Online Non-Contact Monitoring Device and Monitoring Method for Belt Conveyor Idlers

Abstract

The present invention discloses an on-line non-contact monitoring device and monitoring method for a belt conveyor idler, which includes an idler, a magnetic field sensor and a main control module. Among them, the idler includes: a cylindrical shell; the material of the cylindrical shell is rubber and permanent magnet powder. The magnetic field sensor is connected to the main control module and is used to measure the magnitude of the magnetic field formed by the rotation of the cylindrical shell to obtain magnetic field data. The main control module is used to obtain the magnetic field data and judge the operating state of the idler. The present invention utilizes the electromagnetic field effect to real-time monitor the rotation state and wear state of the idler in the belt conveyor, overcomes the influence of the harsh on-site environment, and realizes the all-round real-time monitoring of the idler operation.

Description

Technical Field

[0001] The present invention relates to the field of online non-contact monitoring of idlers for belt conveyors, and particularly to an online non-contact monitoring device and method for idlers of a belt conveyor. Background Art

[0002] Belt conveyors are widely used in various mine sites, and materials are transported from the working face to the designated position through the belt conveyor. The key components of the belt conveyor include the conveyor belt and the idler, and the state of the key parts directly affects the safe and stable operation of the conveyor. The idler is the core component that is most frequently damaged in the conveying equipment. Common damages include wear and cracking of the pipe wall, and locking of the bearing. When the idler fails and then wears the belt, it produces a harsh screeching sound until it is completely locked and damaged, making it impossible to guard against. The fault shutdown seriously restricts the normal operation of the belt conveying production line. Moreover, the damaged idler requires more conveying power, indirectly increasing the power consumption.

[0003] In the existing patent for the non-contact detection method of the wear degree of the outer tube of the idler, image processing technology is used to directly measure the shape of the outer tube, which has quite limitations in a high-dust environment. Summary of the Invention

[0004] The purpose of the present invention is to provide an online non-contact monitoring device and method for idlers of a belt conveyor, aiming to solve the online non-contact monitoring of idlers of a belt conveyor.

[0005] The present invention provides an online non-contact monitoring device for idlers of a belt conveyor, including:

[0006] An idler, a magnetic field sensor, and a main control module. Among them, the idler includes: a cylindrical shell; the material of the cylindrical shell is rubber and permanent magnet powder, the magnetic field sensor is connected to the main control module and is used to measure the magnitude of the magnetic field formed by the rotation of the cylindrical shell to obtain magnetic field data, and the main control module is used to obtain the magnetic field data to judge the operating state of the idler.

[0007] The present invention also provides an online non-contact monitoring method for idlers of a belt conveyor, including:

[0008] In the initial installation stage, when the belt conveyor is running without load, the cylindrical shell rotates. The main control module obtains the magnetic field data in the magnetic field sensor, calculates the two-dimensional integral graph of the magnetic field data and the time series, and the main control module processes the two-dimensional integral graph through FFT to obtain a two-dimensional cloud map as the original feature map;

[0009] When the belt conveyor is running with load, the cylindrical shell rotates. The main control module obtains the operating magnetic field data in the magnetic field sensor, calculates the two-dimensional operating integral graph of the operating magnetic field data and the time series, and the main control module processes the two-dimensional operating integral graph through FFT to obtain a two-dimensional operating cloud map as the original operating feature map;

[0010] The main control module compares the stretching lengths of the feature points in the original feature map and the original operating feature map on the time axis to determine the speed change of the idler, and compares the median values of the feature points to determine the thickness of the idler shell, so as to determine the operating state of the idler.

[0011] By adopting the embodiment of the present invention, the rotation state and wear state of the idler in the belt conveyor are monitored in real time by using the electromagnetic field effect, the influence of the harsh on-site environment is overcome, and the all-round real-time monitoring of the idler operation is realized.

[0012] The above description is only an overview of the technical solution of the present invention. In order to be able to understand the technical means of the present invention more clearly, it is implemented in accordance with the content of the specification. And in order to make the above and other purposes, features and advantages of the present invention more obvious and understandable, the following specifically describes the specific embodiments of the present invention. Description of the Drawings

[0013] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following will briefly introduce the drawings required for the description of the specific embodiments or the prior art. Obviously, the drawings in the following description are some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0014] Figure 1 It is a schematic diagram of the on-line non-contact monitoring device for the idler of the belt conveyor according to the embodiment of the present invention;

[0015] Figure 2 It is a schematic diagram of the idler of the on-line non-contact monitoring device for the idler of the belt conveyor according to the embodiment of the present invention;

[0016] Figure 3 It is a schematic diagram of the overall inspection process of the on-line non-contact monitoring device for the idler of the belt conveyor according to the embodiment of the present invention;

[0017] Figure 4 It is an installation schematic diagram of the on-line non-contact monitoring device for the idler of the belt conveyor according to the embodiment of the present invention.

