A torque detection device for belt conveyors based on photoelectric detection

Abstract

This utility model discloses a torque detection device for a belt conveyor based on photoelectric detection, including a support, a main code disk, a secondary code disk, and a photoelectric encoder. Servo motors are mounted on the upper surfaces of both ends of the support. The main and secondary code disks are symmetrically distributed, and each is connected to an elastic shaft via a splined sleeve. The sides of the main and secondary code disks furthest from each other are connected to the drive shaft of the servo motors via flange couplings. This utility model integrates a dual verification mechanism of direct photoelectric detection and indirect power analysis, overcoming the technical limitations of traditional single detection modes. The photoelectric encoder achieves high-precision torque output of ±0.5% through dual code disk phase difference measurement, combined with dynamic compensation technology of the elastic shaft to eliminate installation errors and environmental interference. The indirect detection module provides redundant data support through the coordinated analysis of motor power and conveyor belt speed, ensuring the reliability of detection results under extreme operating conditions.

Description

Technical Field

[0001] This utility model belongs to the field of belt conveyor operation status monitoring technology, and in particular relates to a belt conveyor torque detection device based on photoelectric detection. Background Technology

[0002] Belt conveyors are vital for material transport in industries such as mining, ports, and power generation. Their operational status directly impacts the continuity of the production chain and personnel safety. Currently, the industry generally relies on traditional detection methods, but this single detection mode has significant hidden dangers: under overload conditions, excessive torque in the drive system can lead to belt breakage, bearing damage, or even equipment overturning. Furthermore, strain gauges in existing technologies are susceptible to temperature drift interference, resulting in data distortion, while indirect power analysis methods struggle to capture hidden faults in mechanical transmission components, creating blind spots in safety monitoring. The lag in manual inspections and offline detection further amplifies the risks, often leading to irreversible losses after an accident.

[0003] In recent years, although some technologies have attempted to improve detection reliability by integrating multi-source data, such as combining vibration and temperature sensors for health assessment, the lack of key parameters (such as real-time torque) still leads to insufficient diagnostic accuracy. More seriously, traditional solutions lack redundant design, and a single sensor failure can trigger a complete system paralysis. Under the background of stringent industrial safety regulations, there is an urgent need for a hybrid solution that integrates the accuracy of direct detection with the economic efficiency of indirect detection. Through dynamic data fusion and threshold correction, this solution can shift from passive response to proactive defense, building a multi-dimensional protection system for the safe operation of belt conveyors.

[0004] The most similar prior art solution to this invention is a belt conveyor torque monitoring system based on a single detection mode, which estimates torque through fixed strain gauges or motor power analysis. In traditional solutions, strain gauges are directly attached to the surface of the drive shaft, and torque is calculated by measuring the change in resistance signal generated by the torsional deformation of the shaft. The signal is transmitted to the PLC controller via a slip ring or wireless transmission module, and then compared with a preset threshold to determine the overload state. Another type of indirect detection solution relies on motor current and speed to calculate power, and then derives the torque value using theoretical formulas, but does not consider the influence of mechanical transmission losses and dynamic load fluctuations.

[0005] Such systems typically use wired connections or basic wireless communication for data transmission, making them susceptible to signal distortion due to electromagnetic interference in industrial environments. Furthermore, they lack multi-dimensional correlation analysis with parameters such as conveyor belt speed and vibration. Fault diagnosis relies solely on static threshold-triggered alarms, lacking the ability to identify progressive faults such as bearing wear and coupling misalignment, resulting in a high false alarm rate. Simultaneously, traditional solutions depend on manual periodic sensor calibration and replacement of worn components, making them ill-suited for harsh conditions such as high dust and high humidity, significantly increasing maintenance costs. The core deficiency of existing technologies lies in their limited detection dimensions and insufficient data fusion depth, failing to construct a closed-loop control system from real-time perception to intelligent decision-making, leading to safety protection lagging behind actual production needs. Utility Model Content

[0006] The purpose of this invention is to provide a belt conveyor torque detection device based on photoelectric detection to solve the technical problems mentioned in the background art.

