A real-time monitoring and troubleshooting device for belt conveyors

Abstract

The present invention is applicable to the field of equipment operation status monitoring, and provides a real-time monitoring and troubleshooting device for a belt conveyor, including a robot body, a main control unit, an energy module, a detection component, and a wireless communication module. The robot can detect the equipment and environment near the track in real time, and transmit the information to the remote control center. The staff can understand the detected information in real time and send control instructions to the robot. The robot detection results of the present invention are stable, and there is no need for personnel to go to the site for detection, which saves manpower; the robot can quickly arrive at the site in dangerous situations and obtain on-site data and information.

Description

Technical Field

[0001] The invention relates to the technical field of equipment operation status monitoring, and in particular to a real-time monitoring and troubleshooting device for a belt conveyor. Background Art

[0002] In the coal production process, belt conveyors are important coal transportation equipment and are widely used. However, during the operation of belt conveyors, it is necessary to monitor the environmental conditions: such as on-site dust concentration, toxic and harmful gas and combustible gas content, ambient temperature, humidity, etc.; equipment status: abnormal roller temperature, audio positioning of belt conveyor failure, abnormal vibration of motor reducer, belt deviation, tearing and edge tearing, etc.; safety behavior: automatic identification and detection of unsafe actions such as illegal operations on site and illegal intrusion of illegal personnel, so as to avoid accidents such as giant foreign objects, coal flow overload, roller damage, belt damage, etc., which may cause heavy losses to equipment and even personnel.

[0003] On the other hand, during the inspection and maintenance of belt conveyors, inspection workers face huge risks when conducting real-time inspections and repairs on belt conveyors, and the coal mining process requires that the belt conveyor system cannot be stopped at any time or for a long time. Summary of the invention

[0004] In order to solve the above technical problems, the present invention provides a real-time monitoring and troubleshooting device for a belt conveyor, which has the flexibility and intelligence of manual inspection, and also overcomes and makes up for some defects and deficiencies in manual inspection. It can realize real-time monitoring and troubleshooting of the belt conveyor, ensure the stable operation of the coal transportation line, and thus improve production efficiency. It is the development direction of intelligent and unmanned inspection technology, and has broad application prospects for the real-time monitoring and troubleshooting device for belt conveyors.

[0005] A real-time monitoring and troubleshooting device for a belt conveyor of the present invention comprises a robot body, a main control unit, an energy module, a detection component for detecting equipment and surrounding environment, and a wireless communication module for exchanging data with a remote control center;

[0006] There is information exchange between the real-time monitoring and troubleshooting device for belt conveyors and the roller temperature monitoring system, which is a roller temperature monitoring module based on infrared thermal imaging, and the roller temperature monitoring system is fixed to the roller frame. The roller temperature monitoring module uses an infrared thermal imager to collect infrared images, processes the collected infrared images of the belt conveyor, analyzes the temperature information of the roller area and issues a fault warning, and transmits the acquired information to the main control unit of the real-time monitoring and troubleshooting device for belt conveyors and the remote control center.

[0007] The idler temperature monitoring module uses an infrared thermal imager to collect infrared images of the transportation equipment, and processes the collected infrared images of the belt conveyor: intercepts the area where the idler is located by using vertical and horizontal projections; filters the image edges by using the aspect ratio of the major and minor axes and the area information based on connected components, eliminates the pseudo-edges formed by edge detection of the intercepted image, and retains the true edges of the idler; connects the idler edge gaps by using morphological closing operations, obtains the closed contour of the idler through boundary tracking and fills the seed area, realizing the automatic segmentation of the idler area; finally, analyzes the temperature information of the idler area and issues a fault warning.

[0008] The main control unit, energy module, detection component and wireless communication module of the real-time monitoring and troubleshooting device for the belt conveyor are all installed on the robot body; the main control unit receives commands from the remote control center, controls the movement of the robot body on the track, and executes relevant commands and actions; the robot body includes a vehicle body unit, and the vehicle body unit includes a motion drive module, a pulley group and a charging bin; the motion drive module drives the pulley group to roll on the track; the elastic element of the pulley group is set to make the vehicle body drive stably; the charging bin has the functions of cleaning and charging.

[0009] Further, the housing includes an annular groove track opened on its circumferential side, and the housing is in a "冂" shape to prevent the housing from interfering with the support structure of the running track during driving. The vehicle body unit can run on the track that encloses it. The detection component includes a detection module and a sliding block, the detection module is slidably connected to the sliding block, and the sliding block slides in the annular groove track. The housing also includes a linear guide rail tangent to the annular groove track, and the detection module can slide continuously at the junction of the sliding block and the linear guide rail, and then move on the linear guide rail. The sliding of the sliding block and the sliding of the detection module relative to the sliding block and the linear guide rail increase the detection range of the detection module.

