A multi-belt remote control system

Abstract

The application discloses a multi-belt remote control system for remotely controlling a plurality of belt conveyors and improving the production efficiency of a mine slag field. The application comprises an operation station, a LORA base station, a LORA terminal, a PLC controller and the belt conveyors. The operation station is installed in a main control room of the mine slag field and connected with the LORA base station. The LORA terminal is installed on the belt conveyors and connected with the LORA base station, and there are at least two belt conveyors. The PLC controller is installed on the belt conveyors and connected with the LORA terminal. The operation station is used for sending control instructions for the belt conveyors to the LORA base station. The LORA base station is used for transmitting the control instructions to the LORA terminal and feeding back operation data of the belt conveyors. The LORA terminal is used for forwarding the control instructions to the PLC controller and feeding back the operation data of the belt conveyors. The PLC controller is used for executing the control instructions and feeding back the operation data of the belt conveyors. The belt conveyors are used for conveying slag.

Description

Technical Field

[0001] This application relates to the field of industrial automation control technology, and in particular to a remote control system for multiple belts. Background Technology

[0002] In industrial settings such as mineral fertilizer production and mine material transfer, belt conveyors are core equipment for continuous material transport, undertaking the long-distance transfer of bulk materials such as slag and ore. The stable operation of belt conveyors affects the continuity of production processes, material turnover efficiency, and enterprise production cost control, and is the foundation for ensuring smooth industrial production.

[0003] In existing technologies, belt conveyors mostly employ control cable connections or access to distributed control systems (DCS) for basic control functions such as starting and stopping the conveyor and providing operational status feedback. This cable-based or DCS-connected control method, to a certain extent, meets the management needs of belt conveyors in short-distance, simple scenarios, allowing operators to gain a preliminary understanding of the conveyor's operation from the central control room, thus establishing a basic automated control system for belt conveying in industrial production.

[0004] However, as industrial settings expand to long-distance, complex outdoor layouts, traditional wired control methods require laying more cables to control each belt conveyor. But with the increased number of cables, problems such as complex joints, leakage, and cross-current can easily arise, leading to decreased production efficiency and failing to meet the modern industrial demands for efficient control of belt conveyor systems. Utility Model Content

[0005] To address the aforementioned technical problems, this application provides a multi-belt remote control system for remotely controlling multiple belt conveyors, thereby improving the production efficiency of slag yards.

[0006] The technical solution provided in this application is described below: This application provides a multi-belt remote control system, characterized in that it includes: Operator station, LoRa base station, LoRa terminal, PLC controller, and belt conveyor; The operating station is installed in the main control room of the slag yard and is connected to the LORA base station; The LORA terminal is installed on the belt conveyor and connected to the LORA base station, and there are at least two belt conveyors; The PLC controller is installed on the belt conveyor and connected to the LORA terminal; The operator station is used to send control commands to the belt conveyor to the LORA base station. The LORA base station is used to transmit the control commands to the LORA terminal and to feed back the operating data of the belt conveyor; The LORA terminal is used to forward the control commands to the PLC controller and to feed back the operating data of the belt conveyor; The PLC controller is used to execute the control instructions and provide feedback on the operating data of the belt conveyor; The belt conveyor is used to transport slag.

[0007] Optionally, the LORA terminal is installed in the motor control cabinet of the belt conveyor, the discharge port of the belt conveyor, the turning point of the belt conveyor, the discharge port of the belt conveyor, the roller of the belt conveyor, and the belt overlap of the belt conveyor.

[0008] Optionally, the LORA base station is communicatively connected to the operator station and is distributed in a star topology in the slag yard.

[0009] Optionally, the LORA terminal is communicatively connected to the LORA base station and to adjacent LORA terminals, forming a ring structure.

[0010] Optionally, the LoRa terminal is a terminal equipped with LoRa technology communication functionality.

