High precision positioning of conveyor discharge carts via optimal velocity profiling and adaptive tracking

To enhance the positioning accuracy of belt conveyor unloaders under slip and high-dust conditions, this paper proposes an integrated solution combining mechanical anti-slip design with an adaptive control algorithm. The system incorporates an innovative encoder-wire rope follower mechanism to effectively overcome detection errors caused by drive wheel slippage. At the control strategy level, an adaptive tracking controller based on an optimal velocity profile is developed. This controller plans an optimal velocity trajectory and integrates a Direct Torque Control (DTC) based motor control algorithm with a state-feedback controller to achieve precise velocity tracking, enabling smooth control throughout the entire process from zero-speed start-up to accurate braking. Experimental results demonstrate that under material mass fluctuations of ±5% to ±20%, the system achieves a positioning accuracy of 98%, exhibiting strong disturbance rejection and robustness, thereby providing a reliable solution for high-precision positioning in industrial environments.