be flexibly adjusted to adapt to different transmission requirements. When the monitoring module 49 detects that the conveyor belt 11 is deviated, the control mechanism 4 will automatically switch the roller 26 and the adjusting shaft 27. After the adjusting shaft 27 contacts the conveyor belt 11, the arc-shaped rubber strip on its surface can assist the adjusting shaft 27 in accurately controlling the deviation of the conveyor belt 11 when it rotates. This solution can flexibly adjust the roller tilt angle through the pressure control mechanism 2, correct the conveyor belt deviation trend in real time, and avoid problems such as belt deviation, edge wear, and side jamming from the root, adapting to various conveying conditions of long and short distances.

[0035] Auxiliary components 3 are symmetrically installed at both ends of the roller 26. The auxiliary components 3 include guide plates 31. A square limiting groove is opened in the middle of the guide plate 31. A sliding block 32 is slidably installed in the square limiting groove. A compression spring 33 is symmetrically fixedly installed on the lower surface of the sliding block 32. The end of the compression spring 33 away from the sliding block 32 is fixed to the guide plate 31. Both ends of the roller 26 are rotatably installed on the sliding block 32. The end of the sliding block 32 away from the roller 26 is rotatably connected to the connecting plate 25.

[0036] This solution uses auxiliary component 3 to achieve buffering and damping control of roller 26, which can effectively offset the impact of falling materials and vibration of conveyor belt operation, reduce hard collisions between roller and frame, significantly reduce equipment operating noise, and improve the working environment. Furthermore, through the cooperation of sliding block 32 and compression spring 33, instantaneous impact force can be buffered and removed, reducing tensile wear of conveyor belt, reducing the stress load on roller shaft and bearing, reducing failures such as roller jamming, deformation, and breakage, reducing the frequency of parts replacement, and saving operation and maintenance costs.

[0037] The control mechanism 4 includes a guide groove 41, which is symmetrically opened on the outer surfaces of both ends of the connecting plate 25. A guide post 42 is slidably installed in the middle of the guide groove 41. An inner support plate 43 is fixedly installed at both ends of the U-shaped frame 23. An arc-shaped groove 44 is symmetrically opened on the inner support plate 43. An outer sliding plate 45 is slidably installed on the outer surface of the inner support plate 43. A positioning groove 46 is symmetrically opened on both sides of the outer sliding plate 45. The outer surface of the guide post 42 is slidably installed through the arc-shaped groove 44 and the positioning groove 46 to achieve guidance and limiting.

[0038] The diameter of the arc center of the arc groove 44 is the same as the diameter of the connecting plate 25 to ensure the smooth rotation of the connecting plate 25. A monitoring module 49 is installed on the upper surface of the inner support plate 43. One side of the outer slide plate 45 is designed with an L-shaped structure. A threaded screw 48 is threaded on the L-shaped side. A drive motor is fixedly installed at one end of the threaded screw 48 and the drive motor is assembled in the middle of one end of the inner support plate 43. A guide rod 47 is symmetrically slidably installed on the L-shaped end of the outer slide plate 45. The guide rod 47 is fixedly installed on the inner support plate 43 to provide guidance and positioning for the sliding of the outer slide plate 45.

[0039] In this plan, the specific working process of the control mechanism 4 is as follows: Figure 4 and Figure 6 As shown, starting the micro motor at one end of the inner support plate 43 drives the threaded screw 48 to rotate. When the threaded screw 48 rotates, it drives the outer sliding plate 45, which is threaded to it, to slide smoothly under the guidance of the guide rod 47. When the outer sliding plate 45 slides, it drives the guide column 42 to press against the guide groove 41, thereby adjusting the rotation angle of the connecting plate 25. At the same time, it realizes the tension adjustment between the roller 26 and the conveyor belt 11, as well as the switching between the roller 26 and the adjusting shaft 27. When the monitoring module 49 detects that the conveyor belt 11 has deviated, the system can realize the fine adjustment of the conveyor belt 11 through automated monitoring and control. At the same time, this solution can fine-tune the angle of the roller 26 according to the actual needs of the site, adapting to different conveying slopes such as horizontal, slightly uphill, and slightly downhill, making it more versatile and eliminating the need to replace the entire set of rollers. When the belt becomes loose or deformed after long-term use, only the angle of the roller 26 needs to be finely adjusted to restore the conveyor belt to normal operation, reducing the frequency of parts replacement and further reducing maintenance costs. In summary, this solution achieves integrated monitoring and automated control. By switching between roller 26 and adjusting shaft 27, the angle of conveyor belt 11 is adjusted and the offset is corrected, forming an intelligent correction system with multi-functional dynamic adjustment capabilities.

