A kind of total load perception-based scraper conveyor adaptive energy-saving control system and method

Abstract

The application discloses a kind of based on total load perception's scraper conveyor adaptive energy-saving control system and method, the system includes scraper conveyor and control module, the scraper conveyor includes assembled load cell, rack and load cell sensing module, the assembled load cell is spliced by several rigid metal plates to be used to install all subsequent components of scraper conveyor;The rack is installed on the upper end surface of the assembled load cell, the chute for load conveying and the drive assembly for driving conveying are configured thereon;The load cell sensing module includes several load cell sensing modules that are uniformly distributed on the lower end surface of the assembled load cell, to monitor the load weight inside the chute of the scraper conveyor in real time;The control module is electrically connected with the load cell sensing module and the drive assembly, to obtain the load weight monitored by the load cell sensing module, and control the drive assembly to adjust the drive chain speed of the drive scraper conveyor.

Description

Technical Field

[0001] This invention relates to the field of energy-saving control technology for underground coal mine transportation equipment, and more specifically, to an adaptive energy-saving control system and method for scraper conveyors based on total load sensing. Background Technology

[0002] Scraper conveyors are the core transportation equipment in fully mechanized mining faces, and their operating power consumption accounts for a large proportion of the total energy consumption of the mine. In actual production, the coal cutting rate of the coal mining machine fluctuates drastically, resulting in an extremely unstable feeding rate of the scraper conveyor. The traditional control method adopts constant speed operation, that is, the conveying speed remains constant regardless of the amount of material fed. The drawback of this method is that when the feeding rate is low, there is little load in the chute, and a large amount of energy is consumed in the unloaded friction between the chain and the scraper and the chute body, resulting in an excessively high proportion of power consumption in the unloaded base. When the feeding rate is high, the load accumulates too much, and the pushing resistance increases nonlinearly, which not only causes a surge in power consumption but also easily leads to safety accidents such as crushing and chain breakage.

[0003] Existing technologies have made some attempts, such as adjusting speed by monitoring motor current. However, the current signal is a mixture of various factors such as friction, load, tilt angle, and jamming, which cannot accurately reflect the actual load. Another example is using a level gauge to monitor the load, but the load volume varies with the material density and particle size. Simply using a level gauge cannot accurately reflect the load, leading to load estimation errors. Therefore, there is an urgent need for a control method that can directly monitor the load, accurately sense the actual load in the chute, and adaptively adjust the conveying speed to achieve the dual goals of energy saving and safety. Summary of the Invention

[0004] This invention aims to address the shortcomings of existing technologies by providing an adaptive energy-saving control system and method for scraper conveyors based on total load sensing. By setting an assembled weighing base plate at the bottom of the scraper conveyor and using a weighing sensing module below the assembled weighing base plate to indirectly measure the load weight inside the scraper conveyor chute, adaptive speed regulation is achieved by combining the total power consumption model for power consumption optimization, thereby minimizing energy consumption while ensuring conveying efficiency.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] This invention provides an adaptive energy-saving control system for scraper conveyors based on total load sensing. In this system, the scraper conveyor adaptive energy-saving control system includes a scraper conveyor and a control module. The scraper conveyor includes an assembled weighing base plate, a frame, and a weighing sensor module. The assembled weighing base plate serves as the load-bearing structure of the scraper conveyor and is specifically composed of several rigid metal plates spliced ​​together to mount all subsequent components of the scraper conveyor. The frame is mounted on the upper surface of the assembled weighing base plate and is also equipped with a chute for load conveying and a drive assembly for driving the scraper conveyor. The weighing sensor module specifically includes several weighing sensor modules, which are evenly distributed within the assembled weighing base plate. On the lower end face of the weighing base plate, several weighing sensor modules are used to monitor the load weight inside the scraper conveyor chute in real time. Each weighing sensor module is a resistance strain gauge load cell, and all weighing sensor modules are connected to the lower end face of the assembled weighing base plate via spherical supports. The control module is electrically connected to the weighing sensor modules and the drive assembly. The control module is configured to: acquire the load weight inside the scraper conveyor chute and the drive chain speed of the scraper conveyor; calculate the target chain speed that minimizes the current total power consumption of the scraper conveyor; and control the drive assembly to adjust the drive chain speed of the scraper conveyor to the target chain speed. The control module specifically includes a data acquisition unit and a control calculation unit.

