Rubber belt deviation monitoring system for rubber belt bucket elevator

Abstract

The rubber belt deviation monitoring system comprises a millimeter wave radar, a PLC and a fixing frame, one side of the fixing frame is fixed to the outer wall of a machine shell of the rubber belt bucket elevator, the millimeter wave radar is installed at the top end of the fixing frame, and the PLC is installed at the top end of the fixing frame. The machine shell is provided with an opening used for radio waves of the millimeter wave radar to enter the machine shell and reach the side wall of a hopper of the rubber belt bucket elevator, the PLC is fixed to the outer wall of the machine shell, and the millimeter wave radar is electrically connected with the PLC. According to the utility model, through the millimeter wave radar and the PLC controller, a complete rubber belt deviation monitoring and processing system is constructed, and high-efficiency real-time monitoring and accurate early warning of rubber belt deviation are realized.

Description

Technical Field

[0001] This utility model relates to the field of conveyor belt deviation technology, and in particular to a conveyor belt deviation monitoring system for conveyor belt bucket elevators. Background Technology

[0002] In cement production processes, belt bucket elevators are core equipment for vertical material conveying. Belt misalignment is a frequent cause of equipment failure, downtime, and safety accidents. Existing misalignment monitoring technologies mainly rely on mechanical misalignment switches, such as two-stage misalignment switches. Their principle is that when the belt misaligns to a preset threshold, it triggers the vertical roller to move, outputting an alarm or shutdown signal through a contact switch. However, this technology has the following limitations: 1) Lag: It can only respond when the misalignment reaches the mechanical trigger threshold, unable to quantify the degree of misalignment in real time or provide early warning; 2) Limited functionality: It only provides switch signals, lacking continuous position data output, making it difficult to support fault trend analysis; 3) Environmental sensitivity: High dust and high temperature conditions can easily lead to wear or false triggering of mechanical contacts, reducing reliability; 4) High maintenance costs: It requires regular calibration of mechanical components and relies heavily on manual inspection.

[0003] In recent years, although deviation detection technology based on machine vision and deep learning has been gradually applied to belt conveyors, traditional image recognition solutions are easily affected by material obstruction and changes in lighting due to the enclosed structure, small space, and high temperature and dust environment inside bucket elevators, making them difficult to apply directly.

[0004] Therefore, there is an urgent need for a high-precision, real-time monitoring system for belt deviation of conveyor bucket elevators that is suitable for their operating conditions. Utility Model Content

[0005] The purpose of this invention is to provide a belt misalignment monitoring system for a belt bucket elevator to solve the above-mentioned problems.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A belt misalignment monitoring system for a belt bucket elevator includes a millimeter-wave radar, a PLC controller, and a mounting bracket. One side of the mounting bracket is fixed to the outer wall of the belt bucket elevator housing. The millimeter-wave radar is mounted on the top of the mounting bracket. The housing has an opening to allow radio waves from the millimeter-wave radar to enter the housing and reach the side wall of the bucket of the belt bucket elevator. The PLC controller is fixed to the outer wall of the housing, and the millimeter-wave radar is electrically connected to the PLC controller.

[0008] Furthermore, the radar outer cover is equipped with a protective cover, the bottom end of which is fixedly connected to the top end of the mounting bracket.

[0009] Furthermore, the protective cover is made of polytetrafluoroethylene.

[0010] Furthermore, an acrylic light-transmitting plate is provided at the opening, and the side of the acrylic light-transmitting plate is fixedly connected to the housing.

[0011] Furthermore, it also includes a lighting lamp for illuminating light under the control of the PLC controller, the lighting lamp being fixed to the outer wall of the housing near the millimeter-wave radar.

[0012] Furthermore, it also includes an audible and visual alarm, which is fixed to the outer wall of the housing and electrically connected to the PLC controller.