[0007] To achieve the above objectives, the specific technical solution of this utility model is as follows: A belt conveyor torque detection device based on photoelectric detection includes a support, a main code disk, a secondary code disk, and a photoelectric encoder. Servo motors are installed on the upper surfaces of both ends of the support. The main code disk and the secondary code disk are symmetrically distributed, and both the main code disk and the secondary code disk are connected to an elastic shaft through a spline sleeve. The side of the main code disk and the secondary code disk that is away from each other is connected to the drive shaft of the servo motor through a flange coupling. Two photoelectric encoders are provided, and the two photoelectric encoders are symmetrically distributed. The photoelectric encoders are in contact with the surface of the elastic shaft. The bottom of the photoelectric encoder is slidably connected to the upper surface of the support through a connecting frame.

[0008] Preferably, the flange of the flange coupling has a plurality of hexagonal bolt holes arranged in a circumferential array on its surface, and the hexagonal bolt holes are filled with thread-locking adhesive.

[0009] Preferably, the surfaces of both the main code disk and the sub-code disk are formed with annular grating stripes by laser etching, and the edges of the grating stripes are treated with an aluminum oxide coating.

[0010] Preferably, the spline teeth of the spline sleeve are designed with an involute profile, and the gaps are filled with grease.

[0011] Preferably, the elastic shaft is composed of a carbon steel mandrel and a glass fiber reinforced nylon shell. The carbon steel mandrel has trapezoidal internal threaded holes at both ends and is locked to the main code disk and the auxiliary code disk by high-strength countersunk bolts. The surface of the glass fiber reinforced nylon shell is provided with a spiral stress relief groove, and a rubber sealing strip is embedded in the spiral stress relief groove.

[0012] Preferably, an annular platinum resistance temperature sensor is embedded inside the elastic shaft, and the wire of the annular platinum resistance temperature sensor is led out through the central through hole of the shaft and connected to the temperature compensation controller.

[0013] Preferably, the upper surface of the bracket is provided with an adjusting slide rail for the lateral sliding of the connecting frame, and laser alignment sensors are provided on the bracket below the main code disk and the sub code disk.

[0014] The torque detection device for belt conveyors based on photoelectric detection of this utility model has the following advantages:

[0015] 1. This utility model integrates a dual verification mechanism of direct photoelectric detection and indirect power analysis, breaking through the technical limitations of traditional single detection modes. The photoelectric encoder achieves high-precision torque output of ±0.5% through dual code disk phase difference measurement, and combines elastic shaft dynamic compensation technology to eliminate installation errors and environmental interference; the indirect detection module provides redundant data support through the coordinated analysis of motor power and conveyor belt speed, ensuring the reliability of detection results under extreme working conditions.

[0016] 2. This utility model, based on a dynamic threshold model and a multi-level response mechanism, achieves progressive protection from early warning to shutdown. When the torque exceeds 105% of the rated value, an audible and visual alarm is triggered and a remote notification is pushed; at 115%, the speed is automatically reduced and auxiliary cooling is activated; at 130% or when the bearing overheats, an emergency shutdown is initiated and hydraulic braking is activated. The system simultaneously integrates multi-parameter analysis of vibration, temperature, etc., and can accurately identify progressive faults such as reducer gear wear and coupling misalignment, avoiding production losses caused by sudden shutdowns.

[0017] 3. The flexible shaft assembly adopts a carbon steel-glass fiber composite structure, which is corrosion-resistant and has excellent torsional stiffness; the photoelectric encoder is equipped with a labyrinth seal and hard chrome plated slide rails, which can adapt to high dust and high humidity environments; the signal transmission adopts double-shielded cables and anti-interference circuit design to ensure data integrity in electromagnetic noise environments. The equipment can operate stably in harsh environments such as mines and ports, significantly reducing the investment in environmental adaptation modifications.