[0011] Optionally, the belt conveyor is equipped with sensors, including motor current sensors or belt misalignment sensors.

[0012] Optionally, the LORA terminal has a closed housing to reduce dust and fog interference from slag heaps.

[0013] Optionally, the operator station is equipped with a human-machine interface for displaying the control commands and the operating data of the belt conveyor.

[0014] Optionally, the LORA terminal is equipped with an independent power supply.

[0015] As can be seen from the above technical solutions, this application has the following beneficial effects: Operators can remotely send control commands to the belt conveyors from the operator station. These commands are then transmitted sequentially through LoRa base stations and LoRa terminals to the PLC controllers of all belt conveyors in the slag yard, controlling the start and stop of the conveyors and avoiding the safety hazards and efficiency losses associated with manual on-site operation. Simultaneously, the PLC controllers can collect the belt conveyor operating data and feed it back to the operator station via LoRa terminals and base stations, facilitating remote monitoring of equipment status and dynamic adjustment of the conveyor operation plans. Through the collaborative architecture of the operator station, LoRa base stations, LoRa terminals, PLC controllers, and belt conveyors, wireless remote control of multiple belt conveyors is achieved. Even with an increased number of conveyors and a more complex layout, the need for extensive cabling is eliminated, reducing wiring costs and the risks associated with excessive cabling, thereby improving the production efficiency of the slag yard. Attached Figure Description

[0016] Figure 1 A schematic diagram of the structure of the multi-belt remote control system provided in this application. Detailed Implementation

[0017] In this application, the terms "upper", "lower", "left", "right", "front", "rear", "top", "bottom", "inner", "outer", "middle", "vertical", "horizontal", "lateral", "longitudinal" and other terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only used to describe the relative positional relationship between the components or parts and do not specifically limit the specific installation orientation of each component or part.

[0018] Furthermore, in addition to indicating location or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in some cases to indicate a certain dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0019] Furthermore, the terms "installation," "setup," "equipped with," "connection," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral structure; 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, or an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0020] Furthermore, the structures, proportions, sizes, etc., drawn in the accompanying drawings of this application are only used to complement the content disclosed in the specification for those skilled in the art to understand and read, and are not intended to limit the conditions under which this application can be implemented. Therefore, they have no substantial technical significance. Any modification to the structure, change in the proportional relationship, or adjustment of the size, without affecting the effects and purposes that this application can produce, should still fall within the scope of the technical content disclosed in this application.

[0021] The technical solutions of this application will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0022] See Figure 1 This application first provides an embodiment of a multi-belt remote control system, which includes: 1. Operator station; 2. LoRa base station; 3. LoRa terminal; 4. PLC controller; and 5. Belt conveyor. Operation station 1 is installed in the main control room of the slag yard and is connected to LORA base station 2; LORA terminal 3 is installed on belt conveyor 5 and connected to LORA base station 2. There are at least two belt conveyors 5. PLC controller 4 is installed on belt conveyor 5 and connected to LORA terminal 3; Operation station 1 is used to send control commands to belt conveyor 5 to LORA base station 2; LORA base station 2 is used to transmit control commands to LORA terminal 3 and to feed back the operating data of belt conveyor 5; LORA terminal 3 is used to forward control commands to PLC controller 4 and to provide feedback on the operating data of belt conveyor 5; PLC controller 4 is used to execute control commands and provide feedback on the operating data of belt conveyor 5; Belt conveyor 5 is used to transport slag.

[0023] Operation Station 1: Operation Station 1 is a central control device deployed in the main control room of the slag yard for remote centralized control. It can consist of an industrial computer, a monitoring display, and a human-machine interface. Operators can send control commands to the belt conveyor 5 through Operation Station 1, such as start / stop commands, belt speed adjustment commands, and unloading direction switching commands. Operation Station 1 can display real-time operating data of each belt conveyor 5 fed back from the LORA base station 2, such as motor current, operating temperature, and belt misalignment. Simultaneously, Operation Station 1 can analyze this operating data and generate reports for fault warning purposes.