[0010] Tracks are arranged on both sides of the coal conveying belt conveyor, that is, the tracks are circular, and a group of the real-time monitoring and troubleshooting devices for the belt conveyor are arranged on the circular track, driving in opposite directions, and monitoring both sides of the same section of the belt at the same time.

[0011] Further, there are multiple groups of detection paddles at both ends of the track. When the robot passes by, the detection paddles send real-time signals to the main control unit for judging the synchronization of a pair of robots.

[0012] Further, a charging pile is provided at the end of the track. The robot monitors the power situation and the distance between its current position and the charging pile in real time, and according to the autonomous charging strategy, autonomously navigates to the charging pile and automatically communicates with the charging pile to start charging.

[0013] The robot energy module is a wireless charging and discharging device. The energy module is placed on the upper part of the housing, forming a charging bin with the "冂"-shaped upper surface. The charging bin can charge and supply energy to the detection module that slides therein.

[0014] The battery capacity is 7AH. The wireless charging module adopts a 100W magnetic resonance principle module, and the charging time is 3H. It can realize functions such as charging distance induction detection and self-adjustment of load changes. When the robot needs to be charged after the patrol, when it returns to the charging pile, it will trigger the in-place switch. After confirming the position, it will send a signal to the charging pile to start charging. When the robot is fully charged, it will send a signal to the charging pile to stop charging.

[0015] Furthermore, the detection module includes an industrial camera and at least one of a camera, a temperature sensor, a humidity sensor, a smoke and dust sensor, an AI camera, and an oxygen content sensor.

[0016] Furthermore, an automatic cleaning device is arranged on the inner surface of the upper end of the charging bin. When the detection module includes a camera, the sliding block slides to the upper end of the housing under the drive of the drive gear set, and the automatic cleaning device performs cleaning work on the camera.

[0017] Furthermore, the robot also includes a fire extinguisher, and the fire extinguisher is fixed on the robot body.

[0018] Furthermore, the main control unit includes a guarantee system, including:

[0019] Foreign object recognition system. Under the condition of the load of the belt conveyor, the detection module of the real-time monitoring and troubleshooting device for the belt conveyor slides to the uppermost end of the linear guide rail to detect the conveyed material. For the bolt foreign objects existing in the belt image collected by the industrial camera, bilateral filtering and piecewise linear transformation algorithms are respectively used for image denoising and image enhancement preprocessing; the iterative adaptive threshold segmentation method is used for image binarization processing; the shape of the bolt foreign objects is recognized based on the aspect ratio of the circumscribed rectangle of the connected components, and the detection and recognition of the bolt foreign object target are completed.

[0020] Coal flow monitoring system. The detection module of the real-time monitoring and troubleshooting device for the belt conveyor slides to the uppermost end of the linear guide rail to detect the conveyed material. The cross-section contour of the coal flow is obtained through a two-dimensional lidar, and the speed information is measured through a speed sensor. Then, the coal flow is obtained by integrating the cross-sectional area and the speed information.

[0021] The belt monitoring system, when the belt conveyor is under load, when the roller temperature monitoring module detects abnormal information, the detection module of the real-time monitoring and troubleshooting device for the belt conveyor slides onto the sliding block, and the belt damage monitoring system is used to monitor the lower conveyor belt in real time; when the belt conveyor is stopped or unloaded, the detection module of the real-time monitoring and troubleshooting device for the belt conveyor slides to the uppermost end of the linear guide rail to detect the belt, and the belt of the belt conveyor is detected by the belt damage monitoring system.

[0022] Among them, the belt damage online monitoring system based on machine vision information uses cracks in belt images collected by industrial cameras under load conditions, and uses bilateral filtering and histogram equalization to perform image filtering and image enhancement preprocessing respectively; uses the selected adaptive value segmentation method to perform image binarization processing; removes small area noise based on the morphological regional features of connected components to complete the detection and identification of crack targets;

[0023] When the belt conveyor is stopped or unloaded, the online belt damage monitoring system based on machine vision information uses a line structured light image acquisition system to read the line structured light image of the conveyor belt, crop and grayscale enhance the image, extract the line structured light center line, fit and calculate the optimized center line line, and then segment the connected domain of the center line image. It determines whether the belt cracks occur based on the obtained connected domains and the number of connected domains, and determines the precise location of the belt cracks.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows: various data information of the belt conveyor during operation is collected in real time by machine vision sensors, and the computer processes the relevant data information through a certain algorithm, and judges and analyzes common problems such as giant foreign objects, coal flow overload, roller damage, belt damage, etc., and finally formulates a basis for determining the type of fault. When these characteristic faults occur in the belt conveyor, the computer will formulate corresponding safety control decisions for the drive motor according to the belt conveyor fault type, thereby ensuring the safe production of the belt conveyor, while minimizing the downtime caused by faults and detections. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 1 is a working schematic diagram of a real-time monitoring and troubleshooting device for a belt conveyor provided by an embodiment of the present invention;

