CN115027907B - PID control-based cooperative self-adaptive adjustment method for tension of conveyor belt - Google Patents
PID control-based cooperative self-adaptive adjustment method for tension of conveyor belt Download PDFInfo
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
- B65G43/04—Control devices, e.g. for safety, warning or fault-correcting detecting slip between driving element and load-carrier, e.g. for interrupting the drive
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G15/00—Conveyors having endless load-conveying surfaces, i.e. belts and like continuous members, to which tractive effort is transmitted by means other than endless driving elements of similar configuration
- B65G15/30—Belts or like endless load-carriers
- B65G15/32—Belts or like endless load-carriers made of rubber or plastics
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G23/00—Driving gear for endless conveyors; Belt- or chain-tensioning arrangements
- B65G23/02—Belt- or chain-engaging elements
- B65G23/04—Drums, rollers, or wheels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G23/00—Driving gear for endless conveyors; Belt- or chain-tensioning arrangements
- B65G23/44—Belt or chain tensioning arrangements
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/10—Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working
Abstract
The invention discloses a conveyor belt tension cooperative self-adaptive adjustment method based on PID control, which comprises the steps of calculating average material mass, average belt speed and material mass flow in unit time of a conveyor belt; calculating the optimal running belt speed of the conveying belt; calculating a theoretical maximum tension difference value of the conveyor belt, and calculating the minimum traction force required by the conveyor belt under the energy-saving variable-frequency speed regulation; and performing variable frequency speed regulation on the conveyor belt according to the optimal running belt speed of the conveyor belt, and adjusting the current wrap angle between the conveyor belt and the driving roller. According to the invention, through monitoring the real-time speed and the tension value of the conveyer belt and adjusting the wrap angle of the driving roller, the problem of unbalanced tension of the conveyer belt in the speed change process can be effectively solved, so that the service life of the conveyer belt is prolonged.
Description
Technical Field
The invention relates to the technical field of sensing and measurement and control, in particular to a conveyor belt tension cooperative self-adaptive adjustment method based on PID control.
Background
As a key continuous transportation device in coal mining, the belt conveyor has high reliability, is easy to arrange depending on terrains, and is widely applied to the sites such as mining area drift, mining area mountain climbing and descending, transportation main drift, wellhead transportation corridor and the like. Because the belt conveyor is started and stopped and needs to buffer under the action of tension of the conveying belt, the tension is particularly required to be timely adjusted according to different conveying amounts, and therefore stable conveying of materials is achieved. Therefore, the automatic tension adjustment of the belt conveyor plays an important role in ensuring the safe and stable conveying of the belt conveyor.
At present, a belt conveyor is commonly used for realizing tension adjustment by heavy hammer tensioning, fixed tensioning or automatic tensioning and other devices. The weight tensioning device adjusts the tensioning force by adjusting the weight of the weight, and is suitable for the running condition that the load on the conveyer belt is considered to be constant and the acceleration of the conveyer belt is constant. And the length is more than 50m and satisfies a certain lower installation space. The fixed tensioning device ensures that the tensioning force on the belt is constant by fixing the position of the tensioning roller, the conveying belt is required to be suspended for transportation during adjustment, the tensioning force of the tensioning mode is required to be judged by field experience of operators, and the working efficiency is low. The automatic tensioning device can realize real-time adjustment of the tension of the conveying belt, and is more complex in structure and more suitable for long-distance transportation.
In summary, the position and tension output of a reasonable tensioning device should make the whole conveyer belt Cheng Zhangli proper, so that the tension required by the normal operation of the conveyer belt can be met, and faults such as excessive stretching of the conveyer belt or overload operation of the rollers caused by excessive tension can be avoided. Therefore, aiming at the tensioning problem of the belt conveyor, it is important to design a tensioning system which is high in flexibility, stable and efficient and capable of detecting in real time.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provides a conveying belt tension cooperative self-adaptive adjustment method based on PID control. The invention has strong practicability, high automation degree, safety and reliability and can realize the self-adaptive control of the conveyer belt tension of the large and small belt conveyer for coal mining.
