A downhole belt conveyor anti-deviation protection test device

Abstract

The utility model relates to mine automation centralized control and production safety monitoring technical field discloses a kind of underground belt conveyor anti-deviation protection test device, including protection test formula deviation sensor, voice alarm box, single-chip microcomputer remote control device, field centralized control cabinet internal network switch, PLC control system, ground centralized control room internal network switch, ground host computer monitoring, auxiliary shaft shaft and optical fiber network, the protection test formula deviation sensor includes deviation sensor main body and explosion-proof cover plate.The utility model can verify the effectiveness of protection device in advance, reduce equipment sudden failure risk, protect production transportation continuity and personnel safety, for production management, ground personnel can remote convenient operation test, reduce manpower and material resources consumption and underground operation risk, can also be in-depth analysis according to system integration stored data, provide scientific basis for equipment maintenance, parameter optimization and production planning, greatly improve management efficiency.

Description

Technical Field

[0001] This utility model relates to the field of centralized control and production safety monitoring technology for mine automation, specifically to a test device for preventing deviation of underground belt conveyors. Background Technology

[0002] Driven by the construction of "smart mines," coal mine main transportation systems have formed a continuous transportation network centered on belt conveyors. Statistics show that in mines with an annual output of 10 million tons, the transportation distance of a single belt conveyor generally exceeds 5 kilometers, with a daily transport volume of over 30,000 tons. As the "main artery" of coal transportation, its operational stability directly affects mine productivity and safety. However, belt conveyors are frequently affected by factors such as roadway geological deformation, uneven load, and idler wear, leading to various malfunctions.

[0003] According to the "Coal Mine Safety Regulations," belt conveyors must be equipped with anti-deviation safety protection. In actual production, deviation failure can lead to material spillage and abnormal equipment wear, or even cause conveyor belt tearing or fire accidents.

[0004] Traditional anti-deviation devices have the following drawbacks:

[0005] The numerous devices, mostly controlled locally, require manual inspection and testing for each protection test. The central control center struggles to obtain real-time operating status for individual devices. For example, troubleshooting a 2km belt conveyor can take over 30 minutes, with the risk of missed detections. In one mine accident analysis, oxidation of the belt misalignment switch contacts caused protection failure, which was not detected and repaired in time. The conveyor belt continued to misalign for 3 hours before tearing, resulting in significant economic losses. These cases demonstrate that existing equipment is insufficient to meet the real-time and predictive safety management requirements of modern mines. Utility Model Content

[0006] The purpose of this utility model is to provide a test device for preventing belt misalignment in underground belt conveyors, which solves the problems of manual inspection and testing in the existing technology, where the control center has difficulty obtaining the real-time operating status of individual devices and there is a risk of missed inspections.

[0007] This utility model provides the following technical solution: a test device for preventing belt misalignment in underground belt conveyors, comprising a protective test type misalignment sensor, a voice alarm box, a microcontroller remote control device, a network switch in a field control cabinet, a PLC control system, a network switch in a ground control room, a ground host computer monitoring system, a secondary shaft shaft, and an optical fiber network. The protective test type misalignment sensor includes a misalignment sensor body and an explosion-proof cover plate. The explosion-proof cover plate is fixedly installed on the outer wall of the misalignment sensor body. A fixing clamp is fixedly installed on the outer wall of the explosion-proof cover plate. A gearbox and a DC motor are fixedly installed on the fixing clamp plate. The output shaft of the DC motor is fixedly connected to the input shaft of the gearbox. A rotary joint is fixedly installed on the output shaft of the gearbox. A misalignment sensor lever is fixedly installed on the outer wall of the rotary joint. A limit switch is fixedly installed on the side of the fixing clamp plate.

[0008] As a preferred embodiment of the above technical solution, the deviation sensor lever is made of corrosion-resistant stainless steel and its surface has been passivated.

[0009] As a preferred embodiment of the above technical solution, the protective test type deviation sensor is electrically connected to the microcontroller remote control device, the protective test type deviation sensor is electrically connected to the voice alarm box and the PLC control system, and the voice alarm box is electrically connected to the microcontroller remote control device.

[0010] As a preferred embodiment of the above technical solution, the voice alarm box is electrically connected to the PLC control system, the microcontroller remote control device is electrically connected to the PLC control system, and the PLC control system is electrically connected to the network switch in the field control cabinet.

[0011] As a preferred embodiment of the above technical solution, the network switch inside the field control cabinet passes through the auxiliary shaft and is electrically connected to the network switch in the ground control room via an optical fiber network. The network switch in the ground control room is electrically connected to the ground host computer monitoring system.

