Monitoring device and monitoring method

Abstract

The present invention provides a monitoring device and a monitoring method, the monitoring device comprising: a tubular belt conveyor, comprising a frame, a pipe belt and a plurality of rollers, the frame being provided with an avoidance hole; the pipe belt being passed through the avoidance hole; a plurality of rollers being arranged at intervals around the circumference of the pipe belt, the rollers comprising a roller shaft and a roller body rotatably sleeved on the outside of the roller shaft; a plurality of groups of resistance strain gauges being arranged one-to-one on the inner wall surfaces of the roller bodies of the plurality of rollers, for monitoring the strain effects generated by the corresponding roller bodies during movement; a host computer being connected to the plurality of groups of resistance strain gauges, for receiving monitoring results of each group of resistance strain gauges and calculating the noise of the tubular belt conveyor according to the monitoring results, so as to solve the problem that the force monitoring method in the prior art is not suitable for monitoring the force of the tubular belt conveyor during the noise generation process.

Description

Technical Field

[0001] The present invention relates to the technical field of tubular belt conveyor monitoring, and in particular to a monitoring device and a monitoring method. Background Art

[0002] Tubular belt conveyors are widely used in industries such as coal transportation due to their large transportation capacity, stable operating speed, and small transportation resistance.

[0003] However, the tubular belt conveyor has a long transport route, and there are noise problems in the drive section, middle section and unloading section. The noise in the middle section is particularly obvious, which directly affects the lives of surrounding residents.

[0004] How to accurately predict the noise generated by tubular belt conveyors during transportation has important guiding significance for the optimal design of tubular belt conveyor structures. The key lies in the prediction of the forces involved in the noise generation process.

[0005] Currently, there are the following problems in predicting the force of tubular belt conveyors during transmission:

[0006] (1) Compared with the flat belt conveyor in the prior art, the tubular belt conveyor, as a new mode of transportation, has a structure that is very different from the traditional belt conveyor. Therefore, the force analysis method for the flat belt conveyor cannot be applied to the tubular belt conveyor.

[0007] (2) In the noise simulation process, the theoretical excitation force is used as the excitation source, without considering the influence of the working conditions during the actual transportation process. Therefore, the simulation results are distorted, and often only the noise law can be studied, but the actual noise level cannot be predicted.

[0008] (3) There is currently no dedicated monitoring device for monitoring the stress conditions of tubular belt conveyors during their movement, which limits the development of online fault diagnosis technology for tubular belt conveyors.

[0009] (4) The monitoring equipment in the prior art is too complicated and inconvenient to install. Summary of the Invention

[0010] The main purpose of the present invention is to provide a monitoring device and a monitoring method to solve the problem that the force monitoring method in the prior art is not suitable for monitoring the force of a tubular belt conveyor during the noise generation process.

[0011] In order to achieve the above-mentioned purpose, according to one aspect of the present invention, a monitoring device is provided, including: a tubular belt conveyor, the tubular belt conveyor includes a frame, a pipe belt and a plurality of rollers, and the frame is provided with an avoidance hole; the pipe belt is inserted into the avoidance hole; a plurality of rollers are arranged at intervals around the circumference of the pipe belt, and the rollers include a roller shaft and a roller body rotatably mounted outside the roller shaft; a plurality of groups of resistance strain gauges are arranged on the inner wall surfaces of the roller bodies of the plurality of rollers in a one-to-one correspondence, so as to monitor the strain effects generated by the corresponding roller bodies during movement; a host computer is connected to the plurality of groups of resistance strain gauges, so as to receive the monitoring results of each group of resistance strain gauges and calculate the noise of the tubular belt conveyor according to the monitoring results.

[0012] Furthermore, the monitoring device includes: a strain conditioner, which is connected to the resistance strain gauge to receive the monitoring signal of the resistance strain gauge and amplify it to generate an amplified signal; a data acquisition card, which is connected to both the strain conditioner and the host computer to collect the amplified signal and transmit it to the host computer.

[0013] Furthermore, the monitoring device includes: a collector ring, including an outer ring and an inner ring, the outer ring is connected to the inner wall surface of the roller body, and the inner ring is connected to the roller shaft; a first connecting line, one end of the first connecting line is connected to the outer ring, and the other end of the first connecting line is connected to the resistance strain gauge; a second connecting line, one end of the second connecting line is connected to the inner ring, and the other end of the second connecting line is connected to the strain conditioner.

[0014] Furthermore, a first wire-releasing groove is provided on the outer circumferential surface of the roller shaft, and two ends of the first wire-releasing groove are respectively connected to the inside and the outside of the roller for avoiding the second connecting line.

[0015] Furthermore, each group of resistance strain gauges is adhered to the corresponding roller body; and / or each group of resistance strain gauges includes multiple resistance strain gauges, and the multiple resistance strain gauges are arranged at intervals around the axis of the corresponding roller shaft.