[0013] Furthermore, it also includes a correction device, which comprises a rotary motor, a rotating shaft, a horizontal plate, a first slider, a second slider, and rollers. The rotary motor is fixed to the outer wall of the machine housing, and its output end is fixedly connected to one end of the rotating shaft. The other end of the rotating shaft passes through the machine housing and is fixedly connected to the middle of the horizontal plate. Support plates one and two are fixedly fixed at both ends of the horizontal plate, respectively. A sliding rod and a lead screw are arranged parallel between support plates one and two, respectively. The two ends of the sliding rod are fixedly connected to support plates one and two, respectively. A rotary motor is fixed on support plate one, and the rotary motor outputs... One end is fixedly connected to one end of the lead screw, and the other end of the lead screw passes through the first support plate and the second support plate and is rotatably connected. The lead screw is rotatably connected to the first support plate. One end of the first slider and the second slider are slidably connected to the slide rod, and the other end is rotatably connected to the lead screw. Opposite threads are provided on both sides of the lead screw. A bracket is fixed to both sides of the first slider and the second slider. Multiple fixed shafts are evenly fixed on the brackets. The rollers are rotatably connected to the fixed shafts. The two rollers are respectively arranged on both sides of the hopper. The rotary motor and the rotating motor are electrically connected to the PLC controller.

[0014] This utility model discloses the following technical effects: It provides a belt misalignment monitoring system for a belt bucket elevator. Through the coordinated operation of millimeter-wave radar, a PLC controller, an audible and visual alarm, and a correction device, a complete belt misalignment monitoring and processing system is constructed. The millimeter-wave radar provides non-contact, precise monitoring, unaffected by environmental interference. Double protection with a PTFE protective cover and an acrylic light-transmitting plate ensures stable radar operation. Illumination enhances monitoring accuracy. The audible and visual alarm promptly alerts to abnormalities. The correction device automatically adjusts the hopper position. The entire system achieves efficient real-time monitoring, accurate early warning, and rapid correction of belt misalignment, effectively improving the operational stability of the belt bucket elevator, reducing malfunction losses, and increasing production efficiency. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 : Schematic diagram of millimeter-wave radar monitoring according to this utility model;

[0017] Figure 2 This utility model discloses an overall structural diagram of a conveyor belt misalignment monitoring system for a conveyor belt bucket elevator.

[0018] Figure 3 : Schematic diagram of the correction device of this utility model;

[0019] Specifically, 101. Millimeter-wave radar; 102. Hopper; 103. PLC controller; 104. Audible and visual alarm; 105. Housing; 106. Fixing frame; 107. Protective cover; 108. Acrylic light-transmitting panel; 109. Lighting lamp; 1010. Rotary motor; 1011. Rotating motor; 1012. Lead screw; 1013. Slide bar; 1014. Slider one; 1015. Slider two; 1016. Support plate one; 1017. Support plate two; 1018. Rotating shaft; 1019. Horizontal plate; 1020. Bracket; 1021. Roller; 1022. Fixing shaft. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0021] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the present utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0022] The specific implementation method is as follows:

[0023] like Figures 1-3As shown, this utility model discloses a belt misalignment monitoring system for a belt bucket elevator, including a millimeter-wave radar 101, a PLC controller 103, and a mounting bracket 106. One side of the mounting bracket 106 is fixed to the outer wall of the housing 105 of the belt bucket elevator. The millimeter-wave radar 101 is installed at the top of the mounting bracket 106. The housing 105 has an opening for the radio waves of the millimeter-wave radar 101 to enter the housing 105 and reach the side wall of the hopper 102 of the belt bucket elevator. The PLC controller 103 is fixed to the outer wall of the housing 105, and the millimeter-wave radar 101 is electrically connected to the PLC controller 103.

[0024] This invention utilizes a millimeter-wave radar 101 to accurately detect the sidewall of the hopper 102 in a non-contact manner, unaffected by harsh environments such as dust and light, and can stably acquire real-time data on the conveyor belt's operating status. The radar's built-in chip efficiently receives and analyzes the data, providing a reliable basis for subsequent judgments. The PLC controller 103 receives the processed signals and accurately issues control commands according to a preset program. In this invention, all working components work closely together through electrical connections, forming a complete chain from monitoring, data processing, signal judgment to early warning. This enables real-time monitoring and rapid response to conveyor belt misalignment, effectively improving the stability and reliability of the conveyor belt bucket elevator, reducing the risk of equipment failure and production interruption losses caused by conveyor belt misalignment, and ensuring efficient and orderly production.