[0007] Furthermore, in the technical solution of the present invention, the data acquisition unit is used to acquire the load weight inside the scraper conveyor chute monitored by the weighing sensor module and the drive chain speed of the scraper conveyor driven by the drive assembly; the control calculation unit is communicatively connected to the data acquisition unit, and the control calculation unit is used to perform the following steps:

[0008] The average load per unit length within the scraper conveyor chute is calculated based on the obtained load weight inside the chute. The formula for calculating the average load per unit length is as follows:

[0009] In the formula, This represents the load weight inside the chute. It is expressed as the length of the chute. This is expressed as the average load per unit length within the chute.

[0010] Based on the steady-state relationship between the drive chain speed, average load per unit length, and current average feed speed of the scraper conveyor, the functional relationship between the average load per unit length and the drive chain speed is calculated. The formula for calculating the functional relationship between the average load per unit length and the drive chain speed is as follows:

[0011] In the formula, This represents the current average feed rate. This is expressed as the driving chain speed;

[0012] Substituting the functional relationship between the average load per unit length and the drive chain speed into the first total power consumption model, the target chain speed that minimizes the total power consumption of the current device is calculated. The calculation formula for the first total power consumption model is as follows:

[0013] In the formula, This represents the total power consumption of the scraper conveyor. This is expressed as the no-load power consumption coefficient. This is expressed as the load power consumption coefficient;

[0014] The formula for calculating the target chain speed is:

[0015] In the formula, Represented as the target chain speed, and ;

[0016] It also controls the drive assembly to adjust the speed of the drive chain conveyed by the drive scraper conveyor to the target chain speed.

[0017] Furthermore, in the technical solution of the present invention, the idle power consumption coefficient The calibration method is as follows: no-load power consumption coefficient Specifically used to calculate the no-load power consumption of the equipment, within the data range of normal operation of the scraper conveyor, its no-load power consumption is approximately directly proportional to the drive chain speed of the scraper conveyor, that is, it is considered as... In the formula, The power consumption is expressed as the no-load power consumption of the equipment. A higher drive chain speed indicates higher no-load power consumption for the scraper conveyor. By clearing the chute, the scraper conveyor is run at multiple different drive chain speeds under no-load conditions. The no-load power consumption corresponding to each drive chain speed is obtained. A first linear function relationship between the no-load power consumption and the drive chain speed is established through linear regression, i.e., linear fitting. In order to obtain .

[0018] Furthermore, in the technical solution of the present invention, the load power consumption coefficient The calibration method is as follows: load power consumption factor Specifically used to calculate equipment load power consumption, within the data range of normal operation of the scraper conveyor, its equipment load power consumption, when the drive chain speed of the scraper conveyor is constant, is approximately directly proportional to the load weight inside the chute, i.e., it is considered as... In the formula, This represents the power consumption under load. When the drive chain speed of the scraper conveyor is constant, the greater the load weight inside the chute, the higher the power consumption under load. By running the scraper conveyor at multiple different drive chain speeds under a constant feed rate, the total power consumption corresponding to each drive chain speed is obtained, and the no-load power consumption coefficient is calibrated based on the above. The first linear function relationship established at each time is subtracted from the idle power consumption of the equipment at the corresponding drive chain speed to obtain the equipment load power consumption. At the same time, the average load per unit length in the chute at each drive chain speed is obtained, and a second linear function relationship between the equipment load power consumption and the average load per unit length is established through linear regression, i.e., linear fitting. In order to obtain .

