Belt Sweeping Box Intelligent Module

The operation of the belt cleaning box module is not carried out by a single module working independently. Instead, it relies on the sequential coordination and functional complementarity of each module to form a complete closed loop from "preparation for cleaning" to "cleaning completion," adapting to the dynamic scenario of continuous conveyor belt operation.
Working Principles and Collaborative Coordination of Core Modules
Different modules have distinct functional roles. Their working principles must align with the two major requirements of "dynamic adaptation to belt operation" and "efficient cleaning." Moreover, modules achieve collaboration through structural design (e.g., positional alignment) or control logic (e.g., sequential triggering), as detailed below:
1. Basic Support Module: Providing a "Stable Benchmark" for Cleaning
The basic support module is the prerequisite for all cleaning actions. Its core function is to fix the positions of functional modules and ensure the conveyor belt does not deviate or bounce during cleaning, maintaining stable contact between the cleaning module and the belt surface. Its working principle can be divided into two parts:
Box System: Positioning and Protection
The upper box (rectangular frame) is fixed to the conveyor frame with bolts, arranging modules such as spraying, cleaning, and drying sequentially along the "belt running direction" (e.g., spraying first, cleaning in the middle, drying last) to ensure precise contact positions between each module and the belt. The lower box (trapezoidal trough) forms a "collection space" to catch dislodged materials and wastewater while preventing material splashing during cleaning to avoid secondary pollution.
Pressure Roller Set: Stabilizing Belt Dynamics
The pressure roller set (including driven rollers and guide pressure rollers) is distributed along both sides of the cleaning module in the direction of belt movement:
Driven rollers rotate following the belt's friction, assisting the conveyor belt in maintaining constant speed operation and preventing belt deceleration due to resistance from cleaning modules;
Guide pressure rollers apply slight pressure from both the upper and lower sides of the belt (adjustable via springs, typically ≤0.2MPa), limiting the belt's vertical bounce amplitude (controlled within ±5mm) to ensure that cleaning scrapers and spray nozzles maintain an "effective contact distance" with the belt surface (e.g., nozzle-to-belt distance of 15-20mm, scraper-to-belt contact pressure of 0.1-0.3MPa).
 Cleaning Functional Module: The "Execution Layer" of Core Cleaning Actions
The cleaning functional module is the core for removing materials. Through the progressive coordination of three sub-modules—"spraying for softening → graded cleaning → drying for dewatering"—it gradually dislodges and processes residual materials, adapting to the characteristics of materials with varying viscosity and particle size:
（1）Spray Softening Module: Reducing Material Adhesion
Working Principle: Through "high-pressure water mist infiltration," it disrupts the adhesion between residual materials and the belt surface (e.g., electrostatic adsorption of dust, molecular attraction of viscous materials), reducing resistance for subsequent cleaning.
Sequential Triggering: When the conveyor belt starts, the intelligent control module (or interlock switch) triggers the solenoid valve, delivering purified water (or weakly alkaline cleaning agents as needed) through pipelines to the nozzles;
Precise Spraying: Nozzles are evenly arranged according to the "belt width" (e.g., 8-10 nozzles for a 1m wide belt), emitting fan-shaped water mist at a pressure of 0.3-0.8MPa to cover the belt surface without dead angles, with water mist particle size controlled at 50-100μm (avoiding excessive mist causing material splashing or insufficient mist failing to infiltrate materials);
Collaborative Linkage: The spray module is installed "50-100mm in front of the cleaning module" to ensure 0.5-1 second of infiltration time for the water mist, allowing materials to soften before entering the cleaning phase.
（2）Multi-Stage Cleaning Module: Dislodging Residual Materials (Core Step)
Working Principle: Through "graded action of scrapers with different materials and angles," it gradually dislodges softened materials, avoiding belt damage or incomplete cleaning from single hard scraping. Typically, cleaning is divided into 2-3 stages:
Cleaning Level Scraper Material Working Principle Target Effect
Primary Cleaning (Initial) Polyurethane (Shore Hardness 60-70) Scraper at a 30°-45° angle to the belt surface, applying 0.1-0.2MPa contact pressure via springs, using polyurethane's flexibility to conform to the belt curvature, scraping off 70%-80% of large, loose residual materials Large viscous materials (e.g., wet coal, slag)
Secondary Cleaning (Precision) Hard Alloy (Tungsten Steel) Scraper at a 15°-20° angle to the belt surface, contact pressure increased to 0.2-0.3MPa, using the alloy's high hardness to remove small, stubborn residues (e.g., dust embedded in belt patterns) Small stubborn materials
Tertiary Cleaning (Supplementary, Optional) Nylon Brush / Soft Rubber High-speed rotating brush (motor-driven, 500-800r/min) or soft rubber scraper with light pressure, sweeping away微量粉尘 left after secondary cleaning to prevent it from entering the drying phase with the belt Trace dust
Structural Coordination: Scrapers at each stage are arranged sequentially along the belt running direction, with spacing controlled at 30-50mm, and the contact position of each subsequent scraper slightly higher than the previous one (difference of 5-10mm) to ensure materials missed by the previous stage are captured by the next, avoiding cleaning omissions.