[0040] The fault early warning module includes a hazard classification unit and an early warning output unit. The hazard classification unit divides belt deviation hazards into three levels: minor, moderate, and severe. The specific classification standards are: minor hazards correspond to belt deviation of 5-10mm, moderate hazards correspond to belt deviation of 10-20mm, and severe hazards correspond to belt deviation ≥20mm. The early warning output unit adopts dual methods of audible and visual alarms and wireless communication alarms, which can simultaneously transmit early warning signals to the field control terminal and remote monitoring platform, and automatically record hazard data to provide reliable data support for subsequent operation and maintenance.

[0041] The intelligent control module also has a built-in self-diagnostic unit, which can perform real-time self-checks on the operating status of the deviation sensing module, adaptive execution module, working condition adaptation module and fault early warning module. When a component fault is detected, it can automatically cut off the power supply to the corresponding component, issue a fault alarm signal, and record the fault type and location in detail, so that staff can quickly locate the fault and handle it in a timely manner, ensuring the stable operation of the system.

[0042] Furthermore, this solution proposes a correction method for an automatic conveyor correction system, including the following steps: S1: After the system starts, the working condition adaptation module collects working condition data such as conveyor running speed, material load, ambient temperature and humidity and dust concentration, and transmits them to the intelligent control module; the deviation sensing module collects the displacement deviation, profile deformation and tension distribution data of the conveyor belt 11 through the monitoring module 49 and the pressure control mechanism 2, and transmits them to the intelligent control module. S2: The intelligent control module uses a built-in convolutional neural network algorithm and an adaptive PID control algorithm to fuse and analyze the collected working condition data and belt misalignment data, identify the belt misalignment type, misalignment amplitude and misalignment cause, generate targeted correction control commands and transmit them to the adaptive execution module. S3: After receiving the correction control command, the adaptive execution module adjusts the rotation angle of the connecting plate 25 through the control mechanism 4 to switch between the roller 26 and the adjustment shaft 27, and performs precise correction adjustment on the conveyor belt 11; at the same time, the belt edge buffer adjustment mechanism buffers the force on the belt edge and reduces belt wear. S4: During the correction process, the fault early warning module uses real-time data from the deviation sensing module and the working condition adaptation module to predict deviation hazards and system component failures through trend analysis algorithms. The hazard classification unit classifies the hazards and issues corresponding warning signals through the early warning output unit. S5: The self-diagnostic unit of the intelligent control module checks the operating status of each module in real time. If a component fault is detected, it automatically cuts off the power supply to the corresponding component, issues a fault alarm signal, and records the fault information. S6: The working condition adaptation module continuously collects working condition data, and the intelligent control module dynamically adapts the correction strategy according to the changes in working conditions to ensure the correction effect under different working conditions; when the conveyor belt 11 resumes normal operation, the system maintains real-time monitoring and executes the above steps in a loop.

[0043] The specific operating steps of the control mechanism 4 in S3 are as follows: start the drive motor at one end of the inner support plate 43 to drive the threaded screw 48 to rotate. The threaded screw 48 drives the outer slide plate 45 to slide smoothly under the guidance of the guide rod 47. When the outer slide plate 45 slides, it drives the guide column 42 to squeeze the guide groove 41, adjusts the rotation angle of the connecting plate 25, and simultaneously realizes the tension adjustment between the roller 26 and the conveyor belt 11, as well as the switching between the roller 26 and the adjusting shaft 27.

[0044] In S3, the auxiliary component 3, through the cooperation of the sliding block 32 and the compression spring 33, achieves buffering and damping control of the roller 26, offsets the impact of falling materials and the vibration of the conveyor belt, buffers and removes instantaneous impact force, and reduces the tensile wear of the conveyor belt and the stress load on the roller shaft and bearing.