[0019] In another aspect, the present invention provides an adaptive energy-saving control method for scraper conveyors based on total load sensing. In the technical solution of the present invention, the adaptive energy-saving control method for scraper conveyors specifically includes the following steps:

[0020] Step S1: Run the scraper conveyor at multiple different drive chain speeds under no-load conditions, obtain the no-load power consumption of the equipment corresponding to each drive chain speed, and establish the first linear function relationship between the no-load power consumption of the equipment and the drive chain speed through linear regression, i.e. Step S2: Under a constant feed rate, the scraper conveyor is operated at multiple different drive chain speeds. The total power consumption of the equipment at each drive chain speed is obtained. Based on the first linear function relationship established in step S1, the no-load power consumption of the equipment at the corresponding drive chain speed is subtracted to obtain the load power consumption of the equipment. At the same time, the average load per unit length in the chute at each drive chain speed is obtained. A second linear function relationship between the load power consumption of the equipment and the average load per unit length is established through linear regression. Step S3: Based on the first and second linear function relationships, construct a first total power consumption model for the device, with the drive chain speed and average load per unit length as inputs and the total power consumption of the device as output. Step S4: Real-time acquisition of the load weight and drive chain speed inside the scraper conveyor chute, and further calculation of the dynamic sampling period based on the chute length and drive chain speed. This dynamic sampling period is used to dynamically characterize the load replacement process inside the chute under different drive chain speeds. That is, the dynamic sampling period represents the time required for the load inside the chute to pass through the chute under different drive chain speeds. The calculation formula for the dynamic sampling period is:

[0021] In the formula, This is represented as a dynamic sampling period, and at the end of each dynamic sampling period, the following sub-steps are executed: Step S41, record the load weight and drive chain speed inside the scraper conveyor and its chute at this moment; Step S42, based on the load weight inside the chute, further calculate the average load per unit length inside the chute. This average load per unit length is expressed as the average load weight on the chute per unit length obtained by normalizing the linear density of the load weight inside the chute, that is, dividing the total load weight by the length of the chute to obtain the average load per unit length inside the chute. The formula for calculating the average load per unit length is: Step S43: Substitute the average load per unit length and the drive chain speed into the total power consumption model of the first device, and then perform derivative calculation on the total power consumption model of the first device to obtain the target chain speed that minimizes the total power consumption of the current device. Specifically, this includes the following steps: Step M1: Based on the steady-state relationship between the chute length, drive chain speed, and dynamic sampling period, i.e.: And the steady-state relationship between the chute length, the load weight inside the chute, and the average load per unit length, i.e.: The functional relationship between the average load per unit length and the drive chain speed is calculated as follows: Step M2: Substitute the functional relationship between the average load per unit length and the drive chain speed into the first device total power consumption model to obtain the second device total power consumption model. The specific form of the second device total power consumption model is as follows: Step M3, the total power consumption model of the second device for the drive chain speed. The second derivative: Therefore, it is a convex function and has a local minimum. Setting its first derivative to zero, the formula for calculating it is:

[0022] ;

[0023] That is, to find the target chain speed that minimizes the total power consumption of the current device, the formula for calculating the target chain speed is: In the formula, Represented as the target chain speed, and ;

[0024] That is, set the first derivative of the total power consumption model of the second device to zero, solve for the target chain speed that minimizes the total power consumption of the current device, and control and adjust the drive chain speed of the scraper conveyor to the target chain speed; step S5, return to step S4, and enter the next dynamic sampling cycle.

[0025] Furthermore, in the technical solution of the present invention, the control calculation unit is also used to perform data processing, analysis and calculation in the adaptive energy-saving control method for scraper conveyors as described above.