The above object of the present invention is achieved by the following technical means:
a conveyor belt tension cooperative self-adaptive adjustment method based on PID control comprises the following steps:
step 1, obtaining the instantaneous belt speed of a conveyor belt in unit time T through a photoelectric encoder, obtaining the material mass M of the conveyor belt in unit time T through an electronic belt scale, obtaining the corresponding conveyor belt tension through tension sensors arranged at a carrier roller and a lower carrier roller on the conveyor belt, and calculating the average material mass M (T), the average belt speed v (T) and the material mass flow M (T) of the conveyor belt in unit time T;
step 2, calculating the optimal running belt speed of the conveyer belt based on the target planning model;
step 3, calculating the tension P of any research point on the wrap angle arc, and calculating the theoretical maximum tension difference F 'of the conveyer belt' max Calculating the minimum traction force F required by the conveyer belt under the energy-saving variable-frequency speed regulation 0 The tension difference value Ps of the actual conveyor belt is at the minimum traction force F by adjusting the first hydraulic rod and the second hydraulic rod 0 And a theoretical maximum tension difference F 'of the conveyor belt' max The first hydraulic rod is close to the driving roller of the conveying belt compared with the second hydraulic rod, the first hydraulic rod is positioned below the descending conveying belt, and the first hydraulic rod pushes the lower conveying belt upwards when being extended and does not contact with the lower conveying belt after being retracted; the second hydraulic rod is positioned above the descending conveyor belt, and downwards presses the conveyor belt when the second hydraulic rod extends, and the second hydraulic rod is not contacted with the lower conveyor belt after the second hydraulic rod retracts;
step 4, the frequency converter executes frequency conversion speed regulation on the conveyer belt according to the optimal running belt speed of the conveyer belt calculated in the step 2, records the acceleration change on the driving roller through a speed sensor connected on the driving roller, calculates the average acceleration after the real-time speed change time as a,
the current wrap angle between the conveyer belt and the driving roller is obtained through a pressure sensor which is circumferentially stuck on the driving roller,
calculating a target wrap angle quantity of a driving roller in the acceleration process of the conveyor, calculating a wrap angle quantity difference value between the current wrap angle quantity and the target wrap angle quantity, and performing PID operation on the wrap angle quantity difference value to obtain a telescopic quantity of a first hydraulic rod, wherein a second hydraulic rod is in contact with a lower conveying belt but the telescopic quantity is not regulated;
and calculating a target wrap angle quantity of the driving roller in the speed reduction process of the conveyor, calculating a wrap angle quantity difference value between the current wrap angle quantity and the target wrap angle quantity, and performing PID operation on the wrap angle quantity difference value to obtain a telescopic quantity of the second hydraulic rod, wherein the first hydraulic rod is retracted and is not contacted with the lower conveying belt.
The target planning model of step 2 as described above is:
wherein θ is 1 ＝cfLg(q Rc +q Ru +2q B cosδ)/η 1 η 2
θ 2 ＝g(cfLcosδ+H)/η 1 η 2
Wherein:
P A the power required by the driving roller of the belt conveyor;
q is the material quantity conveyed by the belt conveyor in each hour;
Q max the maximum conveying material quantity which can be born by the belt conveyor per hour;
l is the total horizontal projection length of the belt conveyor;
h is the total vertical lifting height of the belt conveyor;
ρ is the material density;
delta is the inclination angle of the conveyor belt;
q B the mass of the conveyor belt is the unit length;
q Rc the weight of the carrier roller is rotated for bearing the weight of the side of a unit length;
Q Ru the carrier roller mass is rotated in a return stroke of unit length;
f is the simulated coefficient of friction;
g is gravity acceleration;
c is a length coefficient of the belt conveyor;
V max the maximum belt speed which can be borne by the belt conveyor under full load is set;
V min the minimum belt speed for transporting bulk materials for the belt conveyor;
η 1 is the transmission efficiency;
η 2 is a machineEfficiency is improved;
t is the time t in unit time;
m (t+kT) is an average material mass value from the moment t to k unit time in unit time;
v * and (t+ (k+1) T) is the optimal running belt speed of the conveyor belt after t+ (k+1) T time.
In step 3 described above, the calculation of the tension P at any one of the points of investigation on the cornering circular arc is based on the following formula
p＝P 2 e μθ
Wherein P2 is the tension value at the separation point B, and mu is the friction coefficient between the conveyor belt and the driving roller; lambda is the actual wrap angle between the current conveyor belt and the driving roller, and theta is the wrap angle between the separation point B and the research point P on the conveyor belt;
in step 3, as described above, the theoretical maximum tension difference F 'of the conveyor belt' max Based on the following formula:
wherein lambda is max The maximum wrap angle quantity which can be borne by the conveying belt and the driving roller is set as n, and the friction force reserve coefficient;
in the step 3, the minimum traction force F required by the conveyer belt under the energy-saving variable-frequency speed regulation 0 Based on the following formula:
F O ＝1.1(F Z +F k )
F Z ＝k d (q+q d +q Ro )Lgc′cosβ+(q+q d )Lgsinβ
F k ＝k d (q d +q RU )Lgc″cosβ+q d Lgsinβ
wherein: k (k) d Is a multiplying factor; f (F) Z Resistance of the heavy load section of the conveyor belt; f (F) K Resistance of a light load section of the conveyor belt; q is the linear density of the material; q d Is the density of the conveyor belt; q R0 The mass of the rotating part is the length of each meter of the bearing branch carrier roller; q Ru For returning the branch carrier roller to rotate per meter lengthThe mass of the portion; l is the paving length of the conveying belt; beta is the paving inclination angle of the conveying belt; g is gravity acceleration; c is the total running resistance coefficient; c' is the running resistance coefficient of the heavy load section; and c' is the running resistance coefficient of the no-load section.