[0045] According to the on-site conveying slope requirements, the roller 26 angle is finely adjusted by the control mechanism 4 to adapt to different conveying conditions such as horizontal, slightly uphill, and slightly downhill. When the conveyor belt 11 becomes loose or deformed after long-term use, the roller 26 angle is finely adjusted to restore the conveyor belt 11 to normal operating condition.

[0046] Example 2: Based on Embodiment 1, but with some differences, the automatic conveyor correction system and method proposed in this invention are described below with reference to specific examples and accompanying drawings. The specific content is as follows: This embodiment selects a long-distance heavy-duty raw coal conveyor in the mining industry as the application scenario. The equipment is 120m long, 1000mm wide, and has a belt speed of 2.5m / s. It operates continuously for 24 hours a day. The site conditions include high dust concentration, large load fluctuations, and a 3° slightly uphill conveying gradient. Problems such as belt misalignment, edge wear, idler damage, and low efficiency of manual correction are prominent, providing a real and harsh implementation environment for this system. The hardware deployment was completed on-site according to the design requirements. The original idler group was replaced in the key idler section in the middle of the conveyor. A pressure control mechanism 42, a multi-source sensor monitoring module 49, an adaptive control mechanism 4, and a buffer auxiliary component 3 were installed. At the same time, an intelligent control module was installed in the control cabinet, and early warning terminals were set up on-site and in the remote central control room, forming a complete hardware and control system.

[0047] After system startup, it enters real-time operation mode. The working condition adaptation module continuously collects data such as belt speed, material load, ambient temperature and humidity, and dust concentration. The belt misalignment detection module, through laser displacement sensor, infrared contour sensor, and tension sensor, simultaneously collects information on the edge displacement deviation, contour deformation, and tension distribution of conveyor belt 11. All data is uploaded to the intelligent control module in real time, completing comprehensive perception of multi-dimensional working conditions and belt misalignment status. When the system detects that the right side offset of conveyor belt 11 reaches 12mm, the right side tension is low, and there is slight deformation at the edge, the system enters the intelligent analysis and instruction generation process.

[0048] The intelligent control module uses a convolutional neural network algorithm and an adaptive PID algorithm to fuse and process the collected data, accurately identifying the current misalignment as a moderate right-side misalignment caused by uneven load and slight belt slack. It then calculates the optimal correction parameters and outputs control commands for the deflection angle and adjustment force to the adaptive execution module. Upon receiving the commands, the adaptive execution module immediately activates, driving the threaded screw 48 to rotate, causing the outer slide plate 45 to move smoothly along the guide rod 47. The guide post 42 and guide groove 41 work together to drive the connecting plate 25 to rotate, switching between the roller 26 and the adjusting shaft 27. This allows for coordinated adjustment of the angle and tension of the conveyor belt 11. Simultaneously, the buffer assembly, through the sliding block 32 and compression spring 33, counteracts material impact and equipment vibration, reducing belt edge wear.

[0049] During the correction process, the fault early warning module uses trend analysis algorithms based on real-time data to determine potential hazards. A deviation of 12mm is classified as a moderate deviation hazard, triggering a yellow audible and visual alarm on-site. The warning information is then simultaneously pushed to a remote monitoring platform via wireless communication. The module automatically records the deviation time, deviation value, corresponding operating conditions, and correction actions, providing data for subsequent maintenance. The intelligent control module's built-in self-diagnostic unit simultaneously performs a full module self-check, confirming that sensors, actuators, and communication links are all in normal working order with no component failures, ensuring a stable and reliable correction process.

[0050] After a rapid adjustment of 1.5 seconds, the offset of conveyor belt 11 was corrected from 12mm to within 3mm, restoring normal operation. The system continuously and dynamically adapts its correction strategy based on real-time changes in load, belt speed, and incline. When conveyor belt 11 becomes loose and deformed due to long-term use, it automatically adjusts the roller angle 26 to compensate for tension, eliminating the need for downtime and parts replacement. This embodiment achieves fully automatic monitoring, precise correction, graded early warning, and self-diagnosis of conveyor belt 11 misalignment under complex industrial conditions of variable load, high dust, and slight incline, significantly reducing belt wear and equipment failure rates, and achieving the effect of unattended intelligent conveying.

[0051] Please refer to the above work process. Figures 1 to 6 .