[0018] 4. The self-testing system leverages the existing sensor network to achieve 24 / 7 health monitoring, automatically calibrating the reference phase of the photoelectric encoder and the zero-point drift of the current transformer, reducing the frequency of manual inspections. The fault diagnosis module generates accurate maintenance work orders by matching historical data with real-time features and links them to the spare parts inventory system, shortening downtime. Compared to traditional solutions, the overall operation and maintenance cost is reduced by more than 40%.

[0019] 5. The PLC controller drives the actuators according to an exponential order, forming a "sensing-decision-control" closed loop. For example, when a slight overload is detected, it automatically adjusts the conveyor belt speed to balance the load, rather than simply stopping the machine, thus maximizing production continuity. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0022] Figure 2 for Figure 1 The right view;

[0023] Figure 3 This is a schematic diagram of the main code disk in this utility model;

[0024] Figure 4 This is a schematic diagram of the flange coupling in this utility model.

[0025] The markings in the diagram are as follows: 1. Servo motor; 2. Hex bolt hole; 3. Grating stripe; 4. Main code disk; 5. Flexible shaft; 7. Photoelectric encoder; 8. Flange coupling; 9. Secondary code disk; 10. Bracket; 11. Connecting frame; 12. Adjusting slide rail; 13. Laser alignment sensor. Detailed Implementation

[0026] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the present invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0027] In the description of the embodiments of this utility model, it should be understood that the terms "length", "vertical", "horizontal", "top", "bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing the embodiments of this utility model and simplifying the description, 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 the embodiments of this utility model.

[0028] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of embodiments of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0029] In this embodiment of the invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this embodiment of the invention according to the specific circumstances.

[0030] The following disclosure provides many different implementations or examples for different structures of the embodiments of the present invention. To simplify the disclosure of the embodiments of the present invention, specific examples of components and arrangements are described below. Of course, these are merely examples and are not intended to limit the embodiments of the present invention. Furthermore, reference numerals and / or reference letters may be repeated in different examples of the embodiments of the present invention; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various implementations and / or arrangements discussed.

[0031] To better understand the purpose, structure, and function of this utility model, the following description, in conjunction with the accompanying drawings, provides a more detailed account of a belt conveyor torque detection device based on photoelectric detection.

[0032] like Figure 1-4As shown, this utility model discloses a belt conveyor torque detection device based on photoelectric detection, comprising a support 10, a main code disk 4, a secondary code disk 9, and a photoelectric encoder 7. Servo motors 1 are mounted on the upper surfaces of both ends of the support 10. The main code disk 4 and the secondary code disk 9 are symmetrically distributed. The surfaces of both the main code disk 4 and the secondary code disk 9 are laser-etched to form annular grating stripes 3, and the edges of the grating stripes 3 are treated with an alumina coating to improve wear resistance. The main code disk 4 and the secondary code disk 9 are connected by a flexible shaft 5 via a spline sleeve. The spline teeth of the spline sleeve adopt an involute design, and the gap is filled with grease to reduce friction loss. The sides of the main code disk 4 and the secondary code disk 9 furthest from each other are connected to the drive shaft of the servo motor 1 via a flange coupling 8. The flange of the flange coupling 8 has multiple hexagonal bolt holes 2 arranged in a circumferential array, and the hexagonal bolt holes 2 are filled with thread-locking adhesive to enhance vibration resistance. Two photoelectric encoders 7 are provided, symmetrically distributed, and in contact with the surface of the elastic shaft 5. The elastic shaft 5 is composed of a carbon steel core shaft and a glass fiber reinforced nylon shell. The carbon steel core shaft has trapezoidal internal thread holes machined at both ends, and is locked to the main code disk 4 and the auxiliary code disk 9 by high-strength countersunk bolts. The surface of the glass fiber reinforced nylon shell has a spiral stress relief groove, and a rubber sealing strip is embedded in the spiral stress relief groove to prevent dust intrusion. A ring-shaped platinum resistance temperature sensor is embedded inside the elastic shaft 5. The wire of the ring-shaped platinum resistance temperature sensor is led out through the central through hole of the shaft and connected to a temperature compensation controller to dynamically correct measurement errors caused by thermal expansion. The bottom of the photoelectric encoder 7 is slidably connected to the upper surface of the bracket 10 through the connecting frame 11.