[0012] Compared with the prior art, the beneficial effects of this utility model are:

[0013] This device can send commands from a ground-based PLC to an underground microcontroller, thereby controlling the operation of the DC geared motor, adjusting the position of the belt conveyor's misalignment sensor to trigger an early warning, and simultaneously stopping the belt conveyor with an underground voice alarm. It also provides real-time status information feedback to the ground monitoring center. The entire process utilizes the mine's existing fiber optic network communication system for efficient data exchange and transmission. This invention's remote testing device for preventing belt misalignment in coal mines has significant advantages. In terms of safety, the remote control system can verify the effectiveness of the protection device in advance, reducing the risk of sudden equipment failures and ensuring the continuity of production and transportation as well as personnel safety. For production management, the ground-based PLC can also provide remote control and control of the belt conveyor's anti-misalignment protection system. Personnel can remotely and conveniently operate and test the equipment, reducing manpower and material consumption and the risks of underground operations. Furthermore, the system can conduct in-depth analysis based on integrated and stored data, providing a scientific basis for equipment maintenance, parameter optimization, and production planning, significantly improving management efficiency. From a cost perspective, relying on existing automated monitoring systems, only a small amount of hardware and software development and integration is required, reducing procurement, installation, commissioning, and maintenance costs, minimizing space occupation, and enabling timely problem resolution to extend equipment lifespan and lower overall operating costs. This device promotes the integrated application of coal mine automation technology and is expected to lead the formulation of industry standards and specifications, helping the entire coal mining industry move towards intelligence and efficiency, possessing broad application and promotion value. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the main components of the anti-runaway remote control system;

[0015] Figure 2 This is a schematic diagram of the main structure of the experimental belt misalignment sensor of this utility model;

[0016] Figure 3 This is a schematic diagram of the rear structure of the explosion-proof cover of this utility model;

[0017] Figure 4 This is the wiring diagram for the remote control section of a microcontroller;

[0018] Figure 5 This is the relay wiring diagram for controlling the power supply of the forward and reverse rotation controller;

[0019] Figure 6 This is the wiring diagram for the motor forward and reverse rotation controller;

[0020] Figure 7 This is a PLC program diagram for the deviation protection feature.

[0021] In the diagram: 1. Protective test type deviation sensor; 2. Voice alarm box; 3. Microcontroller remote control device; 4. Network switch in the field control cabinet; 5. PLC control system; 6. Network switch in the ground control room; 7. Ground host computer monitoring; 8. Auxiliary shaft; 9. Fiber optic network; 101. Deviation sensor lever; 102. Rotary joint; 103. Limit switch; 104. DC motor; 105. Explosion-proof cover; 106. Fixing clamp; 107. Gearbox. Detailed Implementation

[0022] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention.

[0023] like Figures 1-7 As shown, this utility model provides a technical solution: a test device for preventing belt misalignment in an underground belt conveyor, including a protective test misalignment sensor 1, a voice alarm box 2, a microcontroller remote control device 3, a network switch in a field control cabinet 4, a PLC control system 5, a network switch in a ground control room 6, a ground host computer monitoring system 7, an auxiliary shaft shaft 8, and an optical fiber network 9. The protective test misalignment sensor 1 includes a misalignment sensor body and an explosion-proof cover plate 105. The explosion-proof cover plate 105 is fixedly installed on the outer wall of the misalignment sensor body. A fixing clamp 106 is fixedly installed on the outer wall of the explosion-proof cover plate 105. A reduction gearbox 107 and a DC motor 104 are fixedly installed on the fixing clamp 106. The output shaft of the DC motor 104 is fixedly connected to the input shaft of the reduction gearbox 107. A rotary joint 10 is fixedly installed on the output shaft of the reduction gearbox 107. 2. A belt misalignment sensor lever 101 is fixedly installed on the outer wall of the rotary joint 102, and a limit switch 103 is fixedly installed on the side of the fixed clamp 106. This device is based on the existing belt conveyor PLC centralized control system. Except for the protective experimental belt misalignment sensor 1 and the single-chip microcomputer remote control device 3, which are additional investments, the rest are existing equipment and facilities. The main body of the belt misalignment sensor is also a commercially available device. The limit switch 103 converts the mechanical displacement signal of the belt misalignment sensor lever 101 into an electrical signal, limiting the movement range of the belt misalignment sensor lever 101 and preventing overtravel damage. The explosion-proof cover 105 adopts an explosion-proof design with an IP65 protection level and the surface is treated with oxidation and rust prevention. The gearbox 107 reduces the speed of the DC motor 104 and increases the output torque to ensure that the belt misalignment sensor lever 101 moves smoothly and powerfully.

