PLC control-based conveyor belt deviation automatic adjusting device

Abstract

The utility model discloses a conveyor belt deviation automatic adjusting device based on PLC control, including deviation rectification roller group and deviation rectification power source, is equipped with deviation sensor group and deviation sensor group for checking with deviation rectification roller group's both sides are located respectively for detecting deviation sensor group, deviation rectification roller group and deviation sensor group for checking are sequentially arranged along the upstream section of conveyor belt's direction of travel, each deviation sensor group is connected to PLC controller respectively, and deviation rectification roller group is equipped with deviation rectification regulating valve between deviation rectification power source, and PLC controller is connected to deviation rectification regulating valve through electric control box, the cooperation of two deviation sensor groups can realize the control adjustment of PLC controller deviation rectification degree and deviation rectification control point's control, and the multistage division of deviation rectification control, to satisfy different use scene, make deviation rectification control flexible adjustable, and moreover can record and inquire the historical deviation data of conveyor belt through PLC controller, to provide data support for the improvement of later conveying system.

Description

Technical Field

[0001] This utility model relates to the technical field of supporting equipment for belt conveyors, and in particular to an automatic belt misalignment adjustment device for conveyors based on PLC control. Background Technology

[0002] Belt conveyors utilize a continuously moving conveyor belt as the load-bearing and traction component to transport bulk materials (such as ore, coal, and grain) and packaged goods (such as parcels and parts) horizontally or at an incline. They are among the most widely used and cost-effective continuous conveying equipment in material handling systems, and can also be applied in production line operations with a certain volume of continuous processes. Belt conveyors offer numerous advantages, including simple structure, stable and reliable operation, strong adaptability to conveyed materials, large conveying capacity, and low power consumption, leading to their widespread use in various manufacturing enterprises.

[0003] Due to factors such as the continuous extension of belt conveyor usage time and uneven distribution of conveyed materials on the conveyor belt, belt misalignment frequently occurs during operation. Severe misalignment can easily cause the conveyor system to malfunction and shut down, thus affecting production efficiency. Therefore, belt conveyors are equipped with anti-misalignment emergency stop devices that work in conjunction with the conveyor belt. When the conveyor belt deviates to a certain extent, the anti-misalignment emergency stop device is triggered, stopping the entire conveyor system to prevent more serious malfunctions and thus avoid greater losses.

[0004] Currently used anti-deviation emergency stop devices generally consist of two levels of control. When the conveyor belt deviates at a small angle, it is corrected by devices such as correction rollers to restore normal operation. When the conveyor belt deviates at a large angle, the conveyor system is stopped directly. The two correction control points are relatively fixed, making it difficult to flexibly adjust them according to different usage scenarios. Furthermore, dedicated maintenance personnel are required to patrol the conveyor belt during operation to ensure timely correction. It is also difficult to record and understand historical deviation data throughout the entire operation of the conveyor belt to provide data support for later querying and improvement of the conveyor system, making it inconvenient to use. Utility Model Content

[0005] The technical problem to be solved by this utility model is to provide an automatic conveyor belt misalignment adjustment device based on PLC control that can adapt the correction control point to different usage scenarios, has adjustable correction control level, and can record and query historical misalignment data.

[0006] To solve the above-mentioned technical problems, the technical solution of this utility model is: an automatic adjustment device for conveyor belt misalignment based on PLC control, including a set of correction rollers located at the bottom of the upper section of the conveyor belt, the correction rollers being connected to a correction power source, and a set of detection misalignment sensors and a set of calibration misalignment sensors respectively located on both sides of the correction rollers for use with the conveyor belt. The detection misalignment sensor set, the correction rollers, and the calibration misalignment sensor set are arranged sequentially along the travel direction of the upper section of the conveyor belt. The detection misalignment sensor set and the calibration misalignment sensor set are respectively connected to a PLC controller. A correction adjustment valve is provided between the correction rollers and the correction power source, and the PLC controller is connected to the correction adjustment valve through an electrical control box.

[0007] As a preferred technical solution, the detection misalignment sensor group includes a left misalignment sensor and a right misalignment sensor installed opposite to each other on both sides of the conveyor belt, and the left misalignment sensor and the right misalignment sensor are respectively connected to the PLC controller.

[0008] As a preferred technical solution, the calibration misalignment sensor group includes a calibration left misalignment sensor and a calibration right misalignment sensor installed opposite to each other on both sides of the conveyor belt, and the calibration left misalignment sensor and the calibration right misalignment sensor are respectively connected to the PLC controller.

[0009] As a preferred technical solution, the correction roller assembly includes a correction roller frame, a correction bottom support roller is rotatably mounted at the top center of the correction roller frame, and correction side support rollers are rotatably and obliquely mounted on both sides of the correction bottom support roller on the correction roller frame. The end of the correction side support roller close to the correction bottom support roller is movably mounted, and the end of the correction side support roller away from the correction bottom support roller is connected to a correction drive component, which is connected to the correction power source.