[0016] Furthermore, the avoidance hole is a hexagonal hole, and the multiple rollers include a first roller, a second roller, a third roller, a fourth roller, a fifth roller and a sixth roller which are arranged in one-to-one correspondence with the six sides of the hexagonal hole; wherein the first roller, the second roller and the third roller are located below the pipe belt, and the second roller and the third roller are respectively located on opposite sides of the first roller; the fourth roller, the fifth roller and the sixth roller are located above the pipe belt, and the fifth roller and the sixth roller are respectively located on opposite sides of the fourth roller.

[0017] Furthermore, the monitoring device includes: a plurality of guide mounting parts, which are arranged on the frame at intervals around the center line of the avoidance hole; a plurality of adjustable roller frames, a plurality of rollers are mounted on the plurality of adjustable roller frames one by one, and a plurality of adjustable roller frames are mounted on the plurality of guide mounting parts one by one and detachably; wherein, the position of the corresponding roller relative to the pipe belt is adjusted by adjusting the position of each adjustable roller frame on the corresponding guide mounting part.

[0018] Furthermore, the adjustable roller frame includes an intermediate support plate and two connecting ears respectively arranged at opposite ends of the intermediate support plate. The guide mounting portion includes a guide mounting space extending radially along the pipe belt. The intermediate support plate is adjustably arranged in the guide mounting space in a direction close to or away from the pipe belt and is detachably connected to the guide mounting portion. The two connecting ears extend in a direction away from the frame to be respectively connected to the opposite ends of the roller.

[0019] According to another aspect of the present invention, a monitoring method is provided, which is applicable to the above-mentioned monitoring device, and the monitoring method includes: formulating noise judgment rules: controlling the movement of the tubular belt conveyor; observing the test contact state between the pipe belt and each roller; collecting the test strain of the corresponding roller monitored by each set of resistance strain gauges and performing data processing on the test strain to obtain the test stress of the corresponding roller; performing simulation analysis on the tubular belt conveyor based on the test contact state between the pipe belt and each roller and the test stress of each roller to obtain the overall noise of the tubular belt conveyor; deriving a preset noise range and a preset stress range for each roller corresponding to the preset noise range based on noise environmental protection standards; real-time monitoring of working conditions: controlling the normal operation of the tubular belt conveyor; observing the real-time contact state between the pipe belt and each roller; collecting the real-time strain of the corresponding roller monitored by each set of resistance strain gauges and performing data processing on the real-time strain to obtain the real-time stress of the corresponding roller; and comparing the real-time stress of each roller with the preset stress range to determine whether the real-time overall noise of the tubular belt conveyor is within the preset noise range.

[0020] Furthermore, the calculation formula of the roller stress includes: Where U is the voltage value measured by the resistance strain gauge, U1 is the reference zero drift voltage, K is the sensitivity coefficient of the resistance strain gauge, U0 is the bridge voltage between the second connecting wire connected to the resistance strain gauge and the strain conditioner, n is the number of bridge arms of the bridge, and K is the bridge voltage of the bridge. S is the gain coefficient of the strain conditioner, and E is the elastic modulus of the roller body.

[0021] Furthermore, the monitoring method includes: when there are no obvious abnormalities in the contact state between the pipe belt and each roller, and the real-time overall noise level of the tubular belt conveyor is within a preset noise range, controlling the working status signal light of the tubular belt conveyor to illuminate green; when there are obvious abnormalities in the contact state between the pipe belt and each roller, and the real-time overall noise level of the tubular belt conveyor is within the preset noise range, controlling the working status signal light of the tubular belt conveyor to illuminate yellow; and when the real-time overall noise level of the tubular belt conveyor exceeds the preset noise range, controlling the working status signal light of the tubular belt conveyor to illuminate red.

[0022] Applying the technical solution of the present invention, the monitoring device of the present invention includes: a tubular belt conveyor, the tubular belt conveyor includes a frame, a pipe belt and a plurality of rollers, and the frame is provided with an avoidance hole; the pipe belt is inserted into the avoidance hole; a plurality of rollers are arranged at intervals around the circumference of the pipe belt, and the rollers include a roller shaft and a roller body rotatably mounted outside the roller shaft; a plurality of groups of resistance strain gauges are arranged one by one on the inner wall surfaces of the roller bodies of the plurality of rollers, so as to monitor the strain effects generated by the corresponding roller bodies during movement; a host computer is connected to the plurality of groups of resistance strain gauges, so as to receive the monitoring results of each group of resistance strain gauges and calculate the noise of the tubular belt conveyor according to the monitoring results. In this way, the present invention uses resistance strain gauges to monitor the strain effect of rollers, which has a much lower cost than non-contact sensors and has better adaptability to low-precision components such as rollers. By monitoring the strain effect generated by each roller during movement, the contact force of each roller can be directly obtained, the contact state between the pipe belt and each roller can be obtained, and the rollers with obviously abnormal contact states can be found. The noise warning criteria of the tubular belt conveyor can be formulated based on the contact state to conduct risk assessment of the movement noise of the tubular belt conveyor, which is conducive to adjusting the installation position of the rollers, and solves the problem that the force monitoring method in the prior art is not suitable for monitoring the force of the tubular belt conveyor during the noise generation process. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The accompanying drawings, which constitute part of this application, are intended to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are intended to explain the present invention and do not constitute an undue limitation of the present invention. In the accompanying drawings:

[0024] Figure 1 It shows a schematic structural diagram of a monitoring device according to the present invention;

[0025] Figure 2 Shown Figure 1 A cross-sectional view of a roller of a tubular belt conveyor of the monitoring device shown in one direction;

[0026] Figure 3 Shown Figure 2A cross-sectional view of the roller shown in another direction;

[0027] Figure 4 Shown Figure 3 The position distribution diagram of multiple rollers of the tubular belt conveyor of the monitoring device shown on the frame;

[0028] Figure 5 Shown Figure 4 The structural diagram of the rack shown;

[0029] Figure 6 Shown Figure 5 A partial enlarged view of the frame at the guide mounting portion is shown;

[0030] Figure 7 Shown Figure 5 A schematic diagram of the structure of an adjustable roller frame installed on the frame shown;

[0031] Figure 8 Shown Figure 4 The schematic diagram of the state when the roller and the pipe belt are in the first contact state;

[0032] Figure 9 Shown Figure 4 The schematic diagram of the state when the roller and the pipe belt are in the second contact state;

[0033] Figure 10 Shown Figure 4 The schematic diagram of the state when the roller and the pipe belt are in the third contact state;

[0034] Figure 11 A flow chart of the monitoring method according to the present invention is shown.

[0035] The above drawings include the following reference numerals:

[0036] 1. Roller body; 2. Roller shaft; 3. Bearing; 4. End cover; 5. Collector ring; 6. First connecting line; 7. Resistance strain gauge; 8. Pipe belt;

[0037] 9. Idlers; 91. First idler; 92. Second idler; 93. Third idler; 94. Fourth idler; 95. Fifth idler; 96. Sixth idler; 9. Idlers; 10. Frame;

[0038] 11. Second connecting line; 12. Strain conditioner; 13. Data acquisition card; 14. Host computer;

[0039] 15. Adjustable roller frame; 151. Intermediate support plate; 152. Connecting ear; 153. First fastener threaded hole; 154. Second fastener through hole;

[0040] 16. Avoidance hole; 17. First fastener;

[0041] 18. Guide mounting portion; 180. Guide mounting space; 181. First guide mounting member; 182. Second guide mounting member; 183. First plate; 184. Second plate; 185. First fastener through hole. DETAILED DESCRIPTION

[0042] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments in this application can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0043] like Figures 1 to 10 As shown, the present invention provides a monitoring device including: a tubular belt conveyor, the tubular belt conveyor includes a frame 10, a pipe belt 8 and a plurality of rollers 9, the frame 10 is provided with an avoidance hole 16; the pipe belt 8 is inserted into the avoidance hole 16; a plurality of rollers 9 are arranged at intervals around the circumference of the pipe belt 8, the rollers 9 include a roller shaft 2 and a roller body 1 rotatably mounted outside the roller shaft 2; a plurality of groups of resistance strain gauges 7 are arranged one by one on the inner wall surface of the roller body 1 of the plurality of rollers 9, so as to monitor the strain effect generated by the corresponding roller body 1 during the movement; a host computer 14 is connected to the plurality of groups of resistance strain gauges 7, so as to receive the monitoring results of each group of resistance strain gauges 7 and calculate the noise of the tubular belt conveyor according to the monitoring results.

[0044] The present invention adopts a resistance strain gauge 7 to monitor the strain effect of the roller 9, which has a much lower cost than a non-contact sensor and has better adaptability to low-precision components such as the roller 9. By monitoring the strain effect generated by each roller 9 during the movement, the contact force of each roller 9 can be directly obtained, and the contact state between the pipe belt 8 and each roller 9 can be obtained. The roller 9 with an obviously abnormal contact state can be found, and the noise judgment rule of the tubular belt conveyor can be formulated based on the contact state to perform risk assessment on the movement noise of the tubular belt conveyor, which is conducive to adjusting the installation position of the roller 9, and solves the problem that the force monitoring method in the prior art is not suitable for monitoring the force of the tubular belt conveyor during the noise generation process.

[0045] The roller body 1 and the roller shaft 2 of the roller 9 are connected via a bearing 3 , and end covers 4 are installed at opposite ends of the roller body 1 .

[0046] like Figure 1 As shown, the tubular belt conveyor includes: a strain conditioner 12, which is connected to the resistance strain gauge 7 for receiving the monitoring signal of the resistance strain gauge 7 and amplifying it to generate an amplified signal; a data acquisition card 13, which is connected to both the strain conditioner 12 and the host computer 14 for collecting the amplified signal and transmitting it to the host computer 14.

[0047] like Figure 2 As shown, the tubular belt conveyor includes: a collector ring 5, including an outer ring and an inner ring, the outer ring is connected to the inner wall surface of the roller body 1, and the inner ring is connected to the roller shaft 2; a first connecting line 6, one end of the first connecting line 6 is connected to the outer ring, and the other end of the first connecting line 6 is connected to the resistance strain gauge 7; a second connecting line 11, one end of the second connecting line 11 is connected to the inner ring, and the other end of the second connecting line 11 is connected to the strain conditioner 12.