[0026] Beneficial Effects: In summary, this invention provides an adaptive energy-saving control system and method for scraper conveyors based on total load sensing. This invention indirectly measures the load weight inside the scraper conveyor chute by installing an assembled weighing base plate at the bottom of the scraper conveyor and utilizing weighing sensor modules evenly distributed below the assembled weighing base plate. Then, based on a total power consumption model and a dynamic sampling period, the target chain speed is calculated in real time to achieve intelligent speed regulation of the scraper conveyor. This effectively avoids the large amount of ineffective no-load power consumption and overload losses associated with the constant-speed operation of traditional scraper conveyors, resulting in significant energy-saving benefits and broad engineering application value. Other features and advantages of this invention will be set forth in the following description. Attached Figure Description

[0027] To more clearly illustrate the embodiments of the present invention, the accompanying drawings used in the embodiments 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.

[0028] Figure 1 This is a partial structural schematic diagram of a scraper conveyor according to an embodiment of the present invention;

[0029] Figure 2 This is a partial structural schematic diagram of an assembled weighing base plate and a weighing sensing module according to an embodiment of the present invention.

[0030] Figure 3 This is a schematic diagram of a control module according to an embodiment of the present invention;

[0031] Figure 4 This is a flowchart of an adaptive energy-saving control method for scraper conveyors based on total load sensing according to an embodiment of the present invention.

[0032] In the diagram, A01 is the assembled weighing base plate; A02 is the frame; A03 is the chute; A04 is the drive assembly; and A05 is the weighing sensor module. Detailed Implementation

[0033] The present invention will be described below with reference to specific embodiments. It should be noted that the embodiments described below are examples of the present invention and are only used to illustrate the present invention, and are not intended to limit the present invention. Other combinations and various modifications within the scope of the present invention can be made without departing from the spirit or scope of the present invention.

[0034] This embodiment provides an adaptive energy-saving control system for scraper conveyors based on total load perception. This adaptive energy-saving control system is used to implement an adaptive energy-saving control method for scraper conveyors. In this embodiment, the adaptive energy-saving control system for scraper conveyors includes a scraper conveyor and a control module.

[0035] Specifically, Figure 1 This is a partial structural schematic diagram of a scraper conveyor according to an embodiment of the present invention, such as... Figure 1 As shown, in this embodiment, the scraper conveyor includes an assembled weighing base plate A01, a frame A02, and a weighing sensor module. The assembled weighing base plate A01 serves as the load-bearing structure of the scraper conveyor and is located at the bottom of the scraper conveyor. The assembled weighing base plate A01 is composed of several rigid metal plates spliced ​​together for mounting all subsequent components of the scraper conveyor; that is, as... Figure 1 As shown, the frame A02 is installed on the upper surface of the assembled weighing base plate A01. The frame A02 is also equipped with a chute A03 for load conveying and a drive assembly A04 for driving the scraper conveyor. Those skilled in the art will understand that the chute A03 also uses scrapers and chains of the prior art, and the drive assembly A04 uses motors of relevant specifications of the prior art according to the specific requirements of the equipment.

[0036] Specifically, Figure 2 This is a partial structural diagram of an assembled weighing base plate and a weighing sensing module according to an embodiment of the present invention, as shown below. Figure 2 As shown, in this embodiment, the weighing sensor module specifically includes several weighing sensor modules A05, which are evenly distributed on the lower end face of the assembled weighing base plate A01 to monitor the load weight inside the scraper conveyor chute A03 in real time. Specifically, the load weight inside the scraper conveyor chute A03 is equal to the sum of the weighing data of each weighing sensor module A05. The weighing sensor modules A05 all adopt resistance strain gauge load cells, and the weighing sensor modules A05 are connected to the lower end face of the assembled weighing base plate A01 through spherical supports. The use of spherical supports allows the assembled weighing base plate A01 to produce slight tilts or deformations, so as to avoid damage to the sensors of the weighing sensor modules A05 due to bending moments.