[0018] Description of the reference numerals:

[0019] 1: Shell; 2: Steel pipe; 3: Bearing; 4: Idler; 5: Magnetic field sensor. Detailed Embodiments

[0020] The technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0021] Device embodiment

[0022] According to an embodiment of the present invention, there is provided an online non-contact monitoring device for a belt conveyor idler. Figure 1 It is a schematic diagram of the online non-contact monitoring device for a belt conveyor idler according to an embodiment of the present invention, as Figure 1 shown, and specifically includes:

[0023] An idler, a magnetic field sensor, and a main control module. Among them, the idler includes: a cylindrical shell; the material of the cylindrical shell is rubber and permanent magnet powder, the magnetic field sensor is connected to the main control module and is used to measure the magnitude of the magnetic field formed by the rotation of the cylindrical shell to obtain magnetic field data, and the main control module is used to obtain the magnetic field data to judge the operating state of the idler. The magnetic field sensor is a coil. The coil is installed below the idler.

[0024] The specific implementation method is as follows:

[0025] Figure 2 It is a schematic diagram of the idler of the online non-contact monitoring device for a belt conveyor idler according to an embodiment of the present invention;

[0026] The idlers of a belt conveyor can be simply divided into a cylindrical shell 1, a steel pipe 2, and a bearing 3. Among them, the cylindrical shell is usually a rubber product. In this patent, a certain amount of permanent magnet powder is incorporated into the raw material rubber of the cylindrical shell and wrapped outside the steel pipe, so as to generate a static magnetic field of a certain magnitude and direction around the idler.

[0027] A specific magnetic field sensor is installed below the position where the idler is installed on the belt conveyor to monitor the operating state of the idler. The magnetic field sensor is mainly composed of multiple groups of coils. When the magnetic field of the idler cuts the coil during the movement of the idler, the coil generates an induced electromotive force. Since the induced electromotive force of the coil is related to two variables, the rotational speed of the idler and the magnitude of the magnetic flux of the coil. The magnetic flux of the coil is related to the characteristics of the magnetic particles of the idler itself and the distance from the magnetic particles. As the cylindrical shell 3 of the idler wears continuously, the distance between the magnetic particles of the idler and the coil increases continuously, and the magnetic flux passing through the coil decreases continuously, and the induced electromotive force in the coil follows and decreases. The thickness of the cylindrical shell of the idler is judged according to the magnitude of the induced electromotive force.

[0028] The generation of the induced electromotive force requires the magnetic field of the coil to cut the coil. Only when the idler rotates, the magnetic field cuts the coil to generate an induced electromotive force. When the rotation of the idler is blocked and the rotational speed decreases, the induced electromotive force of the coil decreases. When the idler is blocked and rotated, the induced electromotive force of the coil is zero, and it is judged whether the idler is blocked in turn.

[0029] Figure 3 It is a schematic diagram of the overall inspection process of the on-line non-contact monitoring device for the idler of the belt conveyor according to the embodiment of the present invention;

[0030] The overall inspection process is as follows Figure 3 As shown, first, at the initial installation stage, in the no-load running environment of the conveyor, initial data is collected. The magnetic flux changes around the sensor are collected at equal intervals, and a 2D array diagram is formed according to the time series. After FFT processing, the low-frequency data is filtered to form a 2D cloud diagram as the original feature diagram. When the equipment is running, the sensing data is collected in real time. A 2D array diagram is formed according to the time series. After FFT processing, the low-frequency data is filtered to continuously establish a 2D array feature diagram. The stretching length of the feature points in the time axis in the two adjacent feature diagrams is compared to judge the speed change of the idler, and the median value of the feature points in the original feature diagram is compared to judge the thickness of the idler barrel skin 3, and finally the abnormal wear, abnormal speed and normal results are formed.

[0031] Figure 4 It is a schematic installation diagram of the on-line non-contact monitoring device for the idler of the belt conveyor according to the embodiment of the present invention;

[0032] A magnetic field sensor 5 is installed below the idler 4 of the belt conveyor. Its installation method is simple and not affected by the on-site environment such as dust.

