Method for monitoring a belt conveyor, monitoring device and processor

Abstract

The application provides a belt conveyor fault monitoring method, a fault monitoring device and a processor. The fault monitoring method comprises: acquiring impact pulse data, vibration data and temperature data of a transmission mechanism in a predetermined time period, the impact pulse data comprising an impact pulse frequency spectrum and an impact pulse amplitude; determining that the transmission mechanism has a fault in the case that a predetermined frequency multiplication occurs in the impact pulse frequency spectrum and the impact pulse amplitude is greater than a standard pulse amplitude; and determining a fault occurrence time of the transmission mechanism based on the impact pulse data, the vibration data and the temperature data in the case that the transmission mechanism has a fault, the fault occurrence time comprising at least one of a first fault period, a second fault period and a third fault period, the first fault period being earlier than the second fault period, and the second fault period being earlier than the third fault period, thereby solving the problem that it is difficult to accurately monitor the fault of the belt conveyor in the whole life cycle in the prior art.

Description

Technical Field

[0001] This application relates to the technical field of belt conveyors, and more specifically, to a fault monitoring method, fault monitoring device, computer-readable storage medium, and processor for belt conveyors. Background Technology

[0002] Belt conveyors are one of the most important production equipment in industrial manufacturing. Sudden malfunctions of belt conveyors can disrupt production and cause material handling disruptions. Therefore, it is essential to monitor belt conveyors during operation to identify potential hazards as early as possible.

[0003] In existing technologies, most methods for fault monitoring of belt conveyor transmission mechanisms rely on single vibration data, single temperature data, or a combination of both. Methods based on single vibration data monitor faults in the 10Hz–5000Hz frequency range, targeting the middle to late stages of the fault. Methods based on single temperature data monitor faults in the later stages of fault deterioration. Neither method can provide comprehensive monitoring of the entire fault process from its early to late stages.

[0004] Furthermore, due to the physical characteristics of vibration sensors, fault signals can only be detected in the middle to late stages of damage, and temperature data is only reflected in the very late stages. In other words, there is currently a lack of a comprehensive monitoring method covering the entire chain from the early to the late stages of a fault. Additionally, due to signal interference and other issues, single monitoring methods cannot be compared and verified, leading to inaccurate fault monitoring results for belt conveyors.

[0005] Therefore, there is an urgent need for a method that can accurately monitor faults throughout the entire lifecycle of belt conveyors. Summary of the Invention

[0006] The main objective of this application is to provide a fault monitoring method, fault monitoring device, computer-readable storage medium, and processor for belt conveyors, so as to solve the problem that it is difficult to accurately monitor faults of belt conveyors throughout their entire life cycle in the prior art.

[0007] According to one aspect of the present invention, a fault monitoring method for a belt conveyor is provided. The belt conveyor includes a transmission mechanism. The fault monitoring method includes: acquiring impact pulse data, vibration data, and temperature data of the transmission mechanism within a predetermined time period, wherein the impact pulse data includes an impact pulse spectrum and an impact pulse amplitude; determining that the transmission mechanism has failed when a predetermined overtone appears in the impact pulse spectrum and the impact pulse amplitude is greater than a standard pulse amplitude; and determining the fault occurrence time of the transmission mechanism based on the impact pulse data, the vibration data, and the temperature data when the transmission mechanism has failed, wherein the fault occurrence time includes at least one of the following: a first fault period, a second fault period, and a third fault period, wherein the first fault period is earlier than the second fault period, and the second fault period is earlier than the third fault period.

[0008] Optionally, the vibration data includes a vibration spectrum and vibration amplitude, and the temperature data includes a temperature amplitude. In the event of a transmission mechanism failure, the failure time of the transmission mechanism is determined based on the impact pulse data, the vibration data, and the temperature data, including at least one of the following: the predetermined octave appears in the impact pulse spectrum; the impact pulse amplitude is greater than the standard pulse amplitude; the difference between the vibration amplitude and the standard vibration amplitude is within a first preset range; and the difference between the temperature amplitude and the standard temperature amplitude is within a second preset range. In this case, the failure time is determined to be the first failure period. The fault occurrence time is determined to be the second fault period when the predetermined harmonic frequency has the same rising and falling trend, the impact pulse amplitude is greater than the standard pulse amplitude, the vibration amplitude is greater than the standard vibration amplitude, the impact pulse amplitude and the vibration amplitude have the same rising and falling trend, and the difference between the temperature amplitude and the standard temperature amplitude is within the second preset range; the fault occurrence time is determined to be the third fault period when the impact pulse amplitude is greater than the standard pulse amplitude, the vibration amplitude is greater than the standard vibration amplitude, the impact pulse amplitude and the vibration amplitude have the same rising and falling trend, the predetermined harmonic frequency appears in the vibration spectrum, and the temperature amplitude is greater than the standard temperature amplitude.