[0024] LoRa Base Station 2: LoRa (Long Range Radio) is a long-range radio transmission technology. LoRa Base Station 2 is a communication hub device based on LoRa wireless technology, equipped with a high-gain antenna, radio frequency module, and data forwarding server. It serves as the transmission bridge between Operator Station 1 and LoRa Terminal 3. At least two LoRa Base Stations 2 are typically set up to receive control commands from Operator Station 1 and broadcast them to the corresponding LoRa Terminal 3 via the LoRa protocol. Simultaneously, LoRa Base Station 2 is responsible for collecting operational data from each LoRa Terminal 3, summarizing it, and transmitting it back to Operator Station 1. LoRa Terminal 3: LoRa Terminal 3 is a terminal equipped with LoRa communication technology. LoRa Terminal 3 is installed at multiple key locations on the belt conveyor 5, including the motor control cabinet, the discharge port, the turning points, the outlet, the rollers, and the belt overlap points. It enables comprehensive monitoring and rapid data acquisition of the belt conveyor 5's operating status through wireless communication technology. LoRa Terminal 3 can modulate received digital signals into LoRa wireless signals and transmit them to LoRa Base Station 2 via Ethernet. It can also demodulate received LoRa signals into digital signals and transmit them to PLC Controller 4, enabling remote acquisition of belt conveyor 5's operating data and wireless transmission of control commands.

[0025] PLC Controller 4: A PLC (Programmable Logic Controller) is a digital electronic device for industrial automation control. The PLC controller collects signals from sensors, buttons, and other devices through various input interfaces, performs logic operations, sequential control, timing and counting based on its built-in user program, and then controls the actions of actuators such as motors and solenoid valves through its output interfaces to achieve automated control of industrial equipment.

[0026] Belt conveyor 5: A belt conveyor 5 is a mechanical device that uses the continuous movement of a conveyor belt to transport materials. In slag heaps, it is mainly used for the continuous transport of slag. Multiple belt conveyors 5 are typically used in slag heaps to maintain production activities. A belt conveyor 5 usually consists of a drive motor, drive drums, a conveyor belt, and idlers. The motor drives the drums to rotate, which in turn drives the closed conveyor belt to circulate, allowing the slag to be smoothly transported from the feed end to the discharge end on the conveyor belt. This achieves material transfer, reduces manual handling costs, and improves the continuity of transportation.

[0027] Working Principle: The operator inputs control commands into operator station 1. Operator station 1 then transmits the control commands wirelessly to LoRa base station 2. LoRa base station 2 forwards the signal to the corresponding LoRa terminal 3 based on the target address of the control command. LoRa terminal 3 transmits the control commands to PLC controller 4. PLC controller 4 parses the control commands and drives the corresponding devices on belt conveyor 5, changing the operating status of belt conveyor 5. Simultaneously, PLC controller 4 collects real-time operating data of belt conveyor 5 through various sensors on belt conveyor 5, such as motor current value and belt offset. PLC controller 4 processes the collected operating data and sends it to LoRa terminal 3, which then sends it to LoRa base station 2. LoRa base station 2 then aggregates the feedback data from all LoRa terminals 3 and transmits it to operator station 1 via Ethernet. Operator station 1 parses and displays the data, providing the operator with operating data for belt conveyor 5, facilitating adjustments to belt conveyor 5. When operator station 1 detects abnormal data, the operator can immediately send control commands such as correction or start / stop of belt conveyor 5 through operator station 1. The control commands are transmitted sequentially through LORA base station 2 and LORA terminal 3 to PLC controller 4. PLC controller 4 executes the control commands, adjusts the operating status of belt conveyor 5, and continuously feeds back the adjusted operating data of belt conveyor 5, realizing dynamic remote control.