[0052] It should be noted that the term "comprising" or any other variation thereof is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0053] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An automatic conveyor belt alignment system, characterized in that, The system includes a drive system (1), on which a transmission platform (12) is installed. A conveyor belt (11) is provided on the transmission platform (12). A deviation sensing module, an intelligent control module, an adaptive execution module, a working condition adaptation module, and a fault early warning module are respectively installed on the transmission platform (12). The deviation sensing module, the adaptive execution module, the working condition adaptation module, and the fault early warning module are all electrically connected to the intelligent control module. The deviation sensing module is equipped with a monitoring module (49), which is equipped with a multi-source sensor fusion structure, including a laser displacement sensor, an infrared contour sensor and a tension sensor. The deviation sensing module is also equipped with a pressure control mechanism (2), which is used to collect the displacement deviation and contour deformation data of the edge of the conveyor belt (11) in real time. The intelligent control module incorporates a convolutional neural network algorithm and an adaptive PID control algorithm, which can fuse and analyze the displacement deviation, profile deformation, and tension distribution data collected by the belt misalignment sensing module to identify the belt misalignment type, misalignment amplitude, and cause. The adaptive execution module is equipped with a control mechanism (4), which is used for the correction adjustment of the conveyor belt (11); the belt edge buffer adjustment mechanism is used to buffer the force on the belt edge during the correction process and reduce belt wear; The operating condition adaptation module is used to collect data on conveyor operating speed, material load, ambient temperature and humidity, and dust concentration, providing operating condition parameter support for the intelligent control module and realizing dynamic adaptation of the correction strategy. The fault early warning module, based on real-time data from the belt misalignment sensing module and the operating condition adaptation module, uses a trend analysis algorithm to predict potential belt misalignment hazards and system component failures, and issues tiered early warning signals.

2. The automatic conveyor correction system according to claim 1, characterized in that, The pressure regulating mechanism (2) includes a support plate (21), both ends of which are fixedly installed on the transmission table (12). A drive plate (22) is installed on the upper surface of the middle part of the support plate (21). A U-shaped frame (23) is fixedly installed in the middle of the drive plate (22). A connecting plate (25) is rotatably installed at both ends of the U-shaped frame (23). A roller (26) is installed at one end of the connecting plate (25), and an adjusting shaft (27) is installed at the other end of the connecting plate (25).

3. The automatic conveyor correction system according to claim 2, characterized in that, The roller (26) is symmetrically equipped with auxiliary components (3) at both ends. The auxiliary components (3) include a guide plate (31). A square limiting groove is provided in the middle of the guide plate (31). A sliding block (32) is slidably installed in the square limiting groove of the guide plate (31). A compression spring (33) is symmetrically fixedly installed on the lower surface of the sliding block (32). The end of the compression spring (33) away from the sliding block (32) is fixedly installed on the guide plate (31). The two ends of the roller (26) are rotatably installed on the sliding block (32). The end of the sliding block (32) away from the roller (26) is rotatably installed on the connecting plate (25).

4. The automatic conveyor correction system according to claim 3, characterized in that, The control mechanism (4) includes a guide groove (41), which is symmetrically opened on the outer surfaces of both ends of the connecting plate (25). A guide post (42) is slidably installed in the middle of the guide groove (41). Inner support plates (43) are fixedly installed at both ends of the U-shaped frame (23). Arc grooves (44) are symmetrically opened on the inner support plates (43). Outer sliding plates (45) are slidably installed on the outer surface of the inner support plates (43). Positioning grooves (46) are symmetrically opened on both sides of the outer sliding plates (45). The outer surface of the guide post (42) is slidably installed through the arc groove (44) and the positioning groove. In (46), the arc groove (44) has a circular arc center diameter that is the same as the diameter of the connecting plate (25). A monitoring module (49) is installed on the upper surface of the inner support plate (43). One side of the outer slide plate (45) is set as L-shaped. A threaded screw (48) is threaded on the L-shaped side of the outer slide plate (45). A drive motor is fixedly installed at one end of the threaded screw (48), and the drive motor is installed in the middle of one end of the inner support plate (43). A guide rod (47) is symmetrically slidably installed at one end of the L-shaped side of the outer slide plate (45). The guide rod (47) is fixedly installed on the inner support plate (43).