[0009] Optionally, acquiring the impact pulse data of the transmission mechanism within a predetermined time period includes: receiving an analog impact signal within the predetermined time period sent by a composite sensor, and converting the analog impact signal into a digital impact signal, wherein the composite sensor is used to detect the analog impact signal; performing speed fluctuation processing and symptom enhancement processing on the digital impact signal to obtain the impact pulse spectrum, wherein the speed fluctuation processing is to filter out the digital impact signal whose speed does not conform to the standard speed range, and the symptom enhancement processing is to enhance the repetitive signals in the digital impact signal; and performing interference suppression processing on each of the digital impact signals to obtain the impact pulse amplitude.

[0010] Optionally, the vibration data includes a vibration spectrum and vibration amplitude. Obtaining the vibration data of the transmission mechanism within a predetermined time period includes: receiving an analog vibration signal within the predetermined time period sent by a composite sensor, and converting the analog vibration signal into a digital vibration signal, wherein the composite sensor is used to detect the analog vibration signal; performing at least filtering and symptom enhancement processing on the digital vibration signal to obtain the vibration spectrum, wherein the symptom enhancement processing enhances repetitive signals in the digital vibration signal; and performing smoothing and noise reduction processing and interference suppression processing on the digital vibration signal to obtain the vibration amplitude, wherein the smoothing and noise reduction processing ensures that a predetermined rotational speed corresponds to a predetermined number of the digital vibration signals.

[0011] Optionally, at least the digital vibration signal is filtered and enhanced to obtain the vibration spectrum, including: applying an envelope filter to the digital vibration signal to obtain the filtered digital vibration signal; adjusting the negative amplitude values ​​in the filtered digital vibration signal to positive amplitude values ​​to obtain a preset vibration signal; and applying the enhancement to the preset vibration signal to obtain the vibration spectrum.

[0012] Optionally, before performing the symptom enhancement processing on the preset vibration signal to obtain the vibration spectrum, the fault monitoring method further includes: performing low-pass filtering processing on the preset vibration signal to obtain the filtered preset vibration signal, wherein the low-pass filtering processing is used to filter out the preset vibration signal outside the preset frequency range; performing sampling processing on the filtered preset vibration signal to obtain the target vibration signal, and determining the vibration spectrum based on the target vibration signal.

[0013] Optionally, the temperature data includes temperature amplitude. Obtaining the temperature data of the transmission mechanism within a predetermined time period includes: receiving an analog temperature signal sent by a temperature sensor within the predetermined time period, and converting the analog temperature signal into a digital temperature signal; and obtaining the temperature amplitude based on the digital temperature signal.

[0014] According to another aspect of the present invention, a fault monitoring device for a belt conveyor is also provided. The belt conveyor includes a transmission mechanism. The fault monitoring device includes: an acquisition unit, configured to acquire impact pulse data, vibration data, and temperature data of the transmission mechanism within a predetermined time period, wherein the impact pulse data includes an impact pulse spectrum and an impact pulse amplitude; a first determination unit, configured to determine that the transmission mechanism has malfunctioned when a predetermined overtone appears in the impact pulse spectrum and the impact pulse amplitude is greater than a standard pulse amplitude; and a second determination unit, configured to determine the fault occurrence time of the transmission mechanism based on the impact pulse data, the vibration data, and the temperature data when the transmission mechanism has malfunctioned, wherein the fault occurrence time includes at least one of the following: a first fault period, a second fault period, and a third fault period, wherein the first fault period is earlier than the second fault period, and the second fault period is earlier than the third fault period.