In the step 4 as described above,
target wrap angle lambda of driving roller in acceleration process of conveyor 2 Based on the following formula:
target wrap angle lambda of driving roller in speed reduction process of conveyor 3 Based on the following formula:
wherein P is 2 For the tension value at separation point B, lambda 1 For the wrap angle of the drive roller before accelerating, lambda' 1 The wrap angle of the driving roller before deceleration is w is the mass of the driving roller, a is the acceleration, and mu is the friction coefficient between the conveying belt and the driving roller.
Compared with the prior art, the invention has the following advantages:
1. according to the invention, through monitoring the real-time speed and the tension value of the conveyer belt and adjusting the wrap angle of the driving roller, the problem of unbalanced tension of the conveyer belt in the speed change process can be effectively solved, so that the service life of the conveyer belt is prolonged.
2. The invention controls the expansion and contraction of the hydraulic rod through the PID system so as to adjust the tension of the conveying belt, and has the advantages of strong flexibility, high adjusting speed, small error and low cost.
3. The hydraulic rods adopted by the invention are all detachable, and can be maintained and replaced if damaged, so that the installation cost is low.
Drawings
FIG. 1 is a schematic diagram of a conveyor belt tension cooperative adaptive adjustment system based on PID control;
FIG. 2 is a schematic diagram of a solution of the infinitesimal method.
In the figure: 1-a hydraulic cylinder; 2-a control system; 3-driving the roller; 4-a pressure sensor; 5-a first tension sensor; 6-an upper carrier roller; 7-an electronic belt scale; 8-a lower carrier roller; 9-a second tension sensor; 10-a second hydraulic stem; 11-a first hydraulic rod.
Detailed Description
The present invention will be further described in detail below in conjunction with the following examples, for the purpose of facilitating understanding and practicing the present invention by those of ordinary skill in the art, it being understood that the examples described herein are for the purpose of illustration and explanation only and are not intended to limit the invention.
A conveyor belt tension cooperative self-adaptive adjusting system based on PID control comprises a control system, a hydraulic cylinder, a first hydraulic rod, a second hydraulic rod, a first tension sensor, a second tension sensor, a pressure sensor and an electronic belt scale.
The pressure sensors are circumferentially distributed on the periphery of the driving roller and used for monitoring the stress of the driving roller, and then information such as meeting points, separating points, wrap angle amounts and the like can be obtained.
The first tension sensor is arranged at a carrier roller on the conveying belt close to the driving roller and used for collecting real-time tension of the upper conveying belt.
The second tension sensor is arranged at the lower carrier roller of the conveyer belt close to the driving roller and is used for collecting real-time tension of the lower conveyer belt.
The electronic belt scale is arranged below the upper conveying belt and is used for measuring the quality of materials on the conveying belt.
The first hydraulic rod is positioned below the descending conveyor belt, pushes the lower conveyor belt upwards during extension, and is not contacted with the lower conveyor belt after retraction compared with the second hydraulic rod which is close to the driving roller of the conveyor belt; the second hydraulic rod is positioned above the descending conveyor belt, and downwards presses the conveyor belt when the second hydraulic rod extends, and the second hydraulic rod is not contacted with the lower conveyor belt after the second hydraulic rod retracts.
The first hydraulic rod and the second hydraulic rod are connected with the hydraulic cylinder, the control system controls the first hydraulic rod and the second hydraulic rod to stretch out and draw back through the hydraulic cylinder, and the control system controls the driving motor of the driving roller through the frequency converter.
A conveyor belt tension cooperative self-adaptive adjustment method based on PID control utilizes the tension cooperative self-adaptive adjustment system based on PID control, and comprises the following steps:
step 1, under the condition of material transmission, obtaining the instantaneous belt speed of a conveying belt in unit time T (T can be set to be 1 s) through a photoelectric encoder; every 1m places electronic belt scale under the conveyer belt, obtains material mass m in the unit time T (T can be set to 1 s) of conveyer belt through electronic belt scale, obtains corresponding conveyer belt real-time tension through the tension sensor that conveyer belt upper idler and lower backing roll department set up simultaneously.
The obtained instantaneous belt speed and corresponding belt tension per frame in a unit time T (the unit time may be set to 1 s).
The average material mass m (T) in the unit time T can be obtained by superposing and averaging the material mass m of single-position length obtained by each electronic belt scale in the unit time T (the unit time can be set to be 1 s); meanwhile, a plurality of instantaneous belt speeds in a unit time T of the conveying belt are subjected to superposition and averaging, and the average belt speed v (T) in the unit time T can be obtained. And obtaining the mass flow M (T) of the material in the unit time T by multiplying the average mass M (T) and the average belt speed v (T) in the unit time T.