[0026] Figure 2 yes Figure 1 The main view of the real-time monitoring and troubleshooting device for the belt conveyor running on the track;

[0027] Markings in the attached drawings: 1. Real-time monitoring and troubleshooting device for belt conveyor; 2. Real-time monitoring and troubleshooting device for belt conveyor; 3. Side rollers; 4. Main rollers; 5. Upper conveyor belt; 5', lower conveyor belt; 6. Sliding block; 7. Circular groove rail; 8. Drive module drive gear set; 9. Spring; 10. Second stabilizing pulley; 11. Annular track; 12. First drive wheel; 13. Linear guide rail. DETAILED DESCRIPTION

[0028] In order to facilitate understanding of the present invention, the present invention will be described more fully below with reference to the relevant drawings. The present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thorough and comprehensive.

[0029] like Figure 1 As shown, a working mode of a real-time monitoring and troubleshooting device for a belt conveyor includes a pair of symmetrically arranged robots 1 and 2, wherein the real-time monitoring and troubleshooting device for the belt conveyor includes a main control unit, an energy module, a detection component for detecting equipment and the surrounding environment, and a wireless communication module for exchanging data with a remote control center (all not shown in the figure); an upper conveyor belt 5, a lower conveyor belt 5'; and side rollers 3 on both sides of the upper conveyor belt 5 and a main roller 4 at the lower end.

[0030] The detection component configured on the robot 1 monitors the upper conveyor belt 5 and the lower conveyor belt 5 ′ in the middle of the robot 1 , and has monitoring viewing angles α1 and α2 respectively.

[0031] The main control unit receives commands from the remote control center, controls the robot 1 to move on the track 11, and executes relevant commands and actions. The energy module provides power to the main control unit, wireless communication module, etc. on the robot 1. The wireless communication module is connected to the main control unit, which is used to send the information detected by the detection component and the robot's own status information to the remote control center, and receive action instructions from the remote control center, thereby controlling the specific operation of the entire robot 1.

[0032] The robot 1 of this embodiment travels on the track 11, can perform real-time detection of the equipment and environment near the track 11, and transmit the detected information to the remote control center through the wireless communication module. The staff at the control center can understand the specific conditions of the equipment and its surrounding environment in real time, and can send instructions to the robot 1 to control its specific operating actions.

[0033] Compared with manual inspection, the robot of the present invention has stable inspection results. The operator only needs to control it in the remote control center, and does not need to go to the site for inspection, which saves manpower. At the same time, the robot can go deep into the site for inspection in dangerous situations such as fire. Compared with the ground mobile inspection robot, the robot of the present invention has the advantages of fast and high efficiency, and is not restricted by ground features.

[0034] The robot body includes a body unit, which includes a motion drive module, a pulley block, and a charging compartment; the motion drive module drives the pulley block to roll on the track 11; the elastic element of the pulley block is set to ensure stable travel of the body; the charging compartment has cleaning and charging functions.

[0035] There is information interaction between the real-time monitoring and troubleshooting device for belt conveyors and the roller temperature monitoring system. The roller temperature monitoring system is a roller temperature monitoring module based on infrared thermal imaging. The plurality of roller temperature monitoring systems are evenly distributed on the roller frame (not shown in the figure). The roller temperature monitoring module uses an infrared thermal imager to collect infrared images, processes the collected infrared images of the belt conveyor, analyzes the temperature information of the roller area and issues a fault warning, and transmits the acquired information to the main control unit of the real-time monitoring and troubleshooting device for belt conveyors and the remote control center.

[0036] The roller temperature monitoring module uses an infrared thermal imager to collect infrared images of transportation equipment, processes the collected infrared images of the belt conveyor, and uses vertical and horizontal projections to intercept the area where the roller is located; uses the major-minor axis ratio and area information based on the connected component to filter the image edge, eliminates the pseudo edge formed by edge detection of the above-mentioned intercepted image, and retains the real edge of the roller; uses morphological closing operations to connect the gaps at the edge of the roller, obtains the closed contour of the roller through boundary tracking, and fills the seed area to achieve automatic segmentation of the roller area; finally, analyzes the temperature information of the roller area and issues a fault warning.

