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Electrical control of belt conveyor machinery
Application of Kotuo Electric Control Systems on Belt Conveyors
A belt conveyor, also known as a rubber belt conveyor or commonly referred to as a "belt machine," is a continuous-action conveying device that has found widespread application in industries such as metallurgy, power generation, chemical engineering, and coal mining.
The electrical control system for belt conveyors typically consists of a control section and a variable-frequency drive section (such as Danfoss, VACON, and Farwide). It not only addresses the issue of high-load torque during belt conveyor startup but also adjusts the running speed of the conveyor belt and the tension force of the belt in real time according to operational requirements, ensuring that the entire system operates stably according to the preset program.
Addressing the complex operational challenges faced by conveyor belts in typical scenarios such as mines and ports—conditions characterized by high temperatures, high humidity, and high dust levels—Changsha Kete has developed and designed an independent duct-based variable-frequency control system that incorporates a multi-level protection framework. This system effectively handles the harsh on-site environment, ensuring the safe and stable operation of conveyor belts. The entire system’s enclosure adopts the Weidmüller TS8/VX25 cabinet design, achieving a protection rating of up to IP55 and making it suitable for both indoor and outdoor environments.
The system generally consists of two main components: a variable-frequency drive cabinet and a control cabinet. If the belt conveyor is used for downward transportation, braking requirements must be taken into account, necessitating the addition of a braking resistor cabinet or an energy-feedback cabinet. The entire system is equipped with a comprehensive set of protection functions, including overvoltage protection, undervoltage protection, overcurrent protection, phase-loss protection, overload protection, short-circuit protection, ground-fault protection, and fault alarm.
The system is driven and speed-controlled by one or more variable-frequency drives. When multiple variable-frequency drives are used simultaneously, a master-slave control mode is typically adopted. This system features a compact structure and comprehensive functionality, allowing flexible combinations based on actual power requirements. It can achieve automatic control within a single cabinet or, through cabinet paralleling, enable multi-machine, high-power operation—making it particularly well-suited for the intelligent operation of long-distance belt conveyors.
The intelligent belt conveyor control system developed by Changsha Kete adopts a modular architectural design and is compatible with induction motors, permanent magnet motors, and direct-drive motors. Based on site-specific operational requirements, the system can flexibly configure belt tensioning systems, downhill braking systems, and energy feedback systems. It supports seamless switching between manual and automatic modes, meeting diverse control needs. The system is equipped with fiber-optic switches that enable high-speed communication over distances of up to tens of kilometers, allowing it to respond in real time to commands from the control center and promptly report back the operational status at the site.
The total length of the conveyor belts on-site can reach several kilometers or even dozens of kilometers, and their locations are widely dispersed with challenging working conditions. If traditional monitoring methods were used, manual inspections would not only involve a huge workload but also pose significant safety risks. Therefore, it is advisable to adopt the intelligent monitoring system for conveyor belts developed by Changsha Kete, which is based on AIoT technology.
The integrated radar-ball system performs real-time detection of personnel intrusions on long-distance, open-air conveyor belts. Temperature-sensing optical fibers are used to monitor for fires along the conveyor belt. By leveraging a fiber-optic stethoscope system combined with an acoustic-vibration-temperature algorithm controller, the system can identify abnormalities in motors, gearboxes, idlers, and bearings, promptly issuing alarms to prevent equipment damage and safety incidents.
A millimeter-wave cross-section radar is used to measure the volume of materials on conveyor belts, aiding in the calculation of material inflow into silos. By combining a fast-scan radar level gauge with millimeter-wave imaging radar, it’s possible to visualize and quantify the volume of materials in storage bins and bulk material yards, intelligently adjust the speed of conveyor belts, and ensure safe production monitoring and energy-efficient operation of conveyor systems.
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