And step 2, calculating the optimal running belt speed of the conveying belt. The real-time object flow is monitored mainly through an electronic belt scale on a conveying belt, so that the object flow is identified, and the optimal running belt speed is output.
And acquiring the mass flow M (T) of the material and the belt speed signal v (T) of the conveyor belt in the unit time T. Calculating the material mass flow difference between adjacent unit time, { ΔM (T), { ΔM (2T) } … |ΔM (iT) }, if { ΔM (T) } of continuous i unit time T, { ΔM (2T), { ΔM (…) } is beyond the prescribed range value |ΔM }, the value of } is equal to the prescribed range value |ΔM }, and the value of } is equal to the prescribed range value max And entering the optimal operation belt speed prediction.
And calculating the average value m (t+kT) of the mass of the material from the moment t in a certain unit time to k unit times. According to the energy-saving control target, establishThe following target planning model predicts the optimal running tape speed v after t+ (k+1) T time * (t+(k+1)T)，m/s；
Wherein θ is 1 ＝cfLg(q Rc +q Ru +2q B cosδ)/η 1 η 2 Equation 3
θ 2 ＝g(cfLcosδ+H)/η 1 η 2 Equation 4
Wherein:
P A the power required by the driving roller of the belt conveyor is kw/h;
q is the material quantity transported by the belt conveyor per hour, and t/h;
Q max the maximum conveying material quantity which can be born by the belt conveyor per hour is t/h;
l is the total horizontal projection length of the belt conveyor;
h is the total vertical lifting height of the belt conveyor;
ρ is the material density;
delta is the inclination angle of the conveyor belt;
q B the mass of the conveyor belt is kg/m;
q Rc the weight of the carrier roller is kg/m of the weight of the carrier roller which is rotated at the bearing side of the unit length;
Q Ru the weight of the return rotary carrier roller is kg/m;
f is the simulated coefficient of friction;
g is gravity acceleration;
c is a length coefficient of the belt conveyor;
V max the maximum belt speed which can be borne by the belt conveyor under full load is set;
V min the minimum belt speed for transporting bulk materials for the belt conveyor;
η 1 is the transmission efficiency;
η 2 is mechanical efficiency;
t is the time t in unit time, and defaults to 0.
Step 3, calculating the tension P of any point on the wrap angle arc, establishing a constraint condition of a tension value of a driving roller, and calculating the minimum traction force F required by the conveying belt under the energy-saving variable-frequency speed regulation 0 。
Step 3.1, calculating the tension P of any research point on the wrap angle arc;
and carrying out stress analysis on the driving roller, wherein the tension value of the conveying belt at the upper end and the tension value of the conveying belt at the lower end of the driving roller are equal under the condition that the conveying belt is not started. When the conveyer belt normally operates, friction force is generated between the driving roller and the conveyer belt. Suppose that the tension value at the point of meeting a of the conveyor belt driving rollers increases to P 1 While the tension at the separation point B is reduced to P 2 The tension difference between the driving rollers is the traction force F, and the traction force f=p 1 -P 2 For the conveyer belt of the friction wrap angle arc section, the conveyer belt is assumed to be a flexible body and is not subjected to bending stress, and the tension value of the position of a research point on the friction wrap angle arc section, which is deviated from a separation point B by a central angle theta, is assumed to be P, the tension value of the position of the friction wrap angle arc section, which is deviated from the research point by a central angle dtheta, is assumed to be P+dP, and the branch counter force of the driving roller on the conveyer belt between the meeting point A and the separation point B is assumed to be P N The pressure sensor stuck on the driving roller measures the wrap angle quantity theta of the meeting point A and the separating point B, and simultaneously establishes a conveyer belt stress equation:
wherein: θ is the wrap angle between the separation point B and the research point on the conveyor belt; μ is the coefficient of friction between the conveyor belt and the drive roller; dθ is the minimum amount of wrap angle formed at the study site; dP n A branch reaction force formed at dθ angle for the research point; dP is the tension value at the point of investigation at dθ. Solving the equation set and substituting the boundary condition θ=0, the tension value at the research point can be obtainedP (θ＝0) ＝P 2 The tension P of the conveyer belt at any point on the wrap angle arc can be obtained,
P＝P 2 e μθ equation 6
The traction force F of the driving roller on the conveyor belt is calculated as follows:
wherein: p2 is the tension value at the separation point B; μ is the coefficient of friction between the conveyor belt and the drive roller; lambda is the actual wrap angle between the current conveyor belt and the driving roller, and is obtained by measuring monitoring data of a pressure sensor circumferentially stuck on the driving roller.