[0025] In this embodiment, the radar outer cover is provided with a protective cover 107, and the bottom end of the protective cover 107 is fixedly connected to the top end of the fixing frame 106.

[0026] The protective cover 107 of this utility model can isolate adverse external factors, prevent the radar from degrading or even being damaged due to moisture and corrosion, and significantly extend the service life of the radar. In addition, the protective cover 107 is fixed to the mounting bracket 106, so that the radar can maintain a stable installation state even under the vibration generated by the operation of the equipment, ensuring the accuracy of the direction and position of the radar wave transmission and reception, thereby maintaining the accuracy and reliability of the monitoring data and improving the overall stability and durability of the conveyor belt deviation monitoring system.

[0027] In this embodiment, the protective cover 107 is made of polytetrafluoroethylene.

[0028] The polytetrafluoroethylene of this invention has extremely low penetration loss to the millimeter-wave radar 101, which hardly affects the transmission and reception of radar waves, ensuring that the millimeter-wave radar 101 can accurately measure the distance to the side wall of the conveyor belt bucket elevator 102, and guaranteeing the high-precision operation of the monitoring system.

[0029] In this embodiment, an acrylic light-transmitting plate 108 is provided at the opening, and the side of the acrylic light-transmitting plate 108 is fixedly connected to the housing 105.

[0030] The acrylic light-transmitting plate 108 of this utility model can effectively block external dust and debris from entering the interior of the housing 105, preventing them from contaminating or damaging components such as the millimeter-wave radar 101 and the conveyor belt bucket elevator hopper 102, thus ensuring the clean operation of the equipment. In terms of ensuring the monitoring function, it has good penetrability of the millimeter-wave radar 101 wave, allowing the radar wave to pass smoothly through the plate and enter the housing 105, achieving accurate monitoring of the side wall of the hopper 102, and ensuring the accuracy and reliability of the monitoring data.

[0031] In this embodiment, a lighting lamp 109 is also included, which is used to emit light under the control of the PLC controller 103. The lighting lamp 109 is fixed on the outer wall of the housing 105 near the millimeter-wave radar 101.

[0032] In environments with insufficient light, such as nighttime operations or dimly lit factory interiors, the lighting 109 can significantly improve the brightness of the monitoring area, effectively compensating for the lack of ambient light and assisting the millimeter-wave radar 101 in obtaining information from the side wall of the conveyor belt bucket elevator 102 more clearly and accurately. This avoids monitoring errors caused by dim lighting and improves monitoring accuracy and reliability. Secondly, the PLC controller 103 intelligently controls the switching on and off and brightness adjustment of the lighting 109 according to the system's operating status, achieving on-demand lighting. Compared with continuous lighting, this effectively reduces energy consumption and saves electricity.

[0033] In this embodiment, an audible and visual alarm 104 is also included. The audible and visual alarm 104 is fixed to the outer wall of the housing 105 and is electrically connected to the PLC controller 103.

[0034] This utility model's audible and visual alarm 104 can attract the attention of operators immediately when a belt bucket elevator malfunctions due to belt misalignment, using both sound and light as dual warning methods. Compared to a single sound or light alarm, its alerting efficiency is higher, ensuring that operators can detect abnormalities in a timely manner. Installed on the outer wall of the casing 105, the alarm signal can be quickly propagated throughout the work site, allowing operators to quickly perceive it regardless of their location around the equipment, effectively avoiding information transmission delays or omissions caused by distance, environmental noise, or other factors. In addition, the intuitive warning method of the audible and visual alarm 104 allows operators to quickly determine the location and status of the equipment malfunction, buying valuable time for subsequent troubleshooting and emergency measures, reducing equipment damage and production interruption losses caused by belt misalignment, and improving the safety and production continuity of the belt bucket elevator.