[0048] Specifically, the inner and outer rings of the collector ring 5 can not only maintain relative rotation, but also transmit signals and current by means of sliding contact with the conductive ring groove with the help of the elastic pressure of the brush; wherein, the outer ring of the collector ring is matched with the inner wall surface of the roller body 1, which can ensure that the first connecting line 6 pasted on the inner wall surface of the roller body 1 and the roller body 1 remain relatively stationary, even if the resistance strain gauge 7 and the first connecting line 6 rotate synchronously with the roller body 1 while ensuring connection with the outer ring of the collector ring 5; the inner ring of the collector ring 5 is matched with the roller shaft, which can ensure the relative stationary state between the second connecting line 11 and the roller shaft 2, thereby realizing the transition of the electrical signal from the resistance strain gauge 7 to the strain conditioner 12.

[0049] After the roller 9 of the present invention is installed, the second connecting line 11 and the strain conditioner 12 need to be connected through a quarter bridge, and then the data acquisition card 13 and the host computer 14 are connected in sequence to realize the construction of the monitoring device.

[0050] like Figure 2 As shown, a first wire-releasing groove is provided on the outer circumference of the roller shaft 2 , and both ends of the first wire-releasing groove are respectively connected to the inside and outside of the roller 9 to avoid the second connecting line 11 .

[0051] Specifically, without affecting the safety factor of the roller 9 , a first wire-releasing groove is milled on the outer peripheral surface of the roller shaft 2 , which is beneficial to the lead-out of the second connecting wire 11 .

[0052] like Figure 3 As shown, each group of resistance strain gauges 7 is pasted on the corresponding roller body 1. Compared with pasting them on the roller shaft 2, the range of measured strain is larger, and the measurement effect is better for low-precision components such as the roller 9; and / or each group of resistance strain gauges 7 includes multiple resistance strain gauges 7, and the multiple resistance strain gauges 7 are arranged at intervals around the axis of the corresponding roller shaft 2, so as to be used to measure the strain at different circumferential positions of the roller body 1.

[0053] Among them, each resistance strain gauge 7 is installed in the middle of the length direction of the corresponding roller body 1. Before assembling the roller 9, it is necessary to wipe the inner surface of the roller body 1 to remove burrs and lubricating grease, etc., and then paste each resistance strain gauge 7 on the roller body 1. Finally, assemble them in the order of roller body 1, collecting ring 5, bearing 3, roller shaft 2 and end cover 4.

[0054] like Figure 4 As shown, the avoidance hole 16 is a hexagonal hole, and the multiple rollers 9 include a first roller 91, a second roller 92, a third roller 93, a fourth roller 94, a fifth roller 95 and a sixth roller 96, which are arranged in a one-to-one correspondence with the six sides of the hexagonal hole; wherein the first roller 91, the second roller 92 and the third roller 93 are located below the pipe belt 8, and the second roller 92 and the third roller 93 are respectively located on the opposite sides of the first roller 91; the fourth roller 94, the fifth roller 95 and the sixth roller 96 are located above the pipe belt 8, and the fifth roller 95 and the sixth roller 96 are respectively located on the opposite sides of the fourth roller 94.

[0055] Specifically, the first roller 91, the second roller 92 and the third roller 93 play a main supporting role, and the fourth roller 94, the fifth roller 95 and the sixth roller 96 play a role in maintaining the tubular shape of the pipe belt 8. Therefore, the monitoring of the strain of multiple rollers 9 is mainly carried out on the first roller 91, the second roller 92 and the third roller 93.

[0056] In order to ensure the stability of the tubular belt conveyor's belt 8 during transportation, the middle section is supported by a plurality of roller groups arranged in sequence along the extension direction of the belt 8. Each roller group includes six rollers 9 distributed in a regular hexagon.

[0057] like Figures 5 to 8 As shown, the tubular belt conveyor includes: a plurality of guide mounting portions 18, which are arranged on the frame 10 at intervals around the center line of the avoidance hole 16; a plurality of adjustable roller frames 15, and a plurality of rollers 9 are mounted on the plurality of adjustable roller frames 15 in a one-to-one correspondence, and the plurality of adjustable roller frames 15 are detachably mounted on the plurality of guide mounting portions 18 in a one-to-one correspondence; wherein, by adjusting the position of each adjustable roller frame 15 on the corresponding guide mounting portion 18, the position of the corresponding roller 9 relative to the pipe belt 8 is adjusted. In this way, by providing the adjustable roller frames 15 and the guide mounting portion 18, the installation position of the roller 9 can be quickly adjusted to ensure the contact state between the pipe belt 8 and each roller 9, which greatly reduces economic costs and improves work efficiency.

[0058] Specifically, the adjustable roller frame 15 includes an intermediate support plate 151 and two connecting ears 152 respectively arranged at opposite ends of the intermediate support plate 151. The guide mounting portion 18 includes a guide mounting space 180 extending radially along the pipe belt 8. The intermediate support plate 151 is adjustably arranged in the guide mounting space 180 in a direction close to or away from the pipe belt 8 and is detachably connected to the guide mounting portion 18. The two connecting ears 152 extend in a direction away from the frame 10 to be respectively connected to the opposite ends of the roller 9.