[0024] As one implementation method in this embodiment, such as Figure 2 As shown, the deviation sensor lever 101 is made of corrosion-resistant stainless steel and the surface has been passivated.

[0025] As one implementation method in this embodiment, such as Figure 1As shown, the protective test type deviation sensor 1 is electrically connected to the microcontroller remote control device 3, the protective test type deviation sensor 1 is electrically connected to the voice alarm box 2 and the PLC control system 5, and the voice alarm box 2 is electrically connected to the microcontroller remote control device 3.

[0026] As one implementation method in this embodiment, such as Figure 1 As shown, the voice alarm box 2 is electrically connected to the PLC control system 5, the microcontroller remote control device 3 is electrically connected to the PLC control system 5, and the PLC control system 5 is electrically connected to the network switch 4 in the field control cabinet.

[0027] As one implementation method in this embodiment, such as Figure 1 As shown, the network switch 4 in the field control cabinet passes through the auxiliary shaft shaft 8 and is electrically connected to the network switch 6 in the ground control room via the fiber optic network 9. The network switch 6 in the ground control room is electrically connected to the ground host computer monitoring 7.

[0028] This device sends commands from a ground-based PLC to an STM32 microcontroller to control the forward and reverse rotation of the motor. Its core principle is to utilize the functional characteristics of different devices to achieve signal transmission, processing, and control. It mainly involves several key stages: signal sending, transmission, reception, and execution. The detailed workflow is as follows:

[0029] The communication layer uses a CM 1241 RS485 module, and the control layer uses a MAX485 TTL to RS485 module. The microcontroller's internal program parses the received signals and determines whether the instruction requires the motor to rotate forward or backward. Based on the parsing result, the microcontroller outputs the corresponding control signals through the set GPIO pins PA3 and PA6.

[0030] like Figure 4 As shown, after the STM32 microcontroller receives the forward rotation command from the PLC, PA1 goes high to activate controller K1, thus activating the forward rotation relay. For the reverse rotation command, PA4 and K2 go high to control the motor controller output. A delay is set for motor rotation to prevent jitter. In actual testing, it was found that when the 24V power supply is supplied, it causes a surge, resulting in PA3 outputting a low level. In addition, multiple test devices are installed underground, labeled with the name of the specified conveyor belt and test device. An RS485 repeater is installed every 300 meters to compensate for signal attenuation during transmission. When the protection is triggered, the labeled location name displays an anomaly, and test records are automatically saved.

[0031] Motor drive and control:

[0032] like Figure 6As shown, the limit sensor monitoring continuously monitors the status changes of SQ1 and SQ2. When the limit sensor is triggered, SW1 and SW2 cut off the forward and reverse power supply, and the motor stops running. The motor forward and reverse controller switches the motor rotation direction according to the signal from K1 or K2. As described above, the high torque of the geared motor causes the deviation sensor lever 101 to move the mechanical deviation sensor, triggering a voice alarm.

[0033] Power Management: The MP1584 module provides a stable 5V power supply to ensure the normal operation of the STM32, reduce voltage fluctuations, and ensure power stability.

[0034] Software logic: Interrupt service: Quickly respond to limit sensor signals to prevent overshoot. Error handling: Detect signal loss or abnormal conditions to ensure system reliability.

[0035] like Figure 4 Figure 5 As shown, the optocoupler relay controls the on / off principle in this invention: V+ and V- are connected to the positive and negative terminals of the power supply, and the X1 channel is connected to the microcontroller to receive or provide feedback status. After initialization, X1 is connected to PA7 for activation. If the rotation is forward to a certain angle, the deviation sensor lever 101 or the rotary joint 102 touches the limit sensor 3SQ1. After processing by the microcontroller, the PA7 level is pulled low, and the optocoupler relay disconnects the power supply, shuts down the forward and reverse controller, and the motor stops rotating. The reverse is also true.

[0036] In summary, this invention addresses the issue of mechanical misalignment sensors, which were previously impossible to control remotely. It presents a system based on an existing automated system, using a microcontroller as the lower-level controller to remotely trigger tests on these sensors. The main structure consists of a control section and an execution section. The control section primarily includes the aforementioned main controller (PLC); a CM1241 RS485 module; a communication module enabling isolated RS485 communication between the PLC and the STM32 microcontroller; a microcontroller such as the STMF103C8T6; and a motor drive board, such as... Figure 4 The main components include a DC motor forward and reverse rotation controller; other components such as twisted-pair shielded cables and underground power supply are not detailed here. The execution part mainly consists of a high-reduction-ratio DC motor; limit sensors controlling the reset and testing angles; and a lever mechanism, which together form a complete device.