[0037] Further, the pulley block includes a first driving wheel 12 and a second stabilizing pulley 10. The first driving wheel 12 is installed on the housing of the vehicle body unit, and the driving module is controlled by the control center to drive the first driving wheel 12. The housing includes an annular groove track 7 opened on its circumferential side, and the housing is in a "冂" shape to prevent the housing from interfering with the support structure of the running track 11 during driving. The vehicle body unit can run on the track 11 wrapped therein. The second stabilizing pulley 10 includes two opposed second stabilizing pulleys 10. One end of the second stabilizing pulley 10 is fixedly connected to a spring 9, and the other end of the spring 9 is fixedly connected to the inner side of the housing; the second stabilizing pulley 10 rolls and rubs against both sides of the track 11, and the spring 9 presses the second stabilizing pulley 10 to keep close contact with the side surface of the track 11.

[0038] Further, the detection component includes a detection module and a sliding block 6. The detection module is slidably connected to the sliding block 6. The sliding block 6 slides in the annular groove track 7. The sliding of the sliding block 6 and the relative sliding of the detection module with respect to the sliding block 6 increase the detection range of the detection module. The inner side of the sliding block 6 meshes with a driving gear. The driving gears are arranged at intervals inside the housing. The driving gear group 8 is driven by the driving module, and the driving gear group 8 drives the sliding block 6 to slide in the groove track 7 by relay. It is only necessary that the interval of the driving gear group 8 is less than the radian angle of the sliding block 6. Preferably, the interval of the driving gear group 8 is 1 / 5 of the circular arc, and the radian angle of the sliding block 6 is 120°. The housing further includes a linear guide rail 13 tangent to the annular groove track 7. The detection module can slide continuously at the connection between the sliding block 6 and the linear guide rail 13, and then move on the linear guide rail 13. The sliding of the sliding block 6, the relative sliding of the detection module with respect to the sliding block 6 and the linear guide rail 13 increase the detection range of the detection module.

[0039] Further, the track 11 is a #4 angle steel in the shape of a工字. The overall structure of the pipe belt conveyor is complex. In order to detect more comprehensively, the track 11 needs to be arranged on both sides of the pipe belt conveyor, that is, the track 11 is circular. A group of the robots are arranged on the circular track 11 and run oppositely to monitor both sides of the same section of the belt simultaneously.

[0040] Further, there are multiple groups of symmetrically arranged detection paddles at both ends of the track 11. When the robot passes by, the detection paddles send real-time signals to the main control unit for judging the synchronism of a pair of the robots.

[0041] Further, a charging pile is provided at the end of the track 11. The robot monitors the power situation and the distance from the current position to the charging pile in real time, and according to the autonomous charging strategy, autonomously navigates to the charging pile and automatically communicates with the charging pile to start charging.

[0042] The robot energy module is a wireless charging and discharging device. The energy module is placed on the upper part of the housing, forming a charging bin with the "冂"-shaped upper surface. The charging bin can charge and supply energy to the detection module that slides therein.

[0043] The battery capacity is 7AH. The wireless charging module adopts a 100W magnetic resonance principle module, and the charging time is 3H. It can realize functions such as charging distance induction detection and self-adjustment of load changes. When the inspection robot needs to be charged after the inspection, when it returns to the charging pile, it will trigger the in-place switch. After confirming the position, it will send a signal to the charging pile to start charging. When the inspection robot is fully charged, it will send a signal to the charging pile to stop charging.

[0044] Further, the detection module includes an industrial camera and at least one of a camera, a temperature sensor, a humidity sensor, a smoke sensor, a dust sensor, an AI camera, and an oxygen content sensor.

[0045] Further, an automatic cleaning device is provided on the inner surface of the upper end of the charging bin. When the detection module includes a camera, the sliding block 6 slides to the upper end of the housing under the drive of the drive gear set 8, and the automatic cleaning device cleans the camera. Preferably, the cleaning device includes an ultra-fine fiber lens cloth wrapped with elastic filler. When the camera is driven by the sliding block 6 and slides under the automatic cleaning device, due to the thickness of the filler, the height of the lens cloth is lower than that of the camera, and the lens cloth wipes the passing camera under the elastic drive, achieving a simple self-cleaning effect.

[0046] Further, the robot also includes a fire extinguisher, which is fixed on the robot body.

[0047] Further, at least one pulley group is installed on each vehicle body unit. Each pulley group includes two second stable pulleys 10 distributed on both sides of the track 11. At least one of the pulley groups is a first drive wheel 12. The pulley group is suspended on the upper surface of the robot running track 11, and the interval between the three pulleys in each pulley group is less than the width of the track 11.