[0033] The type of the idler is a rubber type roller idler.

[0034] Method embodiment

[0035] According to the embodiment of the present invention, an on-line non-contact monitoring method for the idler of a belt conveyor is provided, which specifically includes:

[0036] At the initial installation stage, when the belt conveyor is running without load, the barrel skin rotates. The magnetic field data in the magnetic field sensor is obtained through the main control module, and a 2D whole array diagram of the magnetic field data and the time series is calculated. The main control module processes the 2D whole array diagram through FFT to obtain a 2D cloud diagram as the original feature diagram;

[0037] When the belt conveyor is running with load, the barrel skin rotates. The running magnetic field data in the magnetic field sensor is obtained through the main control module, and a 2D running whole array diagram of the running magnetic field data and the time series is calculated. The main control module processes the 2D running whole array diagram through FFT to obtain a 2D running cloud diagram as the original running feature diagram;

[0038] The main control module compares the stretching length of the feature points in the time axis in the original feature diagram and the original running feature diagram to judge the speed change of the idler, and compares the median value of the feature points to judge the thickness of the idler barrel skin, and judges the running state of the idler.

[0039] Obtaining the magnetic field data collected by the magnetic field sensor through the main control module specifically includes: Judging the operating state of the idler through the main control module specifically includes: Judging whether the rotation speed of the idler is abnormal and whether the wear of the idler drum skin is abnormal.

[0040] The embodiment of the present invention is a system embodiment corresponding to the above method embodiment. The specific operations of each module can be understood with reference to the description of the method embodiment, and will not be elaborated here.

[0041] Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present invention, rather than limiting them; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that: they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements on some or all of the technical features; and these modifications or replacements do not make the essence of the technical solutions of the embodiments of the present invention deviate from the scope of the present solution.

Claims

1. An on-line non-contact monitoring device for a belt conveyor idler, characterized in that, Comprising, Carrier rollers, magnetic field sensors and main control modules. Among them, the carrier rollers include: a cylindrical shell, a steel pipe and bearings; the material of the cylindrical shell is rubber and permanent magnet powder, and the permanent magnet powder is wrapped outside the steel pipe; a magnetic field sensor, connected to the main control module, for measuring the magnitude of the magnetic field formed by the rotation of the cylindrical shell to obtain magnetic field data, and the main control module is used to obtain the magnetic field data and judge the operating state of the carrier roller based on the magnetic field data by using FFT and comparison methods; Among them, the judgment of the operating state of the carrier roller specifically includes: judging whether the rotation speed of the carrier roller is abnormal and whether the wear of the cylindrical shell of the carrier roller is abnormal.

2. The device according to claim 1, characterized in that, The magnetic field sensor is a coil.

3. The device according to claim 2, characterized in that, The coil is installed below the carrier roller.

4. An on-line non-contact monitoring method for a belt conveyor idler, characterized in that, Based on the on-line non-contact monitoring device for the belt conveyor carrier roller according to any one of claims 1 to 3, Comprising, In the initial installation stage, when the belt conveyor is running without load, the cylindrical shell rotates. The main control module obtains the magnetic field data in the magnetic field sensor, calculates the two-dimensional integral map of the magnetic field data and the time series, and the main control module processes the two-dimensional integral map through FFT to obtain the two-dimensional cloud map as the original feature map; When the belt conveyor is running under load, the cylindrical shell rotates. The main control module obtains the running magnetic field data in the magnetic field sensor, calculates the two-dimensional running integral map of the running magnetic field data and the time series, and the main control module processes the two-dimensional running integral map through FFT to obtain the two-dimensional running cloud map as the original running feature map; The main control module judges the speed change of the carrier roller by comparing the stretching lengths of the feature points in the original feature map and the original running feature map on the time axis, and compares the median values of the feature points to judge the thickness of the cylindrical shell of the carrier roller, so as to judge the operating state of the carrier roller.

5. The method according to claim 4, characterized in that, The obtaining of the magnetic field data collected by the magnetic field sensor through the main control module specifically includes: obtaining the magnetic field data in the coil through the main control module.

6. The method according to claim 5, characterized in that, The judgment of the operating state of the carrier roller specifically includes: judging whether the rotation speed of the carrier roller is abnormal and whether the wear of the cylindrical shell of the carrier roller is abnormal.

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