Passive End Anti-Stop Circuit for Conveyor Stalling Detection
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Solution Overview
Problem
Existing transmission equipment, particularly low-speed passive ends like bucket elevators and scraper conveyors, face challenges in detecting stalling issues due to their remote location, leading to frequent failures and significant production disruptions, which current detection systems are costly to address effectively.
Innovation Solution
An anti-stalling circuit and system incorporating a motor main circuit, control circuit with specific relay configurations, and proximity switches are implemented to detect stalling conditions in the passive end, triggering a self-locking mechanism to prevent motor operation until the issue is resolved, utilizing existing control elements with minimal additional cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a detection device is installed on the tail wheel base with a proximity switch and timing unit, then stalling detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines the stalling detection function with the existing motor control circuit by integrating the proximity switch detection into the control circuit's timing unit. This merging approach allows the detection system to share existing components (control circuit, timing unit, alarm device) rather than adding a completely separate detection system, thereby improving reliability while limiting the increase in device complexity.
Solution Approach 2:
The control circuit's timing unit is designed to serve multiple functions: it controls the motor start/stop sequence and simultaneously detects stalling conditions by monitoring the proximity switch signal duration. This multi-functionality allows the same component to perform both control and detection roles, improving reliability without proportionally increasing device complexity.
2Area of stationary object
If detection distance is increased to monitor remote passive end, then coverage area is improved, but measurement precision deteriorates
Solution Approach 1:
The patent uses the conveyor belt itself as an intermediary to transmit the stalling information from the remote passive end to the active end. The belt's tension and movement state serve as the mediator that conveys the stalling condition over distance, allowing detection at the control location without direct proximity sensing at the remote end, thus maintaining detection precision while extending coverage area.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly reduces the likelihood of major failures caused by passive end stalling at a low cost, providing clear visual and audible alarms to facilitate timely maintenance and preventing unsafe re-starts, while maintaining equipment operation until repairs are completed.
Implementation Method 1
a detection device is installed on a tail wheel base, the detection device includes a proximity switch... When the belt is running, a belt running point is closed... the iron plate approaches to the proximity switch once for each circle of rotation, under the influence of the iron plate, the proximity switch is turned on once
Data Source
AI summary
The present invention discloses an anti-stalling circuit, an anti-stalling system composed of same and an anti-stalling method. The anti-stalling circuit includes a motor main circuit and a control circuit; the anti-stalling system includes a substrate rotating synchronously with a passive end and the passive end anti-stalling circuit, the substrate is provided with a notch, the angle of the notch ranges from 150° to 170°, and the proximity switch SQ1 and the proximity switch SQ2 are installed at 180° on both sides of the substrate; and the passive end anti-stalling method is applied to the passive end anti-stalling system. The present invention can greatly reduce the probability of major failures caused by the stalling of a passive end of drive equipment at a limited cost.