[0010] As a preferred technical solution, a roller support plate is fixedly installed on the correction roller frame, and a correction adapter plate is rotatably assembled with the roller support plate, with the end of the correction roller rotatably mounted on the correction adapter plate.

[0011] As a preferred technical solution, the correction drive component is a hydraulic cylinder, which is fixedly installed on the correction roller frame. The correction power source is a hydraulic oil source, and the hydraulic cylinder is connected to the hydraulic oil source through a hydraulic oil circuit. The correction regulating valve is connected in series to the hydraulic oil circuit.

[0012] As a preferred technical solution, the PLC controller is connected to a human-machine interface and an audible and visual alarm.

[0013] As an improvement to the above technical solution, the PLC controller is connected to a remote monitoring machine via a wireless communication device.

[0014] Due to the adoption of the above technical solution, the PLC-controlled automatic conveyor belt misalignment adjustment device includes a misalignment correction roller assembly located at the bottom of the upper section of the conveyor belt. The misalignment correction roller assembly is connected to a misalignment correction power source. On both sides of the misalignment correction roller assembly are respectively provided a detection misalignment sensor assembly and a calibration misalignment sensor assembly for use with the conveyor belt. The detection misalignment sensor assembly, the misalignment correction roller assembly, and the calibration misalignment sensor assembly are arranged sequentially along the travel direction of the upper section of the conveyor belt. The detection misalignment sensor assembly and the calibration misalignment sensor assembly are respectively connected to a PLC controller. A misalignment correction regulating valve is provided between the misalignment correction roller assembly and the misalignment correction power source. The PLC controller is connected to the belt deviation adjustment valve via an electrical control box. This invention offers the following advantages: the PLC controller determines whether belt deviation correction is needed by detecting signals from the belt deviation sensor group. If necessary, it controls the start of the belt deviation correction roller group. Simultaneously, with the cooperation of the verification signal from the belt deviation sensor group, the PLC controller can adjust the degree of belt deviation correction. Furthermore, the PLC controller can also adjust the belt deviation control point and implement multi-level division of belt deviation control to meet different application scenarios, making the belt deviation control flexible and adjustable. Moreover, the PLC controller can record and query historical belt deviation data to provide data support for future improvements to the conveyor system. Attached Figure Description

[0015] The following figures are intended only to illustrate and explain the present invention and do not limit the scope of the present invention. Wherein: Figure 1 This is a structural block diagram of an embodiment of the present utility model; Figure 2 This is a simplified structural diagram of an embodiment of the present utility model; Figure 3 This is a schematic diagram of the structure of the correction roller group according to an embodiment of the present invention; Figure 4 yes Figure 3 Enlarged structural diagram at point A; In the diagram: 1-Conveyor belt; 2-Correction regulating valve; 3-Correction roller frame; 4-Correction bottom idler; 5-Correction side idler; 6-Idler support plate; 7-Correction adapter plate; 8-Hydraulic cylinder; 9-Left deviation sensor for detection; 10-Right deviation sensor for detection; 11-PLC controller; 12-Left deviation sensor for calibration; 13-Right deviation sensor for calibration; 14-Remote monitoring machine. Detailed Implementation

[0016] The present invention will be further described below with reference to the accompanying drawings and embodiments. In the following detailed description, only certain exemplary embodiments of the present invention are described by way of illustration. Undoubtedly, those skilled in the art will recognize that various modifications can be made to the described embodiments without departing from the spirit and scope of the present invention. Therefore, the drawings and description are illustrative in nature and not intended to limit the scope of the claims.

[0017] like Figures 1 to 4 As shown, the PLC-controlled automatic conveyor belt misalignment adjustment device can adaptively adjust the conveyor belt's correction control points according to different usage scenarios. It also allows for multi-level correction control adjustments and can record and query historical conveyor belt misalignment data for future use. Specifically, it includes a correction roller assembly located at the bottom of the upper section of the conveyor belt 1. The correction roller assembly is connected to a correction power source, and a correction regulating valve 2 is installed between the correction roller assembly and the correction power source. When the conveyor belt 1 misaligns, the correction roller assembly corrects the misalignment under the power of the correction power source, returning it to its original position.

[0018] The corrective roller assembly includes a corrective roller frame 3, which is mounted on the belt frame of the conveyor belt 1 to form a support structure for corrective action. A bottom corrective roller 4 is rotatably mounted at the top center of the corrective roller frame 3, contacting the bottom surface of the upper section of the conveyor belt 1 to provide support. Corrective side rollers 5 are rotatably and obliquely mounted on both sides of the bottom corrective roller 4 on the corrective roller frame 3. The side rollers 5 are gradually raised outwards from the bottom corrective roller 4. With the cooperation of the two side rollers 5 and the bottom corrective roller 4, they are adapted to the belt roller assembly used to drive the conveyor belt 1, ensuring that both types of rollers fully contact the bottom surface of the conveyor belt 1 to complete the corrective action.