[0033] The upper surface of the bracket 10 is provided with an adjusting slide rail 12 for the lateral sliding of the connecting frame 11. The surface of the adjusting slide rail 12 is plated with hard chrome to reduce the coefficient of friction. The bracket 10 is equipped with an adjusting handle, which drives the photoelectric encoder 7 to finely adjust its position along the axis via a worm gear mechanism. The photoelectric encoder 7 integrates two sets of infrared transmitter-receiver pairs. The transmitter is equipped with a spherical lens to focus a parallel beam, and the receiver is equipped with a narrow-band filter to block ambient stray light. The relative rotation of the main and auxiliary code disks causes the phase difference of the grating stripes 3 to shift. The photoelectric encoder 7 converts the optical signal into a pulse sequence, which is transmitted to the signal processing unit via shielded twisted pair cable. The signal processing circuit board has a built-in differential amplifier module and digital filter, which can suppress electromagnetic noise and extract effective waveforms. The microcontroller analyzes the waveforms into torque values, and simultaneously collects motor current, voltage, and drum speed data to provide multi-source input for the indirect detection model.

[0034] The above describes the photoelectric detection module, which also includes a dynamic compensation mechanism. This mechanism comprises an axial floating unit and a radial correction component. The axial floating unit consists of a stacked disc spring assembly, installed between the main code disk flange and the drive shaft end face. The springs adjust their initial compression via preload bolts, allowing axial elastic displacement of the code disk to absorb thermal deformation. The radial correction component consists of a miniature linear guide rail and an eccentric cam driven by a stepper motor. Laser alignment sensors 13 are installed on the bracket 10 below both the main code disk 4 and the secondary code disk 9. When the laser alignment sensor 13 detects a concentricity deviation in the code disk, the stepper motor drives the cam to rotate, pushing the secondary code disk to slide along the guide rail to achieve real-time calibration of the grating stripes. The current transformer core of the indirect power analysis module uses a permalloy stacked structure. The secondary side signal is connected to the differential amplifier via a shielded cable. The Hall voltage sensor probe is non-contactly coupled to the motor busbar copper busbar through an insulating sleeve. The magnetoelectric speed encoder is connected to the roller shaft via a shrink sleeve. Rubber damping pads are installed at the bottom of the stator bracket to isolate mechanical vibration.

[0035] It also includes a self-testing system, which ensures reliability through a multi-level mechanism: When the equipment starts up, the elastic shaft is in a free state, the dual encoder is driven by the servo motor to rotate to the reference phase, the photoelectric encoder collects the no-load reference phase difference and writes it into the compensation register, and the current transformer and voltage sensor synchronously perform zero-point drift calibration; During operation, the microcontroller compares the direct photoelectric detection data with the indirectly calculated torque value in real time. When the deviation exceeds the limit, it triggers a sensor health check. If pulse loss or signal abnormality is detected, it automatically switches to the standby detection mode and records the fault code; After an emergency shutdown, the system starts a comprehensive diagnosis. The vibration sensor collects the gear meshing frequency of the reducer, combines it with historical data to construct a fault feature map, generates a maintenance work order, and automatically resets to a safe standby state.