[0035] In this embodiment, as Figure 3As shown, it also includes a correction device, which includes a rotary motor 1010, a rotating shaft 1018, a horizontal plate 1019, a first slider 1014, a second slider 1015, and a roller 1021. The rotary motor 1010 is fixed to the outer wall of the housing 105. The output end of the rotary motor 1010 is fixedly connected to one end of the rotating shaft 1018. The other end of the rotating shaft 1018 passes through the housing 105 and is fixedly connected to the middle of the horizontal plate 1019. Support plates 1016 and 1017 are fixedly fixed at both ends of the horizontal plate 1019, respectively. A slide rod 1013 and a lead screw 1012 are arranged parallel between the support plates 1016 and 1017, respectively. The two ends of the slide rod 1013 are fixedly connected to the support plates 1016 and 1017, respectively. A rotary motor 1011 is fixed on the support plate 1016. The output end of the rotary motor 1011 is fixedly connected to one end of the lead screw 1012. The other end of the lead screw 1012 passes through the support plate 1016 and the support plate 1017 and is rotatably connected. The lead screw 1012 is rotatably connected to the support plate 1016. One end of the slider 1014 and the slider 2 1015 is slidably connected to the slide rod 1013, and the other end is rotatably connected to the lead screw 1012. Opposite threads are provided on both sides of the lead screw 1012. A bracket 1020 is fixed on the side of both slider 1014 and slider 2 1015. Multiple fixed shafts 1022 are evenly fixed on the bracket 1020. Rollers 1021 are rotatably connected to the fixed shafts 1022. Two rollers 1021 are respectively set on both sides of the hopper 102. The rotary motor 1010 and the rotary motor 1011 are electrically connected to the PLC controller 103.

[0036] When the PLC controller 103 receives deviation data from the millimeter-wave radar 101, it can quickly send commands to the rotary motor 1010 and the rotating motor 1011. The rotary motor 1010 then drives the rotating shaft 1018 to rotate, causing the horizontal plate 1019 to move, making the rollers 1021 on both sides of the hopper 102 parallel to the side walls of the hopper 102. The rotating motor 1011 is started, and the slider one 1014 and slider two 1015 move towards the center of the lead screw 1012. The rollers 1021 on both sides contact the side walls of the hopper 102, so that the rollers 1021 apply a directional force to the side walls of the hopper 102. The rotary motor 1010 rotates, causing the rollers 1021 to drive the hopper 102 back to the correct position, thereby causing the belt to... The system quickly corrects the misaligned hopper 102 and conveyor belt back to their normal operating trajectory. Its fast response effectively reduces conveyor belt misalignment time, lowering the risk of material spillage and equipment wear caused by misalignment. After correction, the rotating motor 1011 reverses direction, and sliders 1014 and 1015 move to both sides of the lead screw 1012, while roller 1021 moves away from the hopper 102. Because roller 1021 is in direct contact with the side wall of the hopper 102, the applied force and direction can be flexibly adjusted according to the degree of misalignment, achieving automatic correction without frequent manual adjustments. This reduces labor costs and intensity, improves production efficiency, ensures continuous and stable operation of the conveyor belt bucket elevator, reduces downtime for maintenance, and creates greater economic benefits for the enterprise.

[0037] The workflow of this utility model is as follows: millimeter-wave radar 101 transmits radar waves to the side plate of hopper 102 → the side plate of hopper 102 reflects the radar waves → the radar receives the reflected echo signal → the radar chip processes the signal and outputs a current signal to the PLC → the PLC parses the current signal into a digital signal to obtain the distance value → the real-time offset is calculated by formula.

[0038] Offset calculation: D = D - (Dr - Di)

[0039] Where: D: offset; D: distance between the tape and the side wall when it is in the normal position; Dr: distance value measured by radar; Di: distance between the radar lens and the side wall.

[0040] This invention sets two threshold levels with offsets of ±8mm and ±15mm.

[0041] When a continuous deviation trend occurs but the first-level deviation warning has not yet been triggered, the correction device is activated to perform automatic correction.

[0042] When the deviation value exceeds the first-level threshold (offset of ±8mm), an early warning is triggered, prompting maintenance personnel to go to the site to check the actual deviation status.

[0043] When a continuous deviation trend occurs but the first-level deviation warning has not yet been triggered, maintenance personnel are prompted to go to the site to check the actual deviation status.

[0044] If the offset continues to increase to the secondary threshold (offset of ±15mm), an emergency shutdown will be automatically triggered.