[0028] In this embodiment, operators can remotely send control commands to the belt conveyor 5 from the operating station 1. These commands are then transmitted sequentially through the LORA base station 2 and the LORA terminal 3 to the PLC controllers 4 of all belt conveyors 5 in the slag yard, thereby controlling the start and stop of the belt conveyors 5 and avoiding the safety hazards and efficiency losses associated with manual on-site operation. Simultaneously, the PLC controllers 4 can also collect the operating data of the belt conveyors 5 and feed it back to the operating station 1 through the LORA terminal 3 and the LORA base station 2, facilitating remote monitoring of equipment status and dynamic adjustment of the belt conveyor 5's operating schedule by the operators. Through the collaborative architecture of the operating station 1, LORA base station 2, LORA terminal 3, PLC controller 4, and belt conveyors 5, wireless remote control of multiple belt conveyors 5 is achieved. Even with an increased number of belt conveyors 5 and a complex layout, the need for extensive cabling is eliminated, reducing wiring costs and risks associated with excessive cabling, thereby improving the production efficiency of the slag yard.

[0029] In an optional embodiment, LORA base station 2 is communicatively connected to operator station 1 and is distributed in a star topology at the slag yard.

[0030] LoRa terminal 3 communicates with LoRa base station 2 and with adjacent LoRa terminal 3, forming a ring structure.

[0031] In this embodiment, with operator station 1 as the center, all LORA base stations 2 are distributed in a star topology in the slag yard. All LORA base stations 2 communicate directly with operator station 1, facilitating centralized management and rapid command issuance, and ensuring efficient transmission of control signals. Meanwhile, LORA terminals 3 form a ring structure. Each LORA terminal 3 can not only interact directly with the base station but also relay data through adjacent LORA terminals 3. When the direct link between a LORA terminal 3 and LORA base station 2 is interrupted due to factors such as slag yard dust or distance, data can be transmitted via the ring path, avoiding communication interruption. This hybrid topology architecture achieves both high efficiency in remote control and enhances system reliability through ring redundancy. It effectively solves the communication problems of signal attenuation and wide equipment distribution in the complex environment of the slag yard, ensuring real-time uploading of belt conveyor 5 operating data and timely issuance of control commands, as well as the flexibility and scalability of remote control.

[0032] In an optional embodiment, the belt conveyor 5 is equipped with sensors, including a motor current sensor or a belt misalignment sensor.

[0033] In this embodiment, various sensors, such as motor current sensors or belt misalignment sensors, are installed on the belt conveyor 5 to facilitate the collection of operating data. The motor current sensor collects the current signal of the motor in real time and converts it into a signal recognizable by the PLC controller 4 for transmission. This is used to determine whether the motor of the belt conveyor 5 is overloaded, experiencing phase loss, or stalled, providing crucial data for fault early warning of the belt conveyor 5. The belt misalignment sensor is typically installed on the brackets on both sides of the belt. When the belt misalignment exceeds a preset threshold, the belt misalignment sensor outputs an analog offset value, which is transmitted to the PLC controller 4 via a signal. The PLC controller 4 then feeds back the signal to the operator station 1 through the LORA terminal 3 and the LORA base station 2. The coordinated deployment of various sensors allows for real-time monitoring of the operating status of the belt conveyor 5 from multiple perspectives, providing fundamental data support for the safe and stable operation of the belt conveyor 5.

[0034] In an optional embodiment, the LORA terminal 3 has a closed housing designed to reduce dust and fog interference from slag heaps.

[0035] In this embodiment, during operations at the slag heap, a large amount of dust and mist pollutants are present in the air. Dust intrusion can easily cause short circuits, interface oxidation, and component wear inside the LORA terminal 3, thus affecting the wireless communication stability and lifespan of the LORA terminal 3. The LORA terminal 3 adopts a closed shell, which can effectively block dust and mist, adapt to the harsh environment of the slag heap with high dust and mist, ensure the accuracy and continuity of data transmission, and reduce equipment failure rate and maintenance costs.