[0015] According to another aspect of the present invention, a computer-readable storage medium is also provided, the computer-readable storage medium including a stored program, wherein the program executes any of the described fault monitoring methods for belt conveyors.

[0016] According to another aspect of the present invention, a processor is also provided, the processor being configured to run a program, wherein the program, when running, executes any of the described fault monitoring methods for belt conveyors.

[0017] In this embodiment of the invention, the fault monitoring method for the belt conveyor firstly acquires impact pulse data, vibration data, and temperature data of the transmission mechanism within a predetermined time period. Then, based on the impact pulse data, it is determined whether the transmission mechanism has malfunctioned; that is, if a predetermined harmonic frequency appears in the impact pulse spectrum and the impact pulse amplitude is greater than the standard pulse amplitude, it is determined that the transmission mechanism has malfunctioned. Finally, in the case of a transmission mechanism malfunction, the fault occurrence time of the transmission mechanism is determined based on the impact pulse data, vibration data, and temperature data. The fault occurrence time includes at least one of the following: a first fault period, a second fault period, and a third fault period, wherein the first fault period is earlier than the second fault period, and the second fault period is earlier than the third fault period. Compared with the prior art method of determining whether the transmission mechanism has malfunctioned using a single vibration data, a single temperature data, or a combination of vibration data and temperature data, the fault monitoring method of this application determines whether the transmission mechanism has malfunctioned based on the impact pulse data, thus ensuring a more accurate determination of whether the transmission mechanism has malfunctioned. In the case of a transmission mechanism malfunction, the fault occurrence time of the transmission mechanism is then determined based on the impact pulse data, vibration data, and temperature data. The fault monitoring method of this application is based on impact pulse data, vibration data and temperature data, and realizes fault monitoring of the transmission mechanism throughout its entire life cycle, thereby solving the problem that it is difficult to accurately monitor the faults of belt conveyors throughout their entire life cycle in the prior art. Attached Figure Description

[0018] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. In the drawings:

[0019] Figure 1 A flowchart of a fault monitoring method for a belt conveyor according to an embodiment of this application is shown;

[0020] Figure 2 This illustration shows a process for determining the amplitude and spectrum of an impact pulse according to an embodiment of the present application.

[0021] Figure 3 A schematic diagram illustrating the process of determining vibration amplitude and vibration spectrum according to an embodiment of this application is shown;

[0022] Figure 4 A schematic diagram of the structure of a fault monitoring device for a belt conveyor according to an embodiment of this application is shown.

[0023] The above figures include the following reference numerals:

[0024] 100. Transmission mechanism; 101. Digital impact signal; 102. Interference suppression processing; 103. Impact pulse amplitude; 104. Speed ​​fluctuation processing; 105. Symptom enhancement processing; 106. Impact pulse spectrum; 107. Digital vibration signal; 108. Envelope filter; 109. Rectification; 110. Low-pass filtering processing; 111. Sampling processing; 112. Vibration spectrum; 113. Smoothing and noise reduction processing; 114. Vibration amplitude. Detailed Implementation

[0025] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0026] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of protection of the present application.

[0027] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of this application described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0028] As mentioned in the background section, it is difficult to accurately monitor the faults of belt conveyors throughout their entire lifecycle using existing technologies. To address these issues, this application provides a fault monitoring method, a fault monitoring device, a computer-readable storage medium, and a processor for belt conveyors in a typical embodiment.

[0029] According to an embodiment of this application, a fault monitoring method for a belt conveyor is provided.

[0030] Figure 1 This is a flowchart of a fault monitoring method for a belt conveyor according to an embodiment of this application. Figure 1 As shown, the fault monitoring method includes the following steps:

[0031] Step S101: Obtain the impact pulse data, vibration data and temperature data of the transmission mechanism within a predetermined time period. The impact pulse data includes the impact pulse spectrum and the impact pulse amplitude.

[0032] Step S102: If a predetermined harmonic frequency appears in the above-mentioned impact pulse spectrum and the amplitude of the above-mentioned impact pulse is greater than the amplitude of the standard pulse, it is determined that the above-mentioned transmission mechanism has malfunctioned.

[0033] Step S103: In the event of a failure in the transmission mechanism, the failure time of the transmission mechanism is determined based on the impact pulse data, the vibration data, and the temperature data. The failure time includes at least one of the following: a first failure period, a second failure period, and a third failure period, wherein the first failure period is earlier than the second failure period, and the second failure period is earlier than the third failure period.