[0048] Further, the main control unit includes a guarantee system, including:

[0049] The foreign body identification system, when the belt conveyor is loaded, the detection module of the real-time monitoring and troubleshooting device for the belt conveyor slides to the uppermost end of the linear guide rail to detect the conveyed object, and uses the anchor foreign body in the belt image collected by the industrial camera to perform image denoising and image enhancement preprocessing respectively by using bilateral filtering and piecewise linear transformation algorithms; uses the selected adaptive value segmentation method to perform image binarization processing; performs shape recognition of anchor foreign body based on the aspect ratio of the circumscribed rectangle of the connected component, and completes the detection and recognition of anchor foreign body targets;

[0050] Coal flow monitoring system, the detection module of the real-time monitoring and troubleshooting device for the belt conveyor slides to the uppermost end of the linear guide rail to detect the conveyed object, obtains the cross-sectional profile of the coal flow through a two-dimensional laser radar, measures the speed information through a speed sensor, and then obtains the coal flow by integrating the cross-sectional area of ​​the coal flow and the speed information;

[0051] The belt monitoring system, when the belt conveyor is under load, when the roller temperature monitoring module detects abnormal information, the detection module of the real-time monitoring and troubleshooting device for the belt conveyor slides onto the sliding block 6, and the belt damage monitoring system is used to monitor the lower conveyor belt in real time; when the belt conveyor is stopped or unloaded, the detection module of the real-time monitoring and troubleshooting device for the belt conveyor slides to the uppermost end of the linear guide rail to detect the belt, and the belt of the belt conveyor is detected by the belt damage monitoring system.

[0052] Among them, the belt damage online monitoring system based on machine vision information uses cracks in belt images collected by industrial cameras under load conditions, and uses bilateral filtering and histogram equalization to perform image filtering and image enhancement preprocessing respectively; uses the selected adaptive value segmentation method to perform image binarization processing; removes small area noise based on the morphological regional features of connected components to complete the detection and identification of crack targets;

[0053] When the belt conveyor is stopped or unloaded, the online belt damage monitoring system based on machine vision information uses a line structured light image acquisition system to read the line structured light image of the conveyor belt, crop and grayscale enhance the image, extract the line structured light center line, fit and calculate the optimized center line line, and then segment the connected domain of the center line image. It determines whether the belt cracks occur based on the obtained connected domains and the number of connected domains, and determines the precise location of the belt cracks.

[0054] Preferably, before the real-time signal collected by the robot 1 is transmitted to the remote control center through the wireless communication module, the main control unit compares and analyzes the collected information. Optionally, the information obtained by the two robots is compared, and when the deviation of the information collected by the symmetrically arranged working components 3 and the environmental monitoring information on both sides is greater than a preset threshold and / or when the deviation of the information collected by the symmetrically arranged working components 3 and the environmental monitoring information on both sides and the preset standard value is greater than a preset threshold, it is determined that the working condition of the current monitoring section is abnormal.

[0055] like Figure 1 to Figure 2 As shown, the main functions realized by the present invention are: there is information exchange between the real-time monitoring and troubleshooting device for belt conveyors of the present invention and the roller temperature monitoring system, and the equipment and environment near the track 11 are detected in real time, and the detected information is transmitted to the remote control center through the wireless communication module. The staff can understand the specific conditions of the equipment and its surrounding environment in real time at the control center, and can send instructions to the robot to control its specific operation actions, such as adjusting the position of the sliding block 6 and the position of the detection module according to the monitoring working conditions, charging and cleaning needs, and driving the vehicle body unit to track according to the needs of the monitoring section.

[0056] There is information interaction between the real-time monitoring and troubleshooting device for belt conveyors and the roller temperature monitoring system. The roller temperature monitoring system is a roller temperature monitoring module based on infrared thermal imaging. The plurality of roller temperature monitoring systems are evenly distributed on the roller frame (not shown in the figure). The roller temperature monitoring module uses an infrared thermal imager to collect infrared images, processes the collected infrared images of the belt conveyor, analyzes the temperature information of the roller area and issues a fault warning, and transmits the acquired information to the main control unit of the real-time monitoring and troubleshooting device for belt conveyors and the remote control center.

[0057] The present invention adopts the concept of hierarchical detection. First, due to the high dust content in the working area of ​​the coal mine belt conveyor and the drastic and random changes in illumination, the detection method based on geometric features and illumination correction for threshold value has a great impact. The detection method based on line structured light images reduces the impact of the harsh environment to a certain extent and significantly improves the reliability of the detection method;

[0058] Secondly, since the difference in heat generated by friction on the conveyor belt is relatively small, more attention should be paid when significant differences in monitoring data occur during transportation. Therefore, infrared detection is required to monitor the equipment under load in real time. Once obvious data changes are detected, more accurate detection methods are used for further judgment to improve detection reliability, while minimizing downtime / no-load conditions caused by detection or failure, and improving production efficiency.