Step 3.2, establishing a constraint condition of the tension difference value of the conveyor belt;
the maximum bearable wrap angle during the transportation of the conveyor belt is measured by a pressure sensor stuck on the driving roller, namely the total wrap angle is lambda max Tension value P of separation point B of conveyer belt is measured by tension sensor at lower carrier roller 2 As shown in FIG. 2, the upper carrier roller and the lower carrier roller of the conveyer belt are provided with tension sensors, the tension sensor of the upper carrier roller can obtain the tension value of the meeting point P1, the tension value of the lower carrier roller can obtain the tension value of the separating point P2, the actual traction force is P1-P2, the theoretical value of the formula 8 is the value of the formula 8, the theoretical traction force is calculated by only measuring the value of P2, and the maximum value which can be obtained by the tension of the tight edge is P because of partial loss in the process 1 ＝P 2 e μλmax Maximum traction force F transmissible by conveyor belt max The method comprises the following steps:
wherein: lambda (lambda) max Rad is the maximum amount of wrap angle that can be tolerated between the conveyor belt and the drive roller.
But during actual operation if the current traction exceeds the maximum traction F max The motor may be overloaded causing the belt to break tautly. To avoid thisFor example, the tension P.ltoreq.P at any point on the arc of the wrap angle must be required 2 e μλmax It can be seen that the angle of repose acts as a back-up traction force, an inactive angle. The euler formula considering safety against slipping in practice is:
P＝P 2 e μα ≤P 2 e μα′ equation 9
Wherein: alpha is the sliding angle of the conveyor belt and the driving roller, and rad; alpha 'is the maximum sliding angle allowed, rad, alpha' is less than or equal to lambda max 。
In actual work, the conveyer belt can work under various working conditions such as starting, braking and the like, so that the sliding angle alpha of the conveyer belt and the driving roller can change to a certain extent, and when alpha is more than or equal to 0 and less than or equal to alpha', the conveyer belt only has elastic peristalsis, and the system has a very high safety coefficient; when alpha' is more than or equal to alpha is less than or equal to lambda max When the system safety system is lowered, the conveyor belt still cannot slip; when alpha is greater than or equal to lambda max When the conveyor belt slips, the system works abnormally. Safety coefficient, i.e. driving force reserve coefficient ζ:
the maximum traction force F which can be transmitted when the conveying belt stably runs is shown in the above formula max However, in the actual running process, considering the influence of dynamic load during the acceleration start of the conveyor belt, in order to prevent the conveyor belt from slipping, the maximum traction force needs to have a certain margin, and the theoretical friction traction force F 'is adopted in the specific design process' max I.e. the theoretical maximum tension difference of the conveyor belt.
Wherein: n is friction force reserve coefficient or starting coefficient, n=1.3-1.7.
Tension value P of separation point 2 Not only to satisfy the non-slip condition of theoretical friction traction force, but also to satisfy the condition of sagging, which is to ensureThe belt will not relax during acceleration or emergency braking.
Minimum tension threshold P of conveyor belt required by sag of bearing section min ：
Minimum tension point threshold value P 'of conveying belt is required by perpendicularity of return section' min ：
Wherein: g is gravity acceleration, q is material linear density, i.e. material unit length mass, kg/m, q d The density of the conveyor belt, namely the mass of the conveyor belt per meter, and the paving inclination angle of the conveyor is beta. c max Maximum sag of heavy load section, c' max Maximum sag for return light load section, l ro For bearing the distance between the branch carrier rollers ru Is the spacing of return branch carrier rollers.
Equation 11 is used as the theoretical maximum tension difference for the conveyor belt, which is used to compare the actual conveyor belt tension difference (i.e., the actual traction force) with the conveyor belt separation point P 2 The constraint of equation 12, equation 13, i.e., the belt separation point P, needs to be satisfied 2 Tension of greater than P min And is greater than P' min 。
Step 3.3, determining the minimum traction force F required by the conveying belt under the energy-saving variable-frequency speed regulation 0 ；
The conveyor belt of the belt conveyor can be subjected to various running resistances in the running process, and the calculation of the resistances can also have certain difference due to different classification methods of the conveyor resistances. In order to simplify the calculation and improve the design efficiency, the running resistance of the conveyor can adopt an approximate calculation method. Taking the upward operation of the bearing branch of the belt conveyor as an example, the empirical formula is as follows:
F Z ＝k d (q+q d +q Ro )Lgc′cosβ+(q+q d )Lgsinβ
F k ＝k d (q d +q RU )Lgc″cosβ+q d Lgsinβ
F O ＝F Z +F k equation 14
Wherein: k (k) d Is a multiplying factor; f (F) Z Resistance kn of a heavy load section of the conveyor belt; f (F) K The resistance kn of the light load section of the conveyor belt is set; q is the linear density of the material, namely the mass kn of the unit length of the material; q d The density of the conveyor belt is that of the mass kg/m of the conveyor belt per meter; q R0 The weight kg/m of the rotating part is the weight of each meter of the branch carrier roller; q Ru The weight kg/m of the rotating part of each meter length of the return branch carrier roller is the weight kg/m of the rotating part of each meter length of the return branch carrier roller; l is the paving length m of the conveying belt; beta is the paving inclination angle rad of the conveying belt; g is gravity acceleration kg/m 2 The method comprises the steps of carrying out a first treatment on the surface of the c is the total running resistance coefficient; c' is the running resistance coefficient of the heavy load section; and c' is the running resistance coefficient of the no-load section. If the additional resistance Σf=10% (F) in the conveyor operation is considered Z +F k ) The traction force required on the conveyor driving rollers, i.e. the total running resistance F O
F O ＝F Z +F k +∑F＝1.1(F Z +F k ) Equation 15
The minimum traction force required by the conveyer belt under the energy-saving variable-frequency speed regulation is obtained by calculation of a formula to be F min ＝F 0 (equation 15) and taking the minimum traction as the traction of the conveyor belt under the energy-saving variable-frequency speed regulation.