[0059] like Figure 5 As shown, the guide mounting portion 18 includes a first guide mounting member 181 and a second guide mounting member 182 that are opposite to and spaced apart from each other. The first guide mounting member 181 and the second guide mounting member 182 both include a first plate body 183 and a second plate body 184 that are connected to each other. The first plate body 183 is perpendicular to the main board body of the rack 10, and the second plate body 184 is parallel to the main board body of the rack 10 and is located on the side of the first plate body 183 away from the main board body of the rack 10, so as to jointly form a guide mounting space 180.

[0060] like Figure 4 As shown, the opposite ends of the intermediate support plate 151 are connected to the first plate bodies 183 of the first guide mounting member 181 and the second guide mounting member 182 through the first fastener 17, and each first plate body 183 is provided with a first fastener through hole 185. The opposite ends of the intermediate support plate 151 are provided with a first fastener threaded hole 153, and the first fastener 17 passes through the first fastener through hole 185 and is threadedly connected to the first fastener threaded hole 153.

[0061] Specifically, the first fastener 17 is a set screw, which can lock the corresponding adjustable roller frame 15 and the guide mounting portion 18 while positioning the adjustable roller frame 15 to ensure the support stiffness of the corresponding roller 9.

[0062] like Figure 4 As shown, the opposite ends of the roller shaft 2 are connected to the two connecting ears 152 through second fasteners, and the opposite ends of the roller shaft 2 are respectively provided with second fastener threaded holes, and the two connecting ears 152 are respectively provided with second fastener through holes 154. The second fastener passes through the second fastener through holes 154 and is threadedly connected to the second fastener threaded holes.

[0063] The present invention also provides a monitoring method applicable to the above-mentioned monitoring device, the monitoring method comprising: formulating noise judgment rules: controlling the movement of the tubular belt conveyor; observing the test contact state between the pipe belt 8 and each roller 9; collecting the test strain of the corresponding roller 9 monitored by each group of resistance strain gauges 7 and performing data processing on the test strain to obtain the test stress of the corresponding roller 9; performing simulation analysis on the tubular belt conveyor based on the test contact state between the pipe belt 8 and each roller 9 and the test stress of each roller 9 to obtain the overall noise of the tubular belt conveyor; According to the noise environmental protection standard, a preset noise range and a preset stress range of each roller 9 corresponding to the preset noise range are obtained; the working condition is monitored in real time: the normal operation of the tubular belt conveyor is controlled; the real-time contact status between the pipe belt 8 and each roller 9 is observed; the real-time strain of the corresponding roller 9 monitored by each group of resistance strain gauges 7 is collected and the real-time strain is processed to obtain the real-time stress of the corresponding roller 9; the real-time stress of each roller 9 is compared with the preset stress range to determine whether the real-time overall noise of the tubular belt conveyor is within the preset noise range.

[0064] Specifically, the monitoring method of the present invention comprises:

[0065] Step S1: Formulate noise judgment rules:

[0066] Step S11, controlling the movement of the tubular belt conveyor;

[0067] Step S12: Observe the test contact state between the belt tube 8 and each roller 9;

[0068] Step S13: collecting the test strain values ​​of the corresponding rollers 9 monitored by the resistance strain gauges 7 of each group and performing data processing on the test strain values ​​to obtain the test stress of the corresponding rollers 9;

[0069] Step S14: performing simulation analysis on the tubular belt conveyor based on the tested contact state between the pipe belt 8 and each roller 9 and the tested stress of each roller 9 to obtain the overall noise of the tubular belt conveyor;

[0070] Step S15: according to the noise environmental protection standard, a preset noise range and a preset stress range of each roller 9 corresponding to the preset noise range are obtained;

[0071] Step S2: Real-time monitoring of working status:

[0072] Step S21, controlling the tubular belt conveyor to operate normally;

[0073] Step S23: Observe the real-time contact status between the belt tube 8 and each roller 9;

[0074] Step S23: collecting the real-time strain of the corresponding roller 9 monitored by each group of resistance strain gauges 7 and performing data processing on the real-time strain to obtain the real-time stress of the corresponding roller 9;

[0075] Step S24: Compare the real-time stress of each roller 9 with the preset stress range to determine whether the real-time overall noise of the tubular belt conveyor is within the preset noise range.

[0076] Based on the real-time monitoring of the strain of each roller 9 of the tubular belt conveyor during movement, the real-time contact status between the pipe belt 8 and each roller 9 can be obtained. However, the overall accuracy of the tubular belt conveyor is low, the installation conditions of each roller 9 are inconsistent, and the real-time transportation volume in the pipe belt 8 is not constant, which will affect the real-time strain of each roller 9. It is not accurate enough to judge whether the contact status of each roller 9 is abnormal by simply comparing the real-time strain of each roller 9 monitored with the strain of the roller 9 under normal working conditions. This method is easy to judge for rollers 9 that are not in contact at all, but it is difficult to judge for rollers 9 with no obvious abnormality in the contact status, so it cannot form an effective judgment standard. Therefore, the present invention proposes a monitoring method to judge the overall noise of the tubular belt conveyor during movement and issue a warning of risks based on the early stage of monitoring the strain of each roller 9.