[0037] Specifically, Figure 3 This is a schematic diagram of a control module according to an embodiment of the present invention, such as... Figure 3As shown, in this embodiment, the control module is electrically connected to the weighing sensor module and the drive component A04. It is used to acquire the load weight inside the scraper conveyor chute A03 and the drive chain speed of the scraper conveyor, calculate the target chain speed that minimizes the total power consumption of the scraper conveyor, and control the drive component A04 to adjust the drive chain speed of the scraper conveyor to the target chain speed. Figure 3 As shown, the control module specifically includes a data acquisition unit and a control calculation unit. The data acquisition unit is used to acquire the load weight inside the scraper conveyor chute A03 monitored by the weighing sensor module and the drive chain speed of the scraper conveyor driven by the drive assembly A04. The control calculation unit is communicatively connected to the data acquisition unit and is used to execute the following steps:

[0038] The average load per unit length within chute A03 of the scraper conveyor is calculated based on the obtained load weight inside chute A03. The formula for calculating the average load per unit length is as follows:

[0039] In the formula, This represents the load weight inside chute A03. This is represented by the length of chute A03. This is expressed as the average load per unit length within chute A03, that is, the total load weight within the entire chute A03. Divide by the length of chute A03 To calculate the linear density of the load inside chute A03, i.e., the average load per unit length. This paper employs mean analysis to calculate the average value of relevant operating data of the scraper conveyor within each data acquisition and calculation cycle. This reduces the computational burden on the control module and, in practical applications, filters out the impact of extremely short-term data fluctuations. Furthermore, using mean analysis to regulate the scraper conveyor is a gradual feedback control method with a relatively gentle adjustment range. Because mean calculation lowers the values ​​of significantly fluctuating scraper conveyor operating data, when faced with large data changes, it is necessary to gradually adjust the scraper conveyor through multiple control cycles. This avoids drastic changes in the scraper conveyor's regulation within a short period, which could affect the stability of the equipment. Additionally, based on the scraper conveyor's drive chain speed and average load per unit length... The steady-state relationship between the current average feed rate and the average load per unit length is used to calculate the average load per unit length. The functional relationship between load and drive chain speed, and the average load per unit length. The formula for calculating the functional relationship between the speed of the drive chain and the speed of the chain is:

[0040] In the formula, This represents the current average feed rate. This is expressed as the driving chain speed;

[0041] Then distribute the load per unit length and drive chain speed Substituting the functional relationship between them into the first total power consumption model, the target chain speed that minimizes the total power consumption of the current device is calculated. The calculation formula for the first total power consumption model is:

[0042] In the formula, This is expressed as the total power consumption of the scraper conveyor. This is expressed as the no-load power consumption coefficient. This is expressed as the load power consumption coefficient;

[0043] The formula for calculating the target chain speed is:

[0044] In the formula, Represented as the target chain speed, and ;

[0045] It also controls the drive component A04 to adjust the speed of the drive chain conveyed by the scraper conveyor. To target chain speed .

[0046] Specifically, in this embodiment, the idle power consumption coefficient is... The calibration method is as follows: no-load power consumption coefficient Specifically used to calculate the no-load power consumption of the equipment, which is mainly generated by the sliding friction between the chain, scraper, etc. and the chute A03. According to the classical friction law, the sliding friction force... In the formula, Represented as sliding friction, The coefficient of friction, The positive pressure exerted by the chain, scraper, etc. on chute A03 is approximately constant under the condition that the scraper conveyor's own weight and structure are fixed. The no-load power consumption of the equipment is... In the formula, This is expressed as the device's no-load power consumption. This is expressed as the drive chain speed. Since the drive chain speed of a scraper conveyor is typically within a low range during normal operation, the coefficient of friction is relatively low within this range. The power consumption of the scraper conveyor is less affected by speed, meaning it is within the normal operating range of the equipment. With the drive chain speed of the scraper conveyor It is approximately proportional, that is, it is considered as This represents the drive chain speed of the scraper conveyor when it is unloaded. The larger the device's no-load power consumption The higher the speed, the better; by emptying chute A03, the scraper conveyor can be driven at multiple chain speeds. Run and record the speed of each drive chain. Device idle power consumption Then linear fitting In order to obtain .