Step 3.4, comparing the actual conveyor belt tension difference with a theoretical tension difference;
the upper carrier roller and the lower carrier roller of the conveyer belt are provided with tension sensors, and the difference value of the tension sensors is the actual conveyer belt tension difference value P in the field s After which P is s And a preset belt tension difference safety range value (F 0 ，F′ max ) A comparison is made. If the actual conveyer belt tension difference is outside the preset conveyer belt tension difference safety range, the ARM controller in the tension control execution module calculates the tension difference delta S exceeding the safety range t1 And DeltaS t2
ΔS t1 ＝P s -F′ max
ΔS t2 ＝F 0 -P S
Wherein: ps is the actual conveyor belt tension difference, i.e. the actual traction; f'. max The theoretical maximum traction force is the theoretical conveyer belt tension difference value; f (F) 0 The minimum traction difference value required by the conveyer belt under the energy-saving variable-frequency speed regulation is the theoretical minimum traction.
The control system adjusts the expansion and contraction amounts of the first hydraulic rod and the second hydraulic rod through the hydraulic cylinder, so as to adjust the tension value of the conveying belt, the first hydraulic rod is close to the driving roller of the conveying belt compared with the second hydraulic rod, the first hydraulic rod is positioned below the descending conveying belt, and the first hydraulic rod pushes the lower conveying belt upwards during extension and does not contact with the lower conveying belt after retraction; the second hydraulic rod is positioned above the descending conveyor belt, and downwards presses the conveyor belt when the second hydraulic rod extends, and the second hydraulic rod is not contacted with the lower conveyor belt after the second hydraulic rod retracts; the first hydraulic rod controls the tension value of the conveyer belt by pushing the downward conveyer belt upwards, the second hydraulic rod controls the tension value of the conveyer belt by pushing the downward conveyer belt downwards, the actual tension value of the conveyer belt is fed back in real time in the hydraulic cylinder adjusting process, and the tension value reaches a difference signal delta S after one denier adjustment t1 And DeltaS t2 And when the speed is smaller than 0, immediately stopping the hydraulic cylinder, and entering the step 4 to perform variable frequency speed regulation on the driving roller.
Step 4, determining the wrap angle quantity of the driving roller after the speed of the driving roller is changed;
if the minimum traction force F required by the conveying belt in the step 3 0 At a preset belt tension difference safety range value (F 0 ， F′ max ) And (3) the frequency converter executes frequency conversion speed regulation on the conveying belt according to the optimal running belt speed of the conveying belt calculated in the step (2). The acceleration change on the drive roller is then registered by a speed sensor attached to the drive roller. Recording the rotating speed of the conveying belt every 1s, and when the rotating speed has abrupt change, calculating the average value of the acceleration in each 1s time period within a set time length after the real-time speed change moment to obtain the average acceleration as a;
during the calculation of the shift, the mass of the driving roller is w, and the resultant force of the driving roller is q=wa. Ignoring power loss, the resultant forceQ is equal to the minimum traction force F required by the conveyer belt under the variable frequency speed regulation obtained by the calculation in the step 3 0 。
(1) If the belt conveyor performs acceleration, the frictional driving force f of the driving roller before the acceleration is calculated 1 The method comprises the following steps:
wherein: p (P) 2 Is a separation point tension value; lambda (lambda) 1 To drive the wrap angle of the drum before the speed is increased.