[0037] Working principle:

[0038] Pre-start checks: Ground monitoring personnel check the operating status of the belt conveyor using the existing automated monitoring system to ensure the equipment is in a condition suitable for anti-deviation protection testing. Simultaneously, they communicate with on-site personnel via voice intercom to confirm both parties are ready.

[0039] Remote start-up test: Ground monitoring personnel send a remote test command via host computer software to the protective test type deviation sensor 1. This command is transmitted to the microcontroller control unit through the existing automated monitoring system. Upon receiving the command, the microcontroller first checks the status of relevant equipment, such as whether the geared motor is locked and whether the limit sensors are working properly. If everything is normal, it controls the geared motor to rotate, allowing the relevant mechanical components of the anti-deviation remote control system to operate.

[0040] Test Process Monitoring: Ground personnel send a command to start the test using the protective test-type misalignment sensor 1. The misalignment lever causes the main body of the sensor to shift. During the test, the sensor collects the lever's tilt data in real time and transmits the data to the microcontroller. The microcontroller processes the data quickly, uploading it to the existing automated monitoring system for real-time viewing by ground monitoring personnel. Simultaneously, it determines whether a preset misalignment threshold has been reached. If the threshold is reached for more than a set time, a corresponding alarm signal is triggered, and an alarm is issued to on-site and ground personnel via the voice alarm box 2. The abnormal event is recorded for subsequent analysis, and the system automatically slows down the conveyor speed or completely stops operation to prevent accidents. Ground monitoring personnel can observe the test in real time via a network camera and, combined with the uploaded misalignment data, comprehensively monitor and analyze the test process. If any abnormality is detected, communication with on-site personnel can be initiated via a voice intercom system, and appropriate measures can be taken.

[0041] Test Completion Procedure: After confirming the completion of the test by the ground monitoring personnel (protecting the test-type misalignment sensor 1), a test completion command is sent to the host computer software to reset it. Upon receiving the command, the microcontroller controls the reduction motor to return to its initial position and simultaneously confirms whether the components have accurately returned to their positions and locked based on the signal from the limit switch. After hearing the limit sensor's alarm, the on-site personnel (using the voice alarm box 2) check the status of the relevant equipment to ensure it has returned to its normal state before the test. Then, they report the test completion and equipment status to the ground monitoring personnel via the voice intercom system.

[0042] The above embodiments are only used to illustrate the technical solution of this utility model, and are not intended to limit it.

Claims

1. A test device for preventing belt misalignment in underground belt conveyors, characterized in that: The system includes a protective test-type deviation sensor (1), a voice alarm box (2), a microcontroller remote control device (3), a network switch in the field control cabinet (4), a PLC control system (5), a network switch in the ground control room (6), a ground host computer monitoring system (7), an auxiliary shaft (8), and a fiber optic network (9). The protective test-type deviation sensor (1) includes a deviation sensor body and an explosion-proof cover plate (105). The explosion-proof cover plate (105) is fixedly installed on the outer wall of the deviation sensor body. A fixed clamp (106) is fixedly installed on the outer wall. A gearbox (107) and a DC motor (104) are fixedly installed on the fixed clamp (106). The output shaft of the DC motor (104) is fixedly connected to the input shaft of the gearbox (107). A rotary joint (102) is fixedly installed on the output shaft of the gearbox (107). A deviation sensor lever (101) is fixedly installed on the outer wall of the rotary joint (102). A limit switch (103) is fixedly installed on the side of the fixed clamp (106).

2. The anti-deviation protection test device for an underground belt conveyor according to claim 1, characterized in that: The deviation sensor lever (101) is made of corrosion-resistant stainless steel and its surface has been passivated.

3. The anti-deviation protection test device for an underground belt conveyor according to claim 1, characterized in that: The protective test type deviation sensor (1) is electrically connected to the microcontroller remote control device (3), the protective test type deviation sensor (1) is electrically connected to the voice alarm box (2) and the PLC control system (5), and the voice alarm box (2) is electrically connected to the microcontroller remote control device (3).

4. The anti-deviation protection test device for an underground belt conveyor according to claim 1, characterized in that: The voice alarm box (2) is electrically connected to the PLC control system (5), the microcontroller remote control device (3) is electrically connected to the PLC control system (5), and the PLC control system (5) is electrically connected to the network switch (4) in the field control cabinet.

5. The anti-deviation protection test device for an underground belt conveyor according to claim 1, characterized in that: The network switch (4) in the field control cabinet passes through the auxiliary shaft (8) and is electrically connected to the network switch (6) in the ground control room through the fiber optic network (9). The network switch (6) in the ground control room is electrically connected to the ground host computer monitoring (7).

Images