[0047] Specifically, in this embodiment, the load power consumption factor The calibration method is as follows: load power consumption factor Specifically, it is used to calculate the power consumption of the equipment load. The power consumption of the equipment load comes from the friction between the material and the chute A03, scraper, etc., as well as the shear resistance inside the material. When the drive chain speed... When the temperature is constant, the material is pushed by the scraper, and its normal pressure on the bottom of the chute A03 is proportional to the amount of material, i.e., the load weight. Meanwhile, the equivalent coefficient of friction between the material and the chute can be considered constant for a given material type and humidity. Therefore, its frictional resistance can be calculated as follows: In the formula, This is expressed as frictional resistance. Expressed as the equivalent friction coefficient, Expressed as material quantity. Given gravitational acceleration, the power consumption of the device load can be calculated as follows: In the formula, This is expressed as the equipment load power consumption, which is the equipment load power consumption within the normal operating range of the scraper conveyor. The drive chain speed of the scraper conveyor When constant, it is approximately directly proportional to the load weight inside chute A03. Here, it is based on the average load per unit length inside chute A03 during each data acquisition period. To analyze it, it can be regarded as , representing the drive chain speed of the scraper conveyor. When constant, the greater the load weight inside the chute A03, the greater the equipment load power consumption. The higher the speed, the better; by maintaining a constant feed rate, the scraper conveyor is driven at multiple chain speeds. Run and record the speed of each drive chain. Total power consumption of the device below Subtract the corresponding drive chain speed Device idle power consumption To obtain the device load power consumption Simultaneously record the speed of each drive chain. Average load per unit length in lower chute A03 Then linear fitting In order to obtain .

[0048] Another aspect of this embodiment includes an adaptive energy-saving control method for scraper conveyors based on total load sensing. The aforementioned adaptive energy-saving control system for scraper conveyors is used to implement this adaptive energy-saving control method. Figure 4 The flowchart below illustrates an adaptive energy-saving control method for scraper conveyors based on total load sensing, according to an embodiment of the present invention. Figure 4 As shown, specifically, in this embodiment, the adaptive energy-saving control method for the scraper conveyor includes the following steps:

[0049] Step S1: Run the scraper conveyor at multiple different drive chain speeds while it is unloaded. Run and obtain the speed of each drive chain. Corresponding device no-load power consumption And establish the device's no-load power consumption through linear regression. With drive chain speed The first linear functional relationship between them Step S2: Under a constant feed rate, the scraper conveyor is driven at multiple different chain speeds. Run and obtain the speed of each drive chain. Corresponding total device power consumption And based on the first linear function relationship established in step S1 Deduct the corresponding drive chain speed Device idle power consumption To obtain the device load power consumption Simultaneously obtain the speed of each drive chain. Average load per unit length in lower chute A03 And establish the device load power consumption through linear regression. Average load per unit length The second linear function relationship between them Step S3: Based on the first linear function relationship Relationship between the second linear function Build to drive chain speed and average load per unit length For input, based on the total power consumption of the device The first device total power consumption model is output. Step S4: Real-time acquisition of the load weight inside the scraper conveyor chute A03. and drive chain speed And based on the total length of chute A03 and drive chain speed The dynamic sampling period is further calculated, which is used to dynamically characterize the load in chute A03 at different drive chain speeds. The displacement process ensures that the material in chute A03 has undergone a complete displacement at each sampling time. The dynamic sampling period represents the complete conveying time of the material on the scraper conveyor, further expressed as the load in chute A03 at different drive chain speeds. The time required for the sample to pass through chute A03 is given by the formula for calculating the dynamic sampling period: In the formula, This is represented as the dynamic sampling period, i.e., the dynamic sampling period. Follow the drive chain speed of the scraper conveyor Dynamic changes, dynamic sampling period This refers to the time required for material to pass through chute A03, i.e., one complete conveying cycle. Each time a dynamic sampling cycle is completed... Record the load weight inside the scraper conveyor and chute A03 once. and the drive chain speed of the scraper conveyor And calculate the new target chain speed. Adjust to target chain speed Next dynamic sampling period Then based on the target chain speed Recalculate to ensure that the material in chute A03 completes a full replacement cycle each time a record is made, and the recorded value should be strictly synchronized with the current operating conditions.