[0036] The equipment achieves functional synergy through deep coupling of mechanical structure and control logic: the high-precision data from the photoelectric detection module and the redundant verification of the indirect power analysis module complement each other; the dynamic compensation mechanism of the elastic shaft eliminates installation errors and environmental interference; and the self-testing system relies on the existing sensor network to achieve real-time monitoring of health status. The main code disk flange and drive shaft adopt a transition fit, and the mating surfaces are coated with molybdenum disulfide lubricant to reduce fretting wear; the spline sleeve of the secondary code disk is positioned by pins to ensure coaxiality; the transverse slide rail of the photoelectric encoder has a scale, and the operator drives the encoder to move by fine-tuning handle, and uses a laser alignment instrument to complete the optical path calibration; the spiral stress relief groove of the elastic shaft shell is filled with a silicone buffer layer, and the groove depth is 1 / 3 of the shell thickness to balance strength and stress dispersion requirements. The temperature sensor wires are protected by PTFE insulating sleeves to avoid bending and breakage; the signal processing unit and edge computing module are interconnected through industrial Ethernet to achieve data fusion and dynamic threshold adjustment; hierarchical response commands are transmitted to the actuator via the PLC controller to complete closed-loop management from sensing to control.

[0037] The above solution, through modular integration and functional redundancy design, significantly improves system robustness while ensuring detection accuracy, providing a cost-effective solution for the safe operation of belt conveyors.

[0038] This utility model discloses a photoelectric belt conveyor torque detection device that achieves full-process monitoring through the coordinated operation of a photoelectric detection module, a dynamic compensation mechanism, and a data fusion system. The main code disk of the photoelectric detection module is rigidly connected to the drive shaft via a flange coupling, while the secondary code disk is nested with an elastic shaft via a splined sleeve. The elastic shaft is composed of a carbon steel core shaft and a fiberglass shell, fixed at both ends with countersunk bolts. The photoelectric encoder is mounted on the top of the drive shaft housing via a lateral adjustment slide rail, integrating an infrared photocell and a filter to convert the grating phase difference into a pulse signal. The axial floating unit of the dynamic compensation mechanism uses a disc spring assembly to absorb thermal deformation, and the radial correction component achieves code disk concentricity calibration via a linear guide rail and an eccentric cam. The indirect power analysis module collects motor and drum data through a current transformer, a Hall voltage sensor, and a magnetoelectric encoder. The edge computing unit fuses multi-source information to generate a comprehensive torque index, and the hierarchical response mechanism completes closed-loop control through a PLC controller linked with the actuator.

[0039] S1: The main code disk is fixed to the drive shaft via a flange coupling, and the secondary code disk is connected to the elastic shaft via a spline sleeve. The outer shell of the elastic shaft has a spiral stress relief groove and is filled with a silicone buffer layer. The servo motor drives the dual code disks to rotate to the reference phase, the photoelectric encoder collects the no-load phase difference and writes it into the register, and the current transformer and voltage sensor perform zero-point calibration.

[0040] S2: The load torque of the drive shaft causes the phase shift of the grating of the main and auxiliary code disks. The infrared light source emits a parallel beam, which is modulated by the grating to generate a pulse signal. The transimpedance amplifier and Schmitt trigger convert the light intensity change into a square wave sequence. The microcontroller analyzes the phase difference in real time and calculates the torque value.

[0041] S3: The disc spring assembly allows the main code disk to float axially by ±1.2 mm to absorb thermal expansion; when the laser alignment sensor detects the concentricity deviation of the code disk, the stepper motor drives the eccentric cam to push the secondary code disk to slide along the guide rail to calibrate the grating; the platinum resistance temperature sensor monitors the temperature rise of the elastic shaft and dynamically corrects the torque calculation model.

[0042] S4: The edge computing unit integrates photoelectric pulse signals, motor power data, and vibration spectrum, and uses a Kalman filter algorithm to generate a comprehensive torque index; when the torque exceeds 105% of the rated value, a yellow warning is triggered; when it exceeds 115%, the conveyor belt speed is reduced; and when it exceeds 130% or the bearing overheats, the power is cut off and the hydraulic brake is activated.