[0034] In the aforementioned fault monitoring method for belt conveyors, firstly, impact pulse data, vibration data, and temperature data of the transmission mechanism are acquired within a predetermined time period. Then, based on the impact pulse data, it is determined whether a fault has occurred in the transmission mechanism; that is, a fault is determined when a predetermined harmonic frequency appears in the impact pulse spectrum and the impact pulse amplitude is greater than the standard pulse amplitude. Finally, in the case of a fault in the transmission mechanism, the fault occurrence time is determined based on the impact pulse data, vibration data, and temperature data. The fault occurrence time includes at least one of the following: a first fault period, a second fault period, and a third fault period, wherein the first fault period is earlier than the second fault period, and the second fault period is earlier than the third fault period. Compared with the prior art methods that determine whether a fault has occurred in the transmission mechanism using a single vibration data, a single temperature data, or a combination of vibration data and temperature data, the fault monitoring method of this application determines whether a fault has occurred in the transmission mechanism based on the impact pulse data, thus ensuring a more accurate determination of whether a fault has occurred in the transmission mechanism. In the case of a fault in the transmission mechanism, the fault occurrence time is then determined based on the impact pulse data, vibration data, and temperature data. The fault monitoring method of this application is based on impact pulse data, vibration data and temperature data, and realizes fault monitoring of the transmission mechanism throughout its entire life cycle, thereby solving the problem that it is difficult to accurately monitor the faults of belt conveyors throughout their entire life cycle in the prior art.

[0035] Specifically, an impact pulse is an elastic wave propagating in a rigid material, resulting from the collision between rigid objects. Due to the collision, molecules at the point of impact are accelerated, and this acceleration is transmitted to surrounding molecules through molecules near the impact point until a wavefront (leader wave) is formed. Experiments show that the amplitude of the impact pulse is proportional to the relative velocity of the colliding objects.

[0036] During the operation of belt conveyors, transmission mechanism failures can occur due to wear or improper assembly. This application's belt conveyor fault monitoring method employs three monitoring technologies—impact pulse data, vibration data, and temperature data—to perform composite monitoring of the belt conveyor's transmission mechanism, solving the technical problem of inaccurate monitoring results caused by using only one monitoring method. Furthermore, the effective combination of these three monitoring parameters in this application's belt conveyor fault monitoring method enables full-cycle fault monitoring of the transmission mechanism, from the early stage of fault onset to the middle stage of fault development and the late stage of fault deterioration. The monitored fault frequencies are divided into two bands: 2Hz–10000Hz and 20000Hz–40000Hz. When a transmission mechanism failure is confirmed, the impact pulse data, vibration data, and temperature data are compared laterally, further improving the accuracy of fault monitoring.

[0037] Specifically, the occurrence of a predetermined harmonic in the aforementioned impact pulse spectrum means that, during the operation of the transmission mechanism without any malfunction, the transmission mechanism has a natural operating frequency. If the frequency of the acquired impact pulse spectrum appears to be a predetermined multiple of this natural operating frequency, then the predetermined harmonic is determined to have occurred in the impact pulse spectrum. In one specific embodiment of this application, the predetermined harmonic can be a fourth harmonic. Of course, in practical applications, it is not limited to a fourth harmonic; other harmonics are also possible, such as a second harmonic, a sixth harmonic, etc.

[0038] In practical applications, the first failure period can be considered the early failure period, the second failure period can be considered the mid-term failure period, and the third failure period can be considered the late failure period.

[0039] It should be noted that the steps shown in the flowchart in the accompanying drawings can be executed in a computer system such as a set of computer-executable instructions, and although a logical order is shown in the flowchart, in some cases the steps shown or described may be executed in a different order than that shown here.