[0019] The straightening side idler roller 5 is movably installed at one end near the straightening bottom idler roller 4, and a straightening drive component is connected to the end of the straightening side idler roller 5 away from the straightening bottom idler roller 4. The straightening drive component is connected to the straightening power source. Under the combined drive of the straightening power source and the straightening drive component, the tilt angle of the straightening side idler roller 5 can be adjusted, thereby forcing the conveyor belt 1 to move from one side to the other when straightening is required.

[0020] like Figure 4As shown, a roller support plate 6 is fixedly installed on the correction roller frame 3, and a correction adapter plate 7 is rotatably assembled with the roller support plate 6. The end of the correction side roller 5 is rotatably mounted on the correction adapter plate 7. When the outer end of the correction side roller 5 is driven to rise and fall by the correction drive component, the inner end of the correction side roller 5 can automatically adapt to its inclination through the rotational cooperation between the correction adapter plate 7 and the roller support plate 6, thereby smoothly adjusting the inclination angle of the correction side roller 5 and ultimately achieving the correction of the conveyor belt 1.

[0021] The correction drive component is a hydraulic cylinder 8, which is fixedly mounted on the correction roller frame 3. The telescopic end of the hydraulic cylinder 8 is connected to the correction side idler roller 5. The correction power source is a hydraulic oil source, and the hydraulic cylinder 8 is connected to the hydraulic oil source through a hydraulic oil circuit. The correction regulating valve 2 is connected in series in the hydraulic oil circuit. By controlling the opening and closing of the correction regulating valve 2, the telescopic control of the hydraulic cylinder 8 is realized, thereby completing the tilt angle adjustment of the correction side idler roller 5. Of course, the correction drive component can also be an electric telescopic rod, and the corresponding correction power source is a power supply, and the correction regulating valve 2 can be adjusted to an electric control switch.

[0022] In this embodiment, a detection set of misalignment sensors and a calibration set of misalignment sensors are respectively installed on both sides of the correction roller group to cooperate with the conveyor belt 1. The detection set of misalignment sensors, the correction roller group, and the calibration set of misalignment sensors are arranged sequentially along the upward travel direction of the conveyor belt 1. The detection set of sensors and the calibration set of sensors are respectively connected to a PLC controller 11, which is connected to the correction regulating valve 2 through an electrical control box. The PLC controller 11 determines whether the conveyor belt 1 has misaligned based on the detection signal from the detection set of sensors. If misalignment is detected, the corresponding correction regulating valve 2 is activated through the electrical control box to perform correction. The PLC controller 11 determines whether the conveyor belt 1 has been corrected properly based on the detection signal from the calibration set of sensors, and adjusts the correction regulating valve 2 appropriately based on feedback to increase, decrease, or stop the adjustment of the correction roller group, thereby forming a complete control chain to achieve automatic correction of the conveyor belt 1.

[0023] Specifically, the detection sensor group includes a left misalignment sensor 9 and a right misalignment sensor 10 installed opposite each other on both sides of the conveyor belt 1. The left and right misalignment sensors 9 and 10 are respectively connected to the PLC controller 11. Based on the detection signals from the left and right misalignment sensors 9 and 10, the PLC controller 11 can control the end of the correction roller 5 to rise or fall, adjusting its tilt angle and causing the conveyor belt 1 to move. For example, if the left misalignment sensor 9 generates a detection signal indicating that the conveyor belt 1 is running to the left, the hydraulic cylinder 8 on the left side can be activated, driving the end of the correction roller 5 connected to it to rise, forcing the conveyor belt 1 to move to the right for correction. Of course, when making correction adjustments, the hydraulic cylinders 8 on both sides can be started and controlled simultaneously. This means that the hydraulic cylinder 8 on one side retracts while the hydraulic cylinder 8 on the other side extends, creating a height difference between the two sides of the conveyor belt 1 for accelerated adjustment. The control mode is flexible and can be set through the PLC controller 11.

[0024] In this embodiment, the two misalignment sensor groups are configured similarly. The calibration misalignment sensor group includes a left misalignment sensor 12 and a right misalignment sensor 13 mounted opposite each other on both sides of the conveyor belt 1. The left and right misalignment sensors 12 and 13 are respectively connected to the PLC controller 11. During the correction process, the left and / or right misalignment sensors 13 will generate signals to provide feedback on the movement of the conveyor belt 1, allowing the PLC controller 11 to control the hydraulic cylinder 8 to stop driving via the electrical control box.