[0077] The monitoring method of the present invention uses a certain sampling frequency to collect the strain of each roller 9, and performs data processing according to the above method to obtain the force conditions of the corresponding rollers 9, so as to monitor the force of the entire roller group of the tubular belt conveyor and judge the contact status of each roller 9.

[0078] The contact status of each roller 9 of the tubular belt conveyor during transportation is obtained through a monitoring and detection device. Then, based on the simulation method, the overall noise of the tubular belt conveyor under different contact working conditions is obtained. Therefore, a noise judgment rule is formulated based on the contact status of each roller 9 to conduct a risk assessment of the overall noise of the tubular belt conveyor during transportation.

[0079] During the transport process of the tubular belt conveyor, first, based on the observed real-time contact status of each roller 9, the roller 9 with obvious abnormal contact status is identified and traced to the source. Then, based on the noise judgment rules, the real-time strain of each roller 9 is monitored and the real-time stress is calculated to comprehensively judge the real-time contact status of each roller 9. This function not only ensures that the overall noise of the tubular belt conveyor is within the noise environmental protection standard, but also reduces the misjudgment rate of roller failure and improves work efficiency.

[0080] In the monitoring method of the present invention, the calculation formula of the stress of the roller 9 includes: Wherein, U is the voltage value measured by the resistance strain gauge 7, U1 is the reference zero drift voltage, K is the sensitivity coefficient of the resistance strain gauge 7, U0 is the bridge voltage of the bridge between the second connecting line 11 connected to the resistance strain gauge 7 and the strain conditioner 12, n is the number of bridge arms of the bridge, K is the bridge voltage of the bridge between the second connecting line 11 connected to the resistance strain gauge 7 and the strain conditioner 12, S is the gain coefficient of the strain conditioner 12, and E is the elastic modulus of the roller body 1.

[0081] During the transportation process of the tubular belt conveyor, the pipe belt 8 will act on the surface of the roller 9, and the roller 9 will carry the pipe belt 8 to move; the resistance strain gauge 7 attached to the inner wall surface of the roller body 1 will generate a strain signal as the roller body 1 deforms, and transmit it to the collector ring 5 through the first connecting line 6, and then further transmitted to the strain conditioner 12 by the collector ring 5, thereby realizing the measurement of the strain amount of each roller 9 of the tubular belt conveyor during the movement process.

[0082] The above calculation formula can be obtained by the following steps:

[0083] (1) According to the performance parameters of the resistance strain gauge and the following formula 1, the microstrain με of the roller 9 can be obtained.

[0084]

[0085] (2) Based on the elastic modulus E of the roller body 1 and the following formula 2, the stress σ of the roller 9 can be obtained.

[0086] σ=E×ε Formula 2

[0087] Specifically, the monitoring method includes: when there is no obvious abnormality in the contact state between the pipe belt 8 and each roller 9, and the real-time overall noise of the tubular belt conveyor is within the preset noise range, the working status signal light of the tubular belt conveyor is controlled to display green; when there is an obvious abnormality in the contact state between the pipe belt 8 and each roller 9, and the real-time overall noise of the tubular belt conveyor is within the preset noise range, the working status signal light of the tubular belt conveyor is controlled to display yellow; when the real-time overall noise of the tubular belt conveyor exceeds the preset noise range, the working status signal light of the tubular belt conveyor is controlled to display red.

[0088] The monitoring method of the present invention is specifically as follows:

[0089] (1) Analyze the contact state between the belt tube 8 and the rollers 9 of each roller group, including Figure 8 The single roller contact shown, Figure 9 The two rollers shown are in contact and Figure 10 The three rollers shown are exposed to these three conditions.

[0090] (2) The overall noise of the tubular belt conveyor under each contact working condition is simulated and analyzed to obtain the overall noise of the tubular belt conveyor under each contact working condition. According to the noise environmental protection standard, the preset noise range and the preset stress range of each roller 9 corresponding to the preset noise range are obtained to formulate the contact criteria and contact threshold standards of each roller group, which will serve as the basis for subsequent judgment of the overall noise of the tubular belt conveyor during transportation.

[0091] (3) In order to ensure traceability during the monitoring process, each roller group is first numbered and coded according to NM, where N represents the number of the roller group, N=1, 2, 3, 4..., and M represents the number of the roller 9 located below the pipe belt 8 in the corresponding roller group; for example, M=1 represents the first roller 91 located directly below the pipe belt 8, and M=2 and 3 represent the second roller 92 and the third roller 93 located on the left and right sides of the first roller 91, respectively.

[0092] (4) When the tubular belt conveyor is operating normally, the contact status of each roller is counted according to the stress monitoring value, and the roller 9 with obviously abnormal contact status is traced.

[0093] (5) When the contact state of the roller 9 is excluded and the noise risk of the tubular belt conveyor is warned based on the real-time contact state of the roller group and the noise judgment rules, if it is judged that the real-time overall noise is not within the preset noise range, the abnormal noise position is traced, and the best adjustment strategy for the contact state of the roller group at the abnormal noise position is formulated, guiding the staff to adjust or replace the position of the corresponding roller 9 in time, so as to adjust the position of the roller group whose contact state has no obvious abnormality but the overall noise is not within the preset noise range, so as to meet the noise environmental protection standards.