In the acceleration process, a first hydraulic rod positioned below the lower conveying belt near the driving rolling pushes the lower conveying belt upwards, and a second hydraulic rod is contacted with the lower conveying belt (used for supporting the lower conveying belt) and is used for counteracting the friction driving force f generated by the variable force 2 The method comprises the following steps:
f 2 ＝wa。
after acceleration, the frictional driving force f of the conveyor belt given after the shifting of the driving roller is pre-calculated 3 The method comprises the following steps:
f 3 ＝f 1 +f 2 ＝f 1 +wa
calculating target wrap angle lambda of driving roller during acceleration 2 ：
Wherein: lambda (lambda) 2 Is the target wrap angle of the driving roller during the speed increasing.
Calculating the difference value of the current wrap angle quantity and the target wrap angle quantity, performing PID operation on the difference value of the wrap angle quantity to obtain the expansion and contraction quantity of the first hydraulic rod, controlling the expansion and contraction of the first hydraulic rod through the expansion and contraction quantity of the first hydraulic rod, further controlling the jacking amplitude of the first hydraulic rod on the lower conveying belt, further adjusting the wrap angle quantity, enabling the second hydraulic rod to be in contact with the lower conveying belt but not adjusting the expansion and contraction quantity, and playing a role of supporting the lower conveying belt.
(2) If the belt conveyor performs a deceleration process, the frictional driving force f of the driving roller before deceleration is calculated 1 ’，
Wherein: p (P) 2 Is a separation point tension value; lambda's' 1 Is the wrap angle of the drive roller before deceleration.
During the deceleration process, the first hydraulic rod is restored to the initial position, namely, is not contacted with the lower conveying belt near the driving rolling, and the second hydraulic rod above the lower conveying belt near the driving rolling is pushed downwards to counteract the friction driving force f generated by the variable force 2 ' as
f 2 ’＝wa；
After deceleration, the frictional driving force f of the conveyor belt given after the shifting of the driving roller is pre-calculated 3 ' as
f 3 ’＝f 2 ’-f 1 ’
Calculating target wrap angle lambda of driving roller during deceleration 3 ：
Wherein: lambda (lambda) 3 Is the target wrap angle amount of the driving roller during deceleration.
Calculating a target wrap angle quantity of a driving roller in the speed reduction process of the conveyor, calculating a wrap angle quantity difference value between the current wrap angle quantity and the target wrap angle quantity, performing PID operation on the wrap angle quantity difference value to obtain a telescopic quantity of the second hydraulic rod, retracting the first hydraulic rod without contacting with the lower conveying belt, controlling the second hydraulic rod to stretch and retract through the telescopic quantity of the second hydraulic rod, further controlling the amplitude of the second hydraulic rod for pushing the lower conveying belt, and further adjusting the wrap angle quantity.
It should be noted that the specific embodiments described in this application are merely illustrative of the spirit of the invention. Those skilled in the art may make various modifications or additions to the described embodiments or substitutions thereof without departing from the spirit of the invention or its scope as defined in the accompanying claims.
Claims (5)
1. The PID control-based conveyor belt tension cooperative self-adaptive adjustment method is characterized by comprising the following steps of:
step 1, obtaining the instantaneous belt speed of a conveyor belt in unit time T through a photoelectric encoder, obtaining the material mass M of the conveyor belt in unit time T through an electronic belt scale, obtaining the corresponding conveyor belt tension through tension sensors arranged at a carrier roller and a lower carrier roller on the conveyor belt, and calculating the average material mass M (T), the average belt speed v (T) and the material mass flow M (T) of the conveyor belt in unit time T;
step 2, calculating the optimal running belt speed of the conveyer belt based on the target planning model;
step 3, calculating the tension P of any research point on the wrap angle arc, and calculating the theoretical maximum tension difference F 'of the conveyer belt' max Calculating the minimum traction force F required by the conveyer belt under the energy-saving variable-frequency speed regulation 0 The tension difference value Ps of the actual conveyor belt is at the minimum traction force F by adjusting the first hydraulic rod and the second hydraulic rod 0 And the theoretical maximum tension difference F 'of the conveying belt' max The first hydraulic rod is close to the driving roller of the conveying belt compared with the second hydraulic rod, the first hydraulic rod is positioned below the descending conveying belt, and the first hydraulic rod pushes the lower conveying belt upwards when being extended and does not contact with the lower conveying belt after being retracted; the second hydraulic rod is positioned above the descending conveyor belt, and downwards presses the conveyor belt when the second hydraulic rod extends, and the second hydraulic rod is not contacted with the lower conveyor belt after the second hydraulic rod retracts;
step 4, the frequency converter executes frequency conversion speed regulation on the conveyer belt according to the optimal running belt speed of the conveyer belt calculated in the step 2, records the acceleration change on the driving roller through a speed sensor connected on the driving roller, calculates the average acceleration after the real-time speed change time as a,