[0059] The following describes the working process of the real-time monitoring and troubleshooting device for belt conveyors:

[0060] When the belt conveyor is under load, there is information interaction between the real-time monitoring and troubleshooting device for the belt conveyor and the roller temperature monitoring system.

[0061] The detection module of the real-time monitoring and troubleshooting device for the belt conveyor slides to the uppermost end of the linear guide rail to perform foreign body recognition and coal flow monitoring on the equipment.

[0062] The foreign body recognition system detects the conveyed objects and uses bilateral filtering and piecewise linear transformation algorithms to perform image denoising and image enhancement preprocessing respectively based on the anchor foreign bodies in the belt images collected by the industrial camera. The selective adaptive value segmentation method is used to perform image binarization processing. The shape of the anchor foreign bodies is recognized based on the aspect ratio of the circumscribed rectangle of the connected components to complete the detection and recognition of the anchor foreign body targets.

[0063] The coal flow monitoring system obtains the cross-sectional profile of the coal flow through a two-dimensional laser radar, measures the velocity information through a velocity sensor, and then obtains the coal flow by integrating the cross-sectional area of ​​the coal flow and the velocity information.

[0064] The roller temperature monitoring module uses an infrared thermal imager to collect infrared images of transportation equipment and processes the collected infrared images of the belt conveyor: the area where the roller is located is intercepted by vertical and horizontal projections; the image edge is filtered by using the major-minor axis ratio and area information based on the connected component to eliminate the pseudo edge formed by edge detection of the above intercepted image and retain the real edge of the roller; the gap of the roller edge is connected by morphological closing operation, the closed contour of the roller is obtained by boundary tracking and the seed area is filled to realize automatic segmentation of the roller area; finally, the temperature information of the roller area is analyzed and a fault warning is issued.

[0065] The fault warning judgment step includes:

[0066] Within a certain time threshold, when only one group of roller temperature monitoring modules detects that: the temperature data difference between the left and right rollers 3 in the same group is greater than the first threshold, it is determined that the monitored side roller 3 has a fault, and the roller temperature monitoring module sends interactive information to the main control unit, and the main control unit controls a pair of real-time monitoring and troubleshooting devices for belt conveyors to move to the problem section roller, and the detection module slides to the appropriate positions on both sides of the left and right rollers 3 of the abnormal working condition for detection and identification. When it is identified that the left and right rollers 3 are asymmetrical or the rolling rate is different, the roller is determined to be faulty. After receiving the fault information, the remote control center controls the emergency shutdown and alarms to notify the staff to perform maintenance operations; when the temperature data difference between the left and right rollers 3 in the same group is greater than the second threshold, it is determined that the monitored side roller 3 has a fault, and a fault signal is sent to the remote control center for emergency shutdown (the time threshold, the first threshold, and the second threshold are adaptively set according to the actual working conditions, and the first threshold is less than the second threshold);

[0067] Within a certain time threshold, when only one group of roller temperature monitoring modules detects that: the temperature data of the left and right side rollers 3 or the main roller 4 in the same group is greater than the third threshold and the fourth threshold corresponding to the preset standard temperature difference, it is judged that the monitored side roller 3 or the main roller 4 is faulty, and the roller temperature monitoring module sends interactive information to the main control unit, and the main control unit controls a pair of real-time monitoring and troubleshooting devices for the belt conveyor to move to the problem section roller, and the detection module slides to the appropriate positions on both sides of the abnormal operating condition roller for detection and identification. When it is identified that the roller has a different posture or rolling rate from the upstream and downstream rollers, it is determined that the roller is faulty. After receiving the fault information, the remote control center controls the emergency shutdown and alarms to notify the staff to perform maintenance operations; if the temperature data of the left and right side rollers 3 or the main roller 4 in the same group is greater than the fifth threshold and the sixth threshold corresponding to the preset standard temperature difference, it is determined that the monitored side roller 3 or the main roller 4 has a fault, and a fault signal is sent to the remote control center for emergency shutdown (the preset standard temperature, the third threshold, the fourth threshold, the fifth threshold, and the sixth threshold are adaptively set according to the actual working conditions. Under normal circumstances, the preset standard temperature is the corresponding temperature average under normal working conditions, the third threshold is less than the fifth threshold, and the fourth threshold is less than the sixth threshold);