[0094] (6) Based on the contact status between the pipe belt 8 and each roller 9 and the overall noise level of the tubular belt conveyor, the working status signal lights of the tubular belt conveyor are divided into three categories, namely green, yellow and red.

[0095] From the above description, it can be seen that the above embodiments of the present invention achieve the following technical effects:

[0096] The monitoring device of the present invention includes: a tubular belt conveyor, which includes a frame 10, a pipe belt 8 and a plurality of rollers 9, and an avoidance hole 16 is provided on the frame 10; the pipe belt 8 is inserted into the avoidance hole 16; a plurality of rollers 9 are arranged at intervals around the circumference of the pipe belt 8, and the rollers 9 include a roller shaft 2 and a roller body 1 rotatably mounted outside the roller shaft 2; a plurality of groups of resistance strain gauges 7 are arranged one by one on the inner wall surface of the roller body 1 of the plurality of rollers 9, so as to monitor the strain effect generated by the corresponding roller body 1 during the movement process; a host computer 14 is connected to the plurality of groups of resistance strain gauges 7, so as to receive the monitoring results of each group of resistance strain gauges 7 and calculate the noise of the tubular belt conveyor based on the monitoring results. In this way, the present invention uses a resistance strain gauge 7 to monitor the strain effect of the roller 9, which has a much lower cost than a non-contact sensor and has better adaptability to components with lower precision such as the roller 9. By monitoring the strain effect generated by each roller 9 during the movement, the contact force of each roller 9 can be directly obtained, and the contact state between the pipe belt 8 and each roller 9 can be obtained. The rollers 9 with obviously abnormal contact states can be found, and the noise warning criteria of the tubular belt conveyor can be formulated based on the contact state to perform risk assessment on the movement noise of the tubular belt conveyor, which is conducive to adjusting the installation position of the roller 9, and solves the problem that the force monitoring method in the prior art is not suitable for monitoring the force of the tubular belt conveyor during the noise generation process.

[0097] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0098] Unless otherwise specifically stated, the relative arrangement of the parts and steps, numerical expressions and numerical values ​​set forth in these embodiments do not limit the scope of the present application. At the same time, it should be understood that, for ease of description, the sizes of the various parts shown in the drawings are not drawn according to actual proportional relationships. The techniques, methods and equipment known to those of ordinary skill in the relevant art may not be discussed in detail, but where appropriate, the techniques, methods and equipment should be considered as part of the authorization specification. In all examples shown and discussed here, any specific values ​​should be interpreted as being merely exemplary and not as limitations. Therefore, other examples of the exemplary embodiments may have different values. It should be noted that similar numbers and letters represent similar items in the following figures, and therefore, once an item is defined in one figure, it does not need to be further discussed in subsequent figures.

[0099] In the description of this application, it should be understood that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "horizontal, vertical, vertical, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the device or element referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of this application; the directional words "inside and outside" refer to the inside and outside relative to the outline of each component itself.

[0100] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used herein to describe the spatial positional relationship of a device or feature to other devices or features as shown in the figures. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figures. For example, if the device in the drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below other devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0101] In addition, it should be noted that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of this application.

[0102] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A monitoring method, characterized in that: Applicable to a monitoring device, the monitoring device comprising: A tubular belt conveyor comprises a frame (10), a pipe belt (8) and a plurality of rollers (9), wherein the frame (10) is provided with an avoidance hole (16); the pipe belt (8) is inserted into the avoidance hole (16); the plurality of rollers (9) are arranged at intervals around the circumference of the pipe belt (8), and the rollers (9) comprise roller shafts (2) and roller bodies (1) rotatably sleeved on the outside of the roller shafts (2); A plurality of sets of resistance strain gauges (7) are arranged one by one on the inner wall surfaces of the roller bodies (1) of the plurality of rollers (9) for monitoring the strain effects generated by the corresponding roller bodies (1) during movement; A host computer (14) is connected to the plurality of groups of resistance strain gauges (7) to receive monitoring results of each group of resistance strain gauges (7) and calculate the noise of the tubular belt conveyor according to the monitoring results; The monitoring method comprises: Formulate noise judgment rules: Control the movement of tubular belt conveyors; Observing the test contact state between the pipe belt (8) and each of the rollers (9); Collecting the test strain of the corresponding roller (9) monitored by each group of resistance strain gauges (7) and performing data processing on the test strain to obtain the test stress of the corresponding roller (9); Performing simulation analysis on the tubular belt conveyor based on the test contact state between the pipe belt (8) and each of the rollers (9) and the test stress of each of the rollers (9) to obtain the overall noise of the tubular belt conveyor; According to the noise environmental protection standard, a preset noise range and a preset stress range of each of the rollers (9) corresponding to the preset noise range are obtained; Real-time monitoring of working conditions: Controlling the tubular belt conveyor to operate normally; Observing the real-time contact state between the pipe belt (8) and each of the rollers (9); Collecting the corresponding real-time strain of the roller (9) monitored by each group of resistance strain gauges (7) and performing data processing on the real-time strain to obtain the corresponding real-time stress of the roller (9); Comparing the real-time stress of each of the rollers (9) with the preset stress range to determine whether the real-time overall noise of the tubular belt conveyor is within the preset noise range; The calculation formula of the stress of the roller (9) includes: ； Wherein, U is the voltage value measured by the resistance strain gauge (7), U1 is the reference zero drift voltage, K is the sensitivity coefficient of the resistance strain gauge (7), U0 is the bridge voltage of the bridge between the second connecting line (11) connected to the resistance strain gauge (7) and the strain conditioner (12), n is the number of bridge arms of the bridge, and K is S is the gain coefficient of the strain conditioner (12), and E is the elastic modulus of the roller body (1).