the current wrap angle between the conveyer belt and the driving roller is obtained through a pressure sensor which is circumferentially stuck on the driving roller,
calculating a target wrap angle quantity of a driving roller in the acceleration process of the conveyor, calculating a wrap angle quantity difference value between the current wrap angle quantity and the target wrap angle quantity, and performing PID operation on the wrap angle quantity difference value to obtain a telescopic quantity of a first hydraulic rod, wherein a second hydraulic rod is in contact with a lower conveying belt but the telescopic quantity is not regulated;
calculating a target wrap angle quantity of a driving roller in the speed reduction process of the conveyor, calculating a difference value between the current wrap angle quantity and the target wrap angle quantity, performing PID operation on the difference value of the wrap angle quantity to obtain a telescopic quantity of a second hydraulic rod, retracting the first hydraulic rod without contacting with a lower conveying belt,
the target planning model in the step 2 is as follows:
wherein θ is 1 ＝cfLg(q Rc +q Ru +2q B cosδ)/η 1 η 2
θ 2 ＝g(cfLcosδ+H)/η 1 η 2
Wherein:
P A the power required by the driving roller of the belt conveyor;
q is the material quantity conveyed by the belt conveyor in each hour;
Q max the maximum conveying material quantity which can be born by the belt conveyor per hour;
l is the total horizontal projection length of the belt conveyor;
h is the total vertical lifting height of the belt conveyor;
ρ is the material density;
delta is the inclination angle of the conveyor belt;
q B the mass of the conveyor belt is the unit length;
q Rc the weight of the carrier roller is rotated for bearing the weight of the side of a unit length;
q Ru the carrier roller mass is rotated in a return stroke of unit length;
f is the simulated coefficient of friction;
g is gravity acceleration;
c is a length coefficient of the belt conveyor;
V max the maximum belt speed which can be borne by the belt conveyor under full load is set;
V min the minimum belt speed for transporting bulk materials for the belt conveyor;
η 1 is the transmission efficiency;
η 2 is mechanical efficiency;
t is the time t in unit time;
m (t+kT) is an average material mass value from the moment t to k unit time in unit time;
v * and (t+ (k+1) T) is the optimal running belt speed of the conveyor belt after t+ (k+1) T time.
2. The method for collaborative self-adaptive adjustment of conveyor belt tension based on PID control according to claim 1, wherein in the step 3, the calculation of the tension P at any research point on the wrap angle arc is based on the following formula
P＝P 2 e μθ
Wherein P is 2 For the tension value at the separation point B, μ is the coefficient of friction between the conveyor belt and the drive roller; θ is the amount of wrap angle between the separation point B and the study point P on the conveyor belt.
3. The method for collaborative self-adaptive adjustment of conveyor belt tension based on PID control according to claim 2, wherein in step 3, the theoretical maximum tension difference F 'of the conveyor belt' max Based on the following formula:
wherein lambda is max And n is a friction force reserve coefficient for the maximum wrap angle quantity bearable by the conveying belt and the driving roller.
4. The method for collaborative self-adaptive adjustment of conveyor belt tension based on PID control according to claim 3, wherein in said step 3, the minimum traction force F required by the conveyor belt under energy-saving variable frequency speed regulation is 0 Based on the following formula:
F O ＝1.1(F Z +F k )
F Z ＝k d (q+q d +q Ro )Lgc′cosβ+(q+q d )Lgsinβ
F k ＝k d (q d +q RU )Lgc″cosβ+q d Lgsinβ
wherein: k (k) d Is a multiplying factor; f (F) Z Resistance of the heavy load section of the conveyor belt; f (F) K Resistance of a light load section of the conveyor belt; q is the linear density of the material; q d Is the density of the conveyor belt; q R0 The mass of the rotating part is the length of each meter of the bearing branch carrier roller; q Ru The mass of the rotating part per meter length of the return branch carrier roller is as follows; l is the paving length of the conveying belt; beta is the paving inclination angle of the conveying belt; g is gravity acceleration; c' is the running resistance coefficient of the heavy load section; and c' is the running resistance coefficient of the no-load section.
5. The method for collaborative adaptive adjustment of conveyor belt tension based on PID control of claim 4, wherein in step 4,
target wrap angle lambda of driving roller in acceleration process of conveyor 2 Based on the following formula:
target wrap angle of driving roller in speed reduction process of conveyorQuantity lambda 3 Based on the following formula:
wherein P is 2 For the tension value at separation point B, lambda 1 For the wrap angle of the drive roller before accelerating, lambda' 1 The wrap angle of the driving roller before deceleration is w is the mass of the driving roller, a is the acceleration, and mu is the friction coefficient between the conveying belt and the driving roller.
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Application publication date: 20220909 Assignee: Wuhan Hengwang Port and Channel Engineering Consulting Service Co.,Ltd. Assignor: WUHAN University OF SCIENCE AND TECHNOLOGY Contract record no.: X2023420000193 Denomination of invention: A Collaborative Adaptive Adjustment Method for Conveyor Belt Tension Based on PID Control License type: Common License Record date: 20230621 |
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