[0040] To more accurately determine the failure time of the transmission mechanism, in one embodiment of this application, the vibration data includes a vibration spectrum and vibration amplitude, and the temperature data includes a temperature amplitude. In the event of a transmission mechanism failure, the failure time is determined based on the impact pulse data, the vibration data, and the temperature data, including at least one of the following: the occurrence of a predetermined overtone in the impact pulse spectrum, the impact pulse amplitude being greater than the standard pulse amplitude, the difference between the vibration amplitude and the standard vibration amplitude being within a first preset range, and the difference between the temperature amplitude and the standard temperature amplitude being within a second preset range; in this case, the failure period is determined as the first failure period. If the predetermined overtones appear in both the spectrum and the vibration spectrum and have the same rising and falling trend, the impact pulse amplitude is greater than the standard pulse amplitude, the vibration amplitude is greater than the standard vibration amplitude, the impact pulse amplitude and the vibration amplitude have the same rising and falling trend, and the difference between the temperature amplitude and the standard temperature amplitude is within the second preset range, the fault occurrence period is determined to be the second fault period. If the impact pulse amplitude is greater than the standard pulse amplitude, the vibration amplitude is greater than the standard vibration amplitude, the impact pulse amplitude and the vibration amplitude have the same rising and falling trend, the predetermined overtones appear in the vibration spectrum, and the temperature amplitude is greater than the standard temperature amplitude, the fault occurrence period is determined to be the third fault period.

[0041] Specifically, the first preset range and the second preset range can be adjusted according to the actual situation. In this application, the first preset range and the second preset range are not limited.

[0042] In one specific embodiment of this application, the criteria for determining the first fault period are: the impact pulse spectrum exhibits a fault frequency of 4th harmonic or higher; the impact pulse amplitude is greater than the standard pulse amplitude (i.e., the impact pulse amplitude shows an upward trend); the difference between the vibration amplitude and the standard vibration amplitude is within a first preset range; and the difference between the temperature amplitude and the standard temperature amplitude is within a second preset range (i.e., neither the vibration amplitude nor the temperature amplitude shows significant change). The criteria for determining the second fault period are: both the impact pulse spectrum and the vibration spectrum exhibit predetermined harmonics with the same upward and downward trend (i.e., the impact pulse spectrum and the vibration spectrum remain relatively consistent); the impact pulse amplitude is greater than the standard pulse amplitude, and the vibration amplitude is greater than the standard vibration amplitude (i.e., both the impact pulse amplitude and the vibration amplitude increase); the impact pulse amplitude and the vibration amplitude show the same upward and downward trend (i.e., the impact pulse amplitude and the vibration amplitude remain relatively consistent); and the difference between the temperature amplitude and the standard temperature amplitude is within a second preset range (no significant change in temperature amplitude). The criteria for determining the third fault stage are: the impact pulse amplitude is greater than the standard pulse amplitude, the vibration amplitude is greater than the standard vibration amplitude (i.e., the impact pulse amplitude and vibration amplitude continue to increase), the impact pulse amplitude and vibration amplitude have the same upward and downward trend (i.e., the impact pulse amplitude and vibration amplitude maintain relative consistency), a predetermined harmonic appears in the vibration spectrum (i.e., the vibration spectrum has a fault frequency of 4th harmonic or higher), and the temperature amplitude is greater than the standard temperature amplitude. Of course, in the third fault stage, the fault symptoms in the impact pulse spectrum weaken; that is, due to the increase in vibration amplitude, the change in the impact pulse spectrum is not obvious.

[0043] In another embodiment of this application, such as Figure 2 As shown, acquiring the impact pulse data of the transmission mechanism 100 within a predetermined time period includes: receiving an analog impact signal within the predetermined time period sent by a composite sensor, and converting the analog impact signal into a digital impact signal 101, wherein the composite sensor is used to detect the analog impact signal; performing speed fluctuation processing 104 and symptom enhancement processing 105 on the digital impact signal 101 to obtain the impact pulse spectrum 106, wherein the speed fluctuation processing 104 is to filter out the digital impact signal whose speed does not conform to the standard speed range, and the symptom enhancement processing 105 is to enhance the repetitive signal in the digital impact signal; and performing interference suppression processing 102 on each of the digital impact signals 101 to obtain the impact pulse amplitude 103. In this embodiment, the digital impact signal undergoes speed fluctuation processing and symptom enhancement processing to ensure the accuracy of the obtained impact pulse spectrum. Interference suppression processing is also performed on the digital impact signal to ensure the accuracy of the obtained impact pulse amplitude. This further ensures that the transmission mechanism can be accurately determined based on the impact pulse data, and further ensures that the timing of the transmission mechanism failure can be accurately determined based on the impact pulse data, vibration data, and temperature data.