[0068] Within a certain time threshold, when the upstream and downstream rollers collect abnormal monitoring information in sequence, and the temperature difference with the preset standard temperature is greater than the seventh threshold, it is judged that the belt has a tearing / deviation fault. The roller temperature monitoring module sends interactive information to the main control unit, and the main control unit controls a pair of real-time monitoring and troubleshooting devices for belt conveyors to move to the problem rollers. The detection module slides onto the sliding block 6, and uses the belt damage monitoring system to monitor the lower conveyor belt in real time. Under the load condition of the belt conveyor, the online belt damage monitoring system based on machine vision information uses the cracks in the image of the lower conveyor belt 5' captured by the industrial camera, and uses bilateral filtering and histogram equalization to perform image filtering and image enhancement preprocessing respectively; uses the selected adaptive value segmentation method to perform image binarization processing; removes small area noise based on the morphological regional features of the connected components to complete the detection and identification of crack targets. When it is identified that the lower conveyor belt 5' is torn, the remote control center controls the emergency shutdown after receiving the fault information and alarms to notify the staff to perform maintenance operations; when the upstream and downstream rollers collect abnormal monitoring information in sequence, and the difference with the preset standard temperature is greater than the eighth threshold, it is judged that the belt has a tear / deviation fault, and a fault signal is sent to the remote control center, and an emergency shutdown is performed (the seventh and eighth thresholds are adaptively set according to the actual working conditions, and the seventh threshold is less than the eighth threshold).

[0069] When the belt conveyor is stopped / unloaded, the real-time monitoring and troubleshooting device 1 for the belt conveyor is symmetrically arranged on the rails 11 on both sides, and the detection module slides to the uppermost end of the linear guide rail 13. The line structured light image acquisition system is used to read the line structured light image of the conveyor belt, and the image is cropped and grayed to enhance the image, the line structured light center line is extracted, and the center line line is optimized by fitting calculation. The center line image connected domain is segmented, and the belt crack is determined based on the obtained connected domain and the number of connected domains. At the same time, the precise location of the belt crack is determined. The acquired information is transmitted to the main control unit of the real-time monitoring and troubleshooting device for the belt conveyor, and the remote control center.

[0070] The present invention utilizes machine vision sensors to collect various data information of the belt conveyor in real time during operation. The computer processes the relevant data information through a certain algorithm, judges and analyzes common problems such as giant foreign objects, coal flow overload, roller damage, belt damage, etc., and finally formulates a basis for determining the type of fault. When the belt conveyor has these characteristic faults, the computer will formulate corresponding safety control decisions for the drive motor according to the belt conveyor fault type, thereby ensuring the safe production of the belt conveyor; the idea of ​​hierarchical detection and judgment further improves the detection reliability, while minimizing the shutdown / no-load conditions caused by detection or failure, and improving production efficiency.

[0071] All technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used in the specification of the present invention herein are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0072] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A real-time monitoring and troubleshooting device for a belt conveyor, characterized in that It includes a robot body, a main control unit, an energy module, a detection component for detecting the equipment and the surrounding environment, and a wireless communication module for data exchange with a remote control center. The detection component includes a detection module. There is information interaction between the real-time monitoring and troubleshooting device for the belt conveyor and the idler temperature monitoring system. When the belt conveyor is under load, there is information interaction between the real-time monitoring and troubleshooting device for the belt conveyor and the idler temperature monitoring system. The main control unit includes a guarantee system, and the guarantee system includes a foreign object identification system and a coal flow monitoring system. When the belt conveyor is under load, the idler temperature monitoring system uses an infrared thermal imager to collect infrared images of the transportation equipment, processes the collected infrared images of the belt conveyor, and conducts fault early warning through the analysis of the temperature information in the idler area. The robot body includes a vehicle body unit, and the vehicle body unit includes a motion drive module, a pulley group, and a charging bin. The motion drive module drives the pulley group to roll on the track (11). The pulley group includes a first drive wheel (12) and a second stabilizing pulley (10). The first drive wheel (12) is installed on the shell of the vehicle body unit, and the drive module is controlled by the control center to drive the first drive wheel (12). The shell includes an annular groove track (7) opened on its circumferential side, and the shell is in the shape of "冂". The vehicle body unit can travel on the track (11) that encloses it. The second stabilizing pulley (10) includes two opposed second stabilizing pulleys (10). One end of the second stabilizing pulley (10) is fixedly connected to a spring (9), and the other end of the spring (9) is fixedly connected to the inner side of the shell. The second stabilizing pulley (10) has rolling friction with both sides of the track (11), and the spring (9) presses the second stabilizing pulley (10) to keep close contact with the side of the track (11). The detection component includes a detection module and a sliding block (6). The detection module is slidably connected to the sliding block (6). The sliding block (6) slides in the annular groove track (7). The sliding of the slider and the relative sliding of the detection module with respect to the slider increase the detection range of the detection module. The inner side of the sliding block (6) meshes with a driving gear. The driving gears are arranged at intervals inside the shell. The driving module drives the driving gear group (8), and the driving gear group (8) drives the sliding block (6) to slide in the groove track (7) in a relay manner. The interval of the driving gear group (8) is less than the radian angle of the sliding block (6). The interval of the driving gear group (8) is 1 / 5 of the arc, and the radian angle of the sliding block (6) is 120°. The shell also includes a linear guide rail (13) tangent to the annular groove track (7). The detection module can slide continuously at the connection between the sliding block (6) and the linear guide rail (13), and then move on the linear guide rail (13). At least one pulley block is installed on each of the vehicle body units, each pulley block includes two second stabilizing pulleys (10) distributed on both sides of the track (11), at least one of the pulley blocks is a first driving wheel (12), the pulley blocks are suspended on the upper surface of the robot running track (11), and the interval between the three pulleys in each pulley block is smaller than the width of the track (11).