[0045] This invention utilizes the millimeter-wave radar 101 with IP protection rating to penetrate dust and smoke, enabling continuous tape positioning in isolated high-temperature (resistant to °C) and high-dust environments.

[0046] This utility model Figure 2 for Figure 3 Schematic diagram of AA.

[0047] In practical use, the millimeter-wave radar 101, installed at the top of the fixed frame 106 and protected by a polytetrafluoroethylene protective cover 107, emits radio waves through an acrylic light-transmitting plate 108 at the opening of the housing 105 to monitor the side wall of the hopper 102. The collected data is transmitted to a PLC controller 103, which receives and judges the offset value to determine whether the conveyor is misaligned. If misalignment is found, the PLC controller 103 controls the audible and visual alarm 104 on the outer wall of the housing 105 to issue a warning signal to remind the staff. On the other hand, it controls the rotary motor 1010 of the correction device. The rotary motor 1010 drives the rotating shaft 1018 to make the roller 1021 apply force to the two side walls of the hopper 102 to achieve automatic correction. At the same time, the PLC controller 103 can control the lighting lamp 109 near the millimeter-wave radar 101 to emit light as needed, assisting the radar in accurately monitoring under different lighting conditions and ensuring the stable operation of the conveyor belt bucket elevator.

[0048] In the description of this utility model, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0049] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0050] The embodiments described above are merely preferred embodiments of the present utility model and are not intended to limit the scope of the present utility model. Various modifications and improvements made to the technical solutions of the present utility model by those skilled in the art without departing from the spirit of the present utility model should fall within the protection scope defined by the claims of the present utility model.

Claims

1. A belt misalignment monitoring system for a belt bucket elevator, characterized in that: The device includes a millimeter-wave radar, a PLC controller, and a mounting bracket. One side of the mounting bracket is fixed to the outer wall of the conveyor belt bucket elevator housing. The millimeter-wave radar is mounted on the top of the mounting bracket. The housing has an opening to allow the radio waves from the millimeter-wave radar to enter the housing and reach the side wall of the conveyor belt bucket elevator hopper. The PLC controller is fixed to the outer wall of the housing, and the millimeter-wave radar is electrically connected to the PLC controller. A web-correcting device includes a rotary motor, a rotating shaft, a horizontal plate, a first slider, a second slider, and rollers. The rotary motor is fixed to the outer wall of the machine housing. The output end of the rotary motor is fixedly connected to one end of the rotating shaft. The other end of the rotating shaft passes through the machine housing and is fixedly connected to the middle of the horizontal plate. Support plates one and two are fixedly fixed to both ends of the horizontal plate. A sliding rod and a lead screw are arranged parallel between support plates one and two. The two ends of the sliding rod are fixedly connected to support plates one and two, respectively. A rotary motor is fixed to support plate one. The output end of the rotary motor is connected to the middle of the horizontal plate. One end of the lead screw is fixedly connected, and the other end of the lead screw passes through the first support plate and the second support plate and is rotatably connected. The lead screw is rotatably connected to the first support plate. One end of the first slider and the second slider are slidably connected to the slide rod, and the other end is rotatably connected to the lead screw. Opposite threads are provided on both sides of the lead screw. A bracket is fixed to both sides of the first slider and the second slider. Multiple fixed shafts are evenly fixed on the brackets. The rollers are rotatably connected to the fixed shafts. The two rollers are respectively arranged on both sides of the hopper. The rotary motor and the rotating motor are electrically connected to the PLC controller.

2. The conveyor belt misalignment monitoring system for a conveyor belt bucket elevator according to claim 1, characterized in that: The radar outer cover is equipped with a protective cover, and the bottom end of the protective cover is fixedly connected to the top end of the mounting bracket.

3. The conveyor belt misalignment monitoring system for a conveyor belt bucket elevator according to claim 2, characterized in that: The protective cover is made of polytetrafluoroethylene.

4. The conveyor belt misalignment monitoring system for a conveyor belt bucket elevator according to claim 1, characterized in that: It also includes an audible and visual alarm, which is fixed to the outer wall of the housing and electrically connected to the PLC controller.

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