[0036] In an optional embodiment, the LORA terminal 3 is provided with an independent power supply.

[0037] In this embodiment, the slag heap environment is complex, and the on-site power supply lines are susceptible to vibrations from the belt conveyor 5 and collisions during material transport, leading to power outages or voltage instability. This could interrupt data transmission from the LORA terminal 3, thereby affecting the remote monitoring and control of the belt conveyor 5. An independent power supply allows the LORA terminal 3 to continue operating even in the event of a main power failure, ensuring that critical operational data is not lost and control commands are not interrupted. Furthermore, independent power supply eliminates the need for a complex on-site wiring system, facilitating the deployment of the LORA terminal 3 at various critical locations on the belt conveyor 5 and enhancing the equipment's environmental adaptability and flexibility.

[0038] In an optional embodiment, the operator station 1 is provided with a human-machine interface for displaying control commands and operating data of the belt conveyor 5.

[0039] In this embodiment, the operator station 1 is equipped with a human-machine interface (HMI). The HMI graphically displays control commands issued by the operator and key operating data of the belt conveyor 5 in real time, transforming complex equipment status into visual information. This allows operators to quickly grasp the operating status of the belt conveyor 5 without requiring manual on-site operation. Simultaneously, the interface supports command input, allowing operators to conveniently issue control commands through clicks, drags, and other operations, eliminating the need for complex code programming and lowering the operational threshold. Furthermore, the HMI can integrate an alarm function. When the operating data of the belt conveyor 5 exceeds a preset threshold, the HMI will alert the operator with sound and light. Combined with historical data curves and reporting functions, this helps operators trace faults and perform equipment maintenance, improving the remote management level and production efficiency of material transportation in the slag yard.

Claims

1. A multi-belt remote control system, characterized in that, include: Operator station, LoRa base station, LoRa terminal, PLC controller, and belt conveyor; The operating station is installed in the main control room of the slag yard and is connected to the LORA base station; The LORA terminal is installed on the belt conveyor and connected to the LORA base station, and there are at least two belt conveyors; The PLC controller is installed on the belt conveyor and connected to the LORA terminal; The operator station is used to send control commands to the belt conveyor to the LORA base station. The LORA base station is used to transmit the control commands to the LORA terminal and to feed back the operating data of the belt conveyor; The LORA terminal is used to forward the control commands to the PLC controller and to feed back the operating data of the belt conveyor; The PLC controller is used to execute the control instructions and provide feedback on the operating data of the belt conveyor; The belt conveyor is used to transport slag.

2. The remote control system according to claim 1, characterized in that, The LORA terminal is installed on the motor control cabinet of the belt conveyor, the unloading port of the belt conveyor, the turning point of the belt conveyor, the discharge port of the belt conveyor, the rollers of the belt conveyor, and the belt overlap of the belt conveyor.

3. The remote control system according to claim 1, characterized in that, The LORA base station is communicatively connected to the operator station and is distributed in a star topology in the slag yard.

4. The remote control system according to claim 1, characterized in that, The LORA terminal communicates with the LORA base station and with adjacent LORA terminals, forming a ring structure.

5. The remote control system according to claim 1, characterized in that, The LoRa terminal is a terminal equipped with LoRa technology communication capabilities.

6. The remote control system according to claim 1, characterized in that, The belt conveyor is equipped with sensors, including motor current sensors or belt misalignment sensors.

7. The remote control system according to claim 5, characterized in that, The LORA terminal has a closed housing, which is used to reduce dust and fog interference from slag heaps.

8. The remote control system according to claim 1, characterized in that, The operator station is equipped with a human-machine interface for displaying the control commands and the operating data of the belt conveyor.

9. The remote control system according to claim 5, characterized in that, The LORA terminal is equipped with an independent power supply.

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