[0044] In one specific embodiment of this application, the speed fluctuation processing involves synchronous and continuous updating of the speed signal and the impact pulse result, with the sampling rate adjusted according to the speed. A standard speed range is set during data acquisition, with a default speed fluctuation of + / -20% and a maximum fluctuation of + / -50%. If the maximum speed fluctuation is exceeded, the measurement terminates, and a remeasurement is attempted.

[0045] In another specific embodiment of this application, symptom enhancement involves identifying recurring impulse pulse signals in the time-domain signal and enhancing these signals to suppress random signals, thus obtaining a time-domain signal. An impulse pulse spectrum is then generated based on the enhanced time-domain signal.

[0046] In another specific embodiment of this application, interference suppression can be based on the number of revolutions of the transmission mechanism. For example, one strong pulse is processed every 10 revolutions; if the default measurement time of 50 revolutions is used, then 5 strong pulses are processed.

[0047] In another specific embodiment of this application, the aforementioned composite sensor is a composite sensor of pulse and vibration. This composite sensor of pulse and vibration can be used to detect simulated impact signals and simulated vibration signals of a transmission.

[0048] To ensure the accuracy of the obtained vibration spectrum and vibration amplitude, in another embodiment of this application, the vibration data includes a vibration spectrum and vibration amplitude. Obtaining the vibration data of the transmission mechanism within a predetermined time period includes: receiving an analog vibration signal within the predetermined time period sent by a composite sensor, and converting the analog vibration signal into a digital vibration signal, wherein the composite sensor is used to detect the analog vibration signal; performing at least filtering and symptom enhancement processing on the digital vibration signal to obtain the vibration spectrum, wherein the symptom enhancement processing enhances repetitive signals in the digital vibration signal; and performing smoothing and noise reduction processing and interference suppression processing on the digital vibration signal to obtain the vibration amplitude, wherein the smoothing and noise reduction processing ensures that a predetermined rotational speed corresponds to a predetermined number of the digital vibration signals.

[0049] Specifically, an analog-to-digital converter (ADC) can be used to convert the received analog vibration signal into a digital vibration signal. Alternatively, a 24-bit analog-to-digital converter (ADC) combined with a fixed sampling frequency of 102400 Hz can be used to convert the analog vibration signal into a digital vibration signal.

[0050] Specifically, the above-mentioned smoothing and denoising process (with a fixed smoothing filter) maintains a constant number of samples per revolution. By continuously tracking the rotational speed (in parallel with vibration data acquisition), even if the rotational speed changes significantly during data acquisition, the number of samples is adjusted according to the changes in rotational speed.

[0051] In practical applications, due to the complex operating conditions of the transmission mechanism, the collected analog vibration signals contain a lot of interference signals. Therefore, in order to further ensure that the obtained vibration spectrum is more accurate, in another embodiment of this application, at least the digital vibration signal is filtered and enhanced to obtain the vibration spectrum. This includes: using an envelope filter to filter the digital vibration signal to obtain a filtered digital vibration signal; adjusting the negative amplitude of the filtered digital vibration signal to a positive amplitude to obtain a preset vibration signal; and performing the enhanced signal processing on the preset vibration signal to obtain the vibration spectrum.

[0052] In one specific embodiment of this application, the envelope filter removes high-energy low-frequency signals generated by imbalance and misalignment, while retaining low-energy high-frequency signals from the belt conveyor's drive mechanism. As the belt conveyor's drive mechanism deteriorates due to failure, energy shifts from higher frequencies to lower frequencies. In the early stages of failure, the increase in mechanical background noise at higher frequencies (i.e., frequencies > 5–10 kHz) is more significant, while at lower frequencies (i.e., frequencies < 5–10 kHz), the development of later-stage failures is more pronounced. By applying filters of different frequencies at different frequencies, early signs of failure can be captured and the failure process can be tracked.

[0053] In practical applications, the preset vibration signal is subjected to symptom enhancement processing, which can enhance the repetitive signal in the time domain signal and suppress the random signal, thus further ensuring that the obtained vibration spectrum is more accurate.