[0043] S5: The microcontroller compares photoelectric and indirect detection data in real time. When the deviation exceeds the limit, it triggers a sensor health check. After an emergency shutdown, the vibration sensor collects the gear meshing frequency, the infrared thermal imager scans the bearing temperature field, and combines historical data to generate a fault work order containing fault location, maintenance suggestions and spare parts inventory information, and resets the system to a safe state.

[0044] It is understood that this utility model has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of this utility model. Furthermore, under the teachings of this utility model, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of this utility model.

Claims

1. A belt conveyor torque detection device based on photoelectric detection, characterized in that: The system includes a photoelectric detection module and an indirect detection module. The photoelectric detection module is used to provide multi-source input for the indirect detection model. The photoelectric detection module includes a bracket (10), a main code disk (4), a secondary code disk (9), and a photoelectric encoder (7). Servo motors (1) are installed on the upper surfaces of both ends of the bracket (10). The main code disk (4) and the secondary code disk (9) are symmetrically distributed, and the main code disk (4) and the secondary code disk (9) are connected by an elastic shaft (5) through a spline sleeve. The main code disk (4) and the secondary code disk (9) are connected to the drive shaft of the servo motor (1) through a flange coupling (8) on the side away from each other. There are two photoelectric encoders (7). The two photoelectric encoders (7) are symmetrically distributed, and the photoelectric encoders (7) are in contact with the surface of the elastic shaft (5). The bottom of the photoelectric encoder (7) is slidably connected to the upper surface of the bracket (10) through a connecting frame (11).

2. The belt conveyor torque detection device based on photoelectric detection according to claim 1, characterized in that: The flange of the flange coupling (8) has a plurality of hexagonal bolt holes (2) arranged in a circumferential array on its surface, and the hexagonal bolt holes (2) are filled with thread-locking adhesive.

3. The belt conveyor torque detection device based on photoelectric detection according to claim 1, characterized in that: The surfaces of the main code disk (4) and the sub-code disk (9) are formed with annular grating stripes (3) by laser etching, and the edges of the grating stripes (3) are treated with an aluminum oxide coating.

4. The belt conveyor torque detection device based on photoelectric detection according to claim 1, characterized in that: The spline tooth profile of the spline sleeve adopts an involute design, and the gap is filled with grease.

5. The belt conveyor torque detection device based on photoelectric detection according to claim 1, characterized in that: The elastic shaft (5) is composed of a carbon steel mandrel and a glass fiber reinforced nylon shell. The carbon steel mandrel has trapezoidal internal thread holes at both ends and is locked to the main code disk (4) and the auxiliary code disk (9) by high-strength countersunk bolts. The surface of the glass fiber reinforced nylon shell is provided with a spiral stress relief groove and a rubber sealing strip is embedded in the spiral stress relief groove.

6. The belt conveyor torque detection device based on photoelectric detection according to claim 1, characterized in that: An annular platinum resistance temperature sensor is embedded inside the elastic shaft (5). The wire of the annular platinum resistance temperature sensor is led out through the central through hole of the shaft and connected to the temperature compensation controller.

7. The belt conveyor torque detection device based on photoelectric detection according to claim 1, characterized in that: The upper surface of the bracket (10) is provided with an adjusting slide rail (12) for the lateral sliding of the connecting frame (11), and laser alignment sensors (13) are provided on the bracket (10) below the main code disk (4) and the sub-code disk (9).

8. The belt conveyor torque detection device based on photoelectric detection according to claim 1, characterized in that: The indirect detection module is an indirect power analysis module. The current transformer core of the indirect power analysis module adopts a permalloy laminated structure. The secondary side signal is connected to the differential amplifier through a shielded cable. The Hall voltage sensor probe is non-contactly coupled to the motor bus copper busbar through an insulating sleeve. The magnetoelectric speed encoder is connected to the drum shaft through a shrink sleeve. Rubber shock-absorbing pads are set at the bottom of the stator support to isolate mechanical vibration.

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