（3）Drying and Dewatering Module: Preventing Secondary Pollution
Working Principle: Through "physical drying," it removes residual moisture from the belt surface after cleaning, preventing moisture from causing subsequent materials (e.g., coal powder, cement) to clump and adhere or corrode the belt; it also prevents water from dripping onto the conveyor frame and causing rust.
High-Pressure Air Knife Drying: The air knife outlet is at a 10°-15° angle to the belt surface, emitting compressed air at 0.4-0.6MPa (at ambient temperature) to quickly blow away liquid water on the belt surface, suitable for ordinary working conditions;
Heated Drying (Optional): For low-temperature, high-humidity environments (e.g., northern winters), the air knife includes heating elements (temperature controlled at 40-60°C), using hot air to accelerate moisture evaporation, ensuring the belt surface moisture content is ≤5%;
Positional Linkage: The drying module is installed 30-50mm behind the cleaning module to ensure the belt surface is free of residual materials before drying, preventing moisture from mixing with materials and forming sludge buildup.
3. Auxiliary Processing Module: "Completion and Recycling" After Cleaning
The auxiliary processing module collects waste (materials + wastewater) generated during cleaning and ensures stable system operation through intelligent control, preventing waste accumulation from affecting cleaning efficiency or causing equipment failure:
Waste Discharge and Collection Module:
The bottom of the trapezoidal trough in the lower box has an "inclined guide plate" (inclination angle 10°-15°). Dislodged materials and wastewater slide toward the discharge port under gravity;
The discharge port connects to a screw conveyor (or scraper conveyor) to transport the "material + wastewater" mixture to a dedicated waste bin (recyclable materials like coal can be separated and returned, while waste is centrally processed), preventing mixture accumulation and clogging in the box;
Some modules are equipped with filters to first remove solid particles from the wastewater, then recycle the clean water back to the spray system (water savings rate up to 40%-60%).
Intelligent Control Module (Optional): Dynamic Adaptation and Fault Warning
Pressure Monitoring: Pressure sensors installed on cleaning scrapers monitor the contact pressure between scrapers and the belt in real time. If pressure is too high (e.g., ≥0.4MPa, risking belt wear) or too low (e.g., ≤0.1MPa, leading to incomplete cleaning), spring pressure is automatically adjusted;
Flow Monitoring: Flow sensors in the spray pipeline trigger an alarm and prompt cleaning if nozzle clogging causes flow reduction (e.g., below 80% of rated value);
Interlock Control: Synchronized with the conveyor's main control system, the cleaning module stops when the conveyor stops (preventing idle wear) and starts in sequence ("spray → clean → dry") with a delay when the conveyor starts, ensuring timing coordination.
III. Core Advantages: Principles Embodied in Modular Design
The efficiency of the belt cleaning box module's working principles stems from the "functional decomposition and collaborative optimization" brought by modular design:
Strong Adaptability: Modules can be flexibly combined based on material characteristics (e.g., increasing spray pressure for high-viscosity materials, adding brush cleaning for fine dust) and belt parameters (e.g., adding nozzles for wider belts) without replacing the entire equipment;
Easy Maintenance: If a single module (e.g., spray nozzle, cleaning scraper) is damaged, it can be disassembled and replaced individually without shutting down the entire cleaning box, reducing maintenance time (e.g., scraper replacement takes only 10-15 minutes);
Stable Efficiency: Through temporal and structural coordination among modules, the limitations of single cleaning actions (e.g., spraying alone cannot dislodge materials, cleaning alone may damage the belt) are avoided, ensuring long-term cleaning efficiency remains above 90%.