[0025] The PLC controller 11 is connected to a human-machine interface and an audible and visual alarm. In this embodiment, the deviation control points of the conveyor belt 1 can be adjusted adaptively according to different usage scenarios. For example, the PLC controller 11 can divide the left deviation sensor 9 and the right deviation sensor 10 into 15° control points, 30° control points, 45° control points, and 60° control points, respectively, achieving four levels of control from low to high. Each level corresponds to different measures; for example, level one requires no adjustment, level two adjusts automatically, level three adjusts automatically and triggers an alarm via the audible and visual alarm, and level four triggers an alarm via the audible and visual alarm and initiates an emergency shutdown, facilitating inspection and handling by staff.

[0026] The PLC controller 11 is connected to a remote monitoring unit 14 via a wireless communication device. The remote monitoring unit 14 can be configured as a remote computer, smartphone, etc., to facilitate timely access to and real-time viewing of relevant information from a distance. Furthermore, the PLC controller 11, in conjunction with the remote monitoring unit 14, can record historical misalignment data of the conveyor belt 1, and even generate data tables or curves through program processing for later query and research.

[0027] After testing this embodiment on the belt conveyor of the second phase of the Lingang Yongfeng Raw Material Plant, it was found that the conveyor belt can be automatically corrected to ensure the stability of the conveyor operation. During daily operation, almost no manual operation is required, achieving unattended operation. Maintenance personnel can monitor the belt misalignment and related data in real time through a human-machine interface, and can also set and adjust parameters. The entire device is flexible and reliable in use.

[0028] The description of this utility model is given for illustrative and descriptive purposes only, and is not intended to be exhaustive or to limit the utility model to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described in order to better illustrate the principles and practical application of the utility model, and to enable those skilled in the art to understand the utility model and design various embodiments with various modifications suitable for a particular purpose.

Claims

1. A PLC-controlled automatic belt misalignment adjustment device for conveyors, comprising a set of correction rollers located at the bottom of the upper section of the conveyor belt, the correction rollers being connected to a correction power source, characterized in that: On both sides of the correction roller assembly are respectively provided a detection misalignment sensor group and a calibration misalignment sensor group for use with the conveyor belt. The detection misalignment sensor group, the correction roller assembly, and the calibration misalignment sensor group are arranged sequentially along the upward travel direction of the conveyor belt. The detection misalignment sensor group and the calibration misalignment sensor group are respectively connected to a PLC controller. A correction adjustment valve is provided between the correction roller assembly and the correction power source. The PLC controller is connected to the correction adjustment valve through an electrical control box.

2. The automatic belt misalignment adjustment device for conveyors based on PLC control as described in claim 1, characterized in that: The detection misalignment sensor group includes a left misalignment sensor and a right misalignment sensor installed opposite to each other on both sides of the conveyor belt. The left misalignment sensor and the right misalignment sensor are respectively connected to the PLC controller.

3. The automatic belt misalignment adjustment device for conveyors based on PLC control as described in claim 1, characterized in that: The calibration misalignment sensor group includes a left misalignment sensor and a right misalignment sensor installed opposite each other on both sides of the conveyor belt. The left misalignment sensor and the right misalignment sensor are respectively connected to the PLC controller.

4. The automatic belt misalignment adjustment device for conveyors based on PLC control as described in claim 1, characterized in that: The correction roller assembly includes a correction roller frame, a correction bottom support roller is rotatably mounted at the top center of the correction roller frame, and correction side support rollers are rotatably and obliquely mounted on both sides of the correction bottom support roller on the correction roller frame. The end of the correction side support roller close to the correction bottom support roller is movably mounted, and the end of the correction side support roller away from the correction bottom support roller is connected to a correction drive component, which is connected to the correction power source.

5. The automatic belt misalignment adjustment device for conveyors based on PLC control as described in claim 4, characterized in that: A roller support plate is fixedly installed on the correction roller frame, and a correction adapter plate is rotatably assembled with the roller support plate. The end of the correction roller is rotatably installed on the correction adapter plate.

6. The automatic belt misalignment adjustment device for conveyors based on PLC control as described in claim 4, characterized in that: The correction drive component is a hydraulic cylinder, which is fixedly installed on the correction roller frame. The correction power source is a hydraulic oil source, and the hydraulic cylinder is connected to the hydraulic oil source through a hydraulic oil circuit. The correction regulating valve is connected in series to the hydraulic oil circuit.

7. The automatic belt misalignment adjustment device for conveyors based on PLC control as described in claim 1, characterized in that: The PLC controller is connected to a human-machine interface and an audible and visual alarm.

8. The automatic belt misalignment adjustment device for conveyors based on PLC control as described in claim 1, characterized in that: The PLC controller is connected to a remote monitoring machine via a wireless communication device.

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