2. The monitoring method according to claim 1, characterized in that: The monitoring device comprises: a strain conditioner (12), the strain conditioner (12) being connected to the resistance strain gauge (7) and configured to receive a monitoring signal from the resistance strain gauge (7) and amplify the signal to generate an amplified signal; A data acquisition card (13) is connected to both the strain conditioner (12) and the host computer (14) to acquire the amplified signal and transmit it to the host computer (14).

3. The monitoring method according to claim 2, characterized in that: The monitoring device comprises: A collector ring (5) comprising an outer ring and an inner ring, wherein the outer ring is connected to the inner wall surface of the roller body (1), and the inner ring is connected to the roller shaft (2); a first connecting wire (6), one end of the first connecting wire (6) being connected to the outer ring, and the other end of the first connecting wire (6) being connected to the resistance strain gauge (7); A second connecting line (11), one end of the second connecting line (11) is connected to the inner ring, and the other end of the second connecting line (11) is connected to the strain conditioner (12).

4. The monitoring method according to claim 3, characterized in that: A first wire-releasing groove is provided on the outer circumferential surface of the roller shaft (2), and both ends of the first wire-releasing groove are respectively connected to the inside and outside of the roller (9) to avoid the second connecting line (11).

5. The monitoring method according to claim 1, characterized in that: Each group of the resistance strain gauges (7) is adhered to the corresponding roller body (1); and / or Each group of the resistance strain gauges (7) comprises a plurality of the resistance strain gauges (7), and the plurality of resistance strain gauges (7) are arranged at intervals around the axis of the corresponding roller shaft (2).

6. The monitoring method according to claim 1, characterized in that: The avoidance hole (16) is a hexagonal hole, and the plurality of rollers (9) include a first roller (91), a second roller (92), a third roller (93), a fourth roller (94), a fifth roller (95), and a sixth roller (96) which are arranged in a one-to-one correspondence with the six sides of the hexagonal hole; wherein, The first roller (91), the second roller (92) and the third roller (93) are located below the pipe belt (8), and the second roller (92) and the third roller (93) are respectively located on opposite sides of the first roller (91); The fourth roller (94), the fifth roller (95) and the sixth roller (96) are located above the pipe belt (8), and the fifth roller (95) and the sixth roller (96) are respectively located on opposite sides of the fourth roller (94).

7. The monitoring method according to claim 1, characterized in that: The tubular belt conveyor comprises: A plurality of guide mounting portions (18) are arranged on the frame (10) at intervals around the center line of the avoidance hole (16); A plurality of adjustable roller frames (15), wherein the plurality of rollers (9) are mounted on the plurality of adjustable roller frames (15) in a one-to-one correspondence, and the plurality of adjustable roller frames (15) are mounted on the plurality of guide mounting portions (18) in a one-to-one correspondence and in a detachable manner; The position of the corresponding roller (9) relative to the pipe belt (8) is adjusted by adjusting the position of each adjustable roller frame (15) on the corresponding guide mounting portion (18).

8. The monitoring method according to claim 7, characterized in that: The adjustable roller frame (15) includes an intermediate support plate (151) and two connecting ears (152) respectively arranged at opposite ends of the intermediate support plate (151); the guide mounting portion (18) includes a guide mounting space (180) extending radially along the pipe belt (8); the intermediate support plate (151) is adjustably arranged in the guide mounting space (180) in a direction close to or away from the pipe belt (8) and is detachably connected to the guide mounting portion (18); the two connecting ears (152) extend in a direction away from the frame (10) to be respectively connected to opposite ends of the roller (9).

9. The monitoring method according to claim 1, characterized in that: The monitoring method comprises: When there is no obvious abnormality in the contact state between the pipe belt (8) and each of the rollers (9), and the real-time overall noise of the tubular belt conveyor is within the preset noise range, the working state signal light of the tubular belt conveyor is controlled to display green; When the contact state between the tubular belt (8) and each of the rollers (9) is obviously abnormal, and the real-time overall noise of the tubular belt conveyor is within the preset noise range, the working state signal light of the tubular belt conveyor is controlled to display yellow; When the real-time overall noise of the tubular belt conveyor exceeds the preset noise range, the working status signal light of the tubular belt conveyor is controlled to display red.

Images