5. The automatic conveyor correction system according to claim 1, characterized in that, The fault early warning module includes a hazard classification unit and an early warning output unit. The hazard classification unit classifies belt deviation hazards into three levels: minor, moderate, and severe. Minor hazards correspond to belt deviation of 5-10mm, moderate hazards correspond to belt deviation of 10-20mm, and severe hazards correspond to belt deviation ≥20mm. The early warning output unit adopts both audible and visual alarms and wireless communication alarms, which can transmit early warning signals to the field control terminal and remote monitoring platform, while recording hazard data to provide support for subsequent operation and maintenance.

6. The automatic conveyor correction system according to claim 1, characterized in that, The intelligent control module also has a built-in self-diagnostic unit, which can perform real-time self-checks on the operating status of the deviation sensing module, adaptive execution module, working condition adaptation module and fault early warning module. When a component fault is detected, the power supply of the corresponding component is automatically cut off, a fault alarm signal is issued, and the fault type and fault location are recorded.

7. A method for correcting the deviation of a conveyor based on any one of claims 1-7, characterized in that, Includes the following steps: S1: After the system starts, the working condition adaptation module collects the conveyor parameters, including the operating speed, material load, ambient temperature and humidity and dust concentration, and transmits them to the intelligent control module; the deviation sensing module collects the displacement deviation, profile deformation and tension distribution data of the conveyor belt (11) through the monitoring module (49) and the pressure control mechanism (2), and transmits them to the intelligent control module. S2: The intelligent control module uses a built-in convolutional neural network algorithm and an adaptive PID control algorithm to fuse and analyze the collected working condition data and belt misalignment data, identify the belt misalignment type, misalignment amplitude and misalignment cause, generate targeted correction control commands and transmit them to the adaptive execution module. S3: After receiving the correction control command, the adaptive execution module adjusts the rotation angle of the connecting plate (25) through the control mechanism (4) to realize the switching between the roller (26) and the adjustment shaft (27) and to make precise correction adjustment of the conveyor belt (11); at the same time, the belt edge buffer adjustment mechanism buffers the belt edge force and reduces belt wear. S4: During the correction process, the fault early warning module uses real-time data from the deviation sensing module and the working condition adaptation module to predict deviation hazards and system component failures through trend analysis algorithms. The hazard classification unit classifies the hazards and issues corresponding warning signals through the early warning output unit. S5: The self-diagnostic unit of the intelligent control module checks the operating status of each module in real time. If a component fault is detected, it automatically cuts off the power supply to the corresponding component, issues a fault alarm signal, and records the fault information. S6: The working condition adaptation module continuously collects working condition data, and the intelligent control module dynamically adapts the correction strategy according to the changes in working conditions to ensure the correction effect under different working conditions; when the conveyor belt (11) resumes normal operation, the system maintains real-time monitoring status and executes the above steps in a loop.

8. The correction method of the automatic correction system for a conveyor according to claim 7, characterized in that, The specific operation steps of the control mechanism (4) in S3 are as follows: start the drive motor at one end of the inner support plate (43) to drive the threaded screw (48) to rotate. The threaded screw (48) drives the outer slide plate (45) to slide smoothly under the guidance of the guide rod (47). When the outer slide plate (45) slides, it drives the guide column (42) to squeeze the guide groove (41), adjust the rotation angle of the connecting plate (25), and realize the tension adjustment between the roller (26) and the conveyor belt (11), as well as the switching between the roller (26) and the adjustment shaft (27).

9. The correction method of an automatic correction system for a conveyor according to claim 7, characterized in that, In the S3, the auxiliary component (3) achieves buffer damping control of the roller (26) through the cooperation of the sliding block (32) and the compression spring (33), which counteracts the impact of falling materials and the vibration of the conveyor belt, buffers and removes instantaneous impact force, and reduces the tensile wear of the conveyor belt and the stress load on the roller shaft and bearing.

10. The correction method of an automatic correction system for a conveyor according to claim 7, characterized in that, According to the on-site conveying slope requirements, the roller (26) angle is finely adjusted by the control mechanism (4) to adapt to different conveying conditions such as horizontal, slightly uphill, and slightly downhill. When the conveyor belt (11) becomes loose or deformed after long-term use, the roller (26) angle is finely adjusted to restore the conveyor belt (11) to normal operation.

Images