[0050] In each dynamic sampling period At the end, perform the following sub-steps: Step S41, record the load weight inside the scraper conveyor and its chute A03 at this moment. and drive chain speed Step S42: Based on the load weight within chute A03, further calculate the average load per unit length within chute A03. Average load per unit length This is expressed as the load weight inside chute A03. The average load weight per unit length of chute A03 obtained by normalizing the linear density is expressed as the average load weight for each dynamic sampling period. The load weight inside the chute A03 After normalizing the linear density, the average load per unit length within chute A03 was calculated. Average load per unit length The calculation formula is: Step S43: Distribute the load per unit length evenly. and drive chain speed Substitute into the total power consumption model of the first device Then, the total power consumption model of the first device. The derivative is used to calculate the total power consumption of the current device. Minimum target chain speed Specifically, it includes the following steps: Step M1, based on the total length of chute A03 and the drive chain speed and dynamic sampling period The steady-state relationship between them is:

[0051] and chute length The load weight inside the chute and average load per unit length The steady-state relationship between them is:

[0052] The average load per unit length was calculated. and drive chain speed The functional relationship between them is:

[0053] Step M2: Distribute the load per unit length evenly. and drive chain speed Substituting the functional relationship between them into the total power consumption model of the first device, we obtain the total power consumption model of the second device. The specific form of the total power consumption model of the second device is as follows: ;

[0054] Step M3, the total power consumption model of the second device for the drive chain speed The second derivative: Therefore, it is a convex function and has a local minimum. Setting its first derivative to zero, the formula for calculating it is:

[0055] ;

[0056] That is, to solve for the current total power consumption of the device. Minimum target chain speed The target chain speed The calculation formula is: In the formula, Represented as the target chain speed, and ;

[0057] That is, by setting the first derivative of the total power consumption model of the second device to zero, we can solve for the total power consumption of the current device. Minimum target chain speed And control and adjust the drive chain speed of the scraper conveyor. To target chain speed Step S5: Return to step S4 and enter the next dynamic sampling cycle. Specifically, in this embodiment, the control calculation unit is also used to perform data processing, analysis, and calculation in the adaptive energy-saving control method for scraper conveyors described above.

[0058] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. An adaptive energy-saving control method for scraper conveyors based on total load sensing, characterized in that, Includes the following steps: Step S1: Run the scraper conveyor at multiple different drive chain speeds under no-load conditions, obtain the no-load power consumption of the equipment corresponding to each drive chain speed, and establish the first linear function relationship between the no-load power consumption of the equipment and the drive chain speed through linear regression. Step S2: Under a constant feed rate, the scraper conveyor is operated at multiple different drive chain speeds. The total power consumption of the equipment corresponding to each drive chain speed is obtained. Based on the first linear function relationship established in Step S1, the no-load power consumption of the equipment at the corresponding drive chain speed is subtracted to obtain the load power consumption of the equipment. At the same time, the average load per unit length in the chute at each drive chain speed is obtained, and a second linear function relationship between the load power consumption of the equipment and the average load per unit length is established through linear regression. Step S3: Based on the first and second linear function relationships, a first total power consumption model of the equipment is constructed with the drive chain speed and the average load per unit length as inputs and the total power consumption of the equipment as output. Step S4: The load weight and drive chain speed inside the scraper conveyor chute are obtained in real time, and the power consumption is calculated based on the chute length. The dynamic sampling period is further calculated based on the drive chain speed. This dynamic sampling period is used to dynamically characterize the load replacement process in the chute under different drive chain speeds. At the end of each dynamic sampling period, the following sub-steps are executed: Step S41: Record the load weight and drive chain speed inside the scraper conveyor and its chute at this moment; Step S42: Calculate the average load per unit length in the chute based on the load weight; Step S43: Substitute the average load per unit length and drive chain speed into the first equipment total power consumption model, and then perform derivative calculation on the first equipment total power consumption model to obtain the target chain speed that minimizes the current equipment total power consumption, and control and adjust the drive chain speed of the scraper conveyor to the target chain speed; Step S5: Return to step S4 and enter the next dynamic sampling period.