2. A real-time monitoring and troubleshooting device for a belt conveyor as claimed in claim 1, characterized in that: The fault warning step comprises: within a certain time threshold, when only one group of roller temperature monitoring modules detects that the temperature data difference between the left and right rollers (3) in the same group is greater than a first threshold, it is judged that the monitored side roller (3) has a fault, and the real-time monitoring and troubleshooting device for the belt conveyor and the detection module are moved to appropriate positions on both sides of the problem roller for detection and identification; when fault information is identified, emergency shutdown and alarm processing are performed; when the temperature data difference between the left and right rollers (3) in the same group is greater than a second threshold, it is judged that the monitored side roller (3) has a fault, a fault signal is sent to the remote control center, and emergency shutdown is performed.

3. A real-time monitoring and troubleshooting device for a belt conveyor as claimed in claim 1, characterized in that: The fault warning step comprises: within a certain time threshold, when only one group of roller temperature monitoring modules detects that: the temperature data of the left and right side rollers (3) or the main roller (4) in the same group is greater than the third threshold and the fourth threshold corresponding to the preset standard temperature difference, it is judged that the monitored side roller (3) or the main roller (4) has a fault, and the real-time monitoring and troubleshooting device for the belt conveyor and the detection module are moved to appropriate positions on both sides of the roller of the problem section for detection and identification; when it is identified that the roller has a different posture from the upstream and downstream rollers or there is a difference in rolling speed, it is determined that the roller is faulty, emergency shutdown and alarm processing are carried out; when the temperature data of the left and right side rollers (3) or the main roller (4) in the same group is greater than the fifth threshold and the sixth threshold corresponding to the preset standard temperature difference, it is judged that the monitored side roller (3) or the main roller (4) has a fault, and a fault signal is sent to the remote control center, and emergency shutdown is carried out.

4. A real-time monitoring and troubleshooting device for a belt conveyor as claimed in claim 1, characterized in that: The fault warning step includes: within a certain time threshold, when the upstream and downstream rollers collect abnormal monitoring information in sequence, and the temperature difference with the preset standard temperature is greater than the seventh threshold, it is determined that the belt has a tear / deviation fault, and the real-time monitoring and troubleshooting device for the belt conveyor and the detection module are moved to appropriate positions on both sides of the rollers of the problem section for detection and identification; using the cracks in the image of the lower conveyor belt (5') collected by the industrial camera, when it is identified that the lower conveyor belt (5') has a tear, emergency shutdown and alarm processing; when the upstream and downstream rollers collect abnormal monitoring information in sequence, and the temperature difference with the preset standard temperature is greater than the eighth threshold, it is determined that the belt has a tear / deviation fault, and a fault signal is sent to the remote control center, and emergency shutdown is performed.

5. A real-time monitoring and troubleshooting device for a belt conveyor as claimed in claim 1, characterized in that: When the belt conveyor is in a stopped / unloaded state, the real-time monitoring and troubleshooting device (1) for the belt conveyor is symmetrically arranged on the rails (11) on both sides, and the detection module slides to the uppermost end of the linear guide rail (13); the line structured light image acquisition system is used to read the line structured light image of the conveyor belt, the image is cropped and gray-scale enhanced, the line structured light center line is extracted, the center line line is optimized by fitting calculation, and the center line image connected domain is segmented, and whether the belt crack occurs is determined based on the obtained connected domain and the number of connected domains, and the precise location of the belt crack is determined; and the acquired information is transmitted to the main control unit of the real-time monitoring and troubleshooting device for the belt conveyor and the remote control center.

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