2. The adaptive energy-saving control method for scraper conveyors according to claim 1, characterized in that, In step S3, the specific form of the total power consumption model of the first device is as follows: ,in, This is expressed as the total power consumption of the device. Indicated as the driving chain speed, Expressed as the average load per unit length. This is expressed as the no-load power consumption coefficient. It is expressed as the load power consumption coefficient.

3. The adaptive energy-saving control method for scraper conveyors according to claim 2, characterized in that, In step S4, the dynamic sampling period is represented as the time required for the load in the chute to pass through the chute at different drive chain speeds.

4. The adaptive energy-saving control method for scraper conveyors according to claim 3, characterized in that, In step S4, the average load per unit length is expressed as the average load weight per unit length of the chute obtained by normalizing the linear density of the load weight inside the chute.

5. The adaptive energy-saving control method for scraper conveyors according to claim 4, characterized in that, The process of differentiating the total power consumption model of the first device to obtain the target chain speed that minimizes the total power consumption of the current device includes the following steps: Step M1: Based on the steady-state relationship between the chute length, drive chain speed, and dynamic sampling period, as well as the steady-state relationship between the chute length, the load weight inside the chute, and the average load per unit length, calculate the functional relationship between the average load per unit length and the drive chain speed; Step M2: Substitute the functional relationship between the average load per unit length and the drive chain speed into the total power consumption model of the first device to obtain the total power consumption model of the second device. The specific form of the total power consumption model of the second device is as follows: ,in, This represents the load weight inside the chute. This is represented as the dynamic sampling period; Step M3: Set the first derivative of the total power consumption model of the second device to zero, and solve for the target chain speed that minimizes the total power consumption of the current device.

6. An adaptive energy-saving control system for a scraper conveyor based on total load sensing, comprising a scraper conveyor and a control module, for implementing the adaptive energy-saving control method for a scraper conveyor as described in any one of claims 1-5, characterized in that, The scraper conveyor includes an assembled weighing base plate serving as a load-bearing structure, a frame mounted on the upper surface of the assembled weighing base plate, and weighing sensor modules evenly distributed on the lower surface of the assembled weighing base plate. The frame also contains a chute for load conveying and a drive assembly for driving the scraper conveyor. The control module is electrically connected to the weighing sensor module and the drive assembly. The control module is configured to: acquire the load weight inside the scraper conveyor chute and the drive chain speed of the scraper conveyor; calculate the target chain speed that minimizes the current total power consumption of the scraper conveyor; and control the drive assembly to adjust the drive chain speed of the scraper conveyor to the target chain speed.

7. The adaptive energy-saving control system for scraper conveyors according to claim 6, characterized in that, All the weighing sensing modules use resistance strain gauge load cells, and the weighing sensing modules are connected to the lower end face of the assembled weighing base plate through spherical supports.

8. The adaptive energy-saving control system for scraper conveyors according to claim 6, characterized in that, The control module includes: a data acquisition unit, used to acquire the load weight inside the scraper conveyor chute and the drive chain speed of the scraper conveyor; and a control calculation unit, communicatively connected to the data acquisition unit, used to perform data processing, analysis and calculation in the adaptive energy-saving control method for scraper conveyors as described in any one of claims 1-5.

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