[0054] In one embodiment of this application, before performing the aforementioned symptom enhancement processing on the aforementioned preset vibration signal to obtain the aforementioned vibration spectrum, the aforementioned fault monitoring method further includes: performing low-pass filtering processing on the aforementioned preset vibration signal to obtain the filtered aforementioned preset vibration signal, wherein the aforementioned low-pass filtering processing is used to filter out the aforementioned preset vibration signal outside the preset frequency range; performing sampling processing on the filtered aforementioned preset vibration signal to obtain the target vibration signal, and determining the aforementioned vibration spectrum based on the aforementioned target vibration signal, thereby further ensuring that the obtained vibration spectrum is more accurate.

[0055] In practical applications, the cutoff frequency of the above low-pass filtering is 20Hz.

[0056] Specifically, the filtered preset vibration signal is sampled to obtain the target vibration signal. Specifically: at a low-pass filter frequency of 40kHz, the sampling rate is 102,400 samples / second, and all samples are selected. At a low-pass filter frequency of 20kHz, the sampling rate is 51,200 samples / second, and one sample is selected from every two samples. At a low-pass filter frequency of 5kHz, the sampling rate is 12,800 samples / second, and one sample is selected from every eight samples. At a low-pass filter frequency of 10Hz, the sampling rate is 25.6 samples / second, and one sample is selected from every 4,000 samples.

[0057] In one specific embodiment of this application, such as Figure 3 As shown, after receiving the analog vibration signal from the transmission mechanism 100 transmitted by the composite sensor within a predetermined time, the analog vibration signal is first converted into a digital vibration signal 107. Then, an envelope filter 108 is used to filter the digital vibration signal 107 to obtain a filtered digital vibration signal 107. Next, the negative amplitude values ​​in the filtered digital vibration signal 107 are adjusted to positive amplitude values ​​(i.e., rectification 109) to obtain a preset vibration signal. Then, the preset vibration signal is subjected to low-pass filtering 110 to obtain a filtered preset vibration signal. The filtered preset vibration signal is then subjected to sampling processing 111 and symptom enhancement processing 105 to obtain a target vibration signal. Finally, the vibration spectrum 112 is determined based on the target vibration signal.

[0058] In another specific embodiment of this application, such as Figure 3 As shown, after receiving the analog vibration signal from the transmission mechanism 100 transmitted by the composite sensor within a predetermined time, the analog vibration signal is converted into a digital vibration signal 107. Then, an envelope filter 108 is used to filter the digital vibration signal 107 to obtain the filtered digital vibration signal 107. Next, the filtered digital vibration signal 107 undergoes smoothing and noise reduction processing 113 and interference suppression processing 102 to obtain the vibration amplitude 114.

[0059] In order to obtain the temperature amplitude more easily, in another embodiment of this application, the temperature data includes the temperature amplitude. Obtaining the temperature data of the transmission mechanism within a predetermined time period includes: receiving an analog temperature signal sent by a temperature sensor within the predetermined time period, and converting the analog temperature signal into a digital temperature signal; and obtaining the temperature amplitude based on the digital temperature signal.

[0060] This application also provides a fault monitoring device for a belt conveyor. It should be noted that the fault monitoring device for a belt conveyor in this application can be used to execute the fault monitoring method for belt conveyors provided in this application. The fault monitoring device for a belt conveyor provided in this application will be described below.

[0061] Figure 4 This is a schematic diagram of the structure of a fault monitoring device for a belt conveyor according to an embodiment of this application. The belt conveyor includes a transmission mechanism, such as... Figure 4 As shown, the fault monitoring device includes:

[0062] The acquisition unit 10 is used to acquire the impact pulse data, vibration data and temperature data of the transmission mechanism within a predetermined time period. The impact pulse data includes the impact pulse spectrum and the impact pulse amplitude.

[0063] The first determining unit 20 is used to determine that the transmission mechanism has malfunctioned when a predetermined overtone appears in the above-mentioned impact pulse spectrum and the amplitude of the above-mentioned impact pulse is greater than the amplitude of the standard pulse.

[0064] The second determining unit 30 is used to determine the failure time of the transmission mechanism based on the impact pulse data, the vibration data and the temperature data when the transmission mechanism fails. The failure time includes at least one of the following: a first failure period, a second failure period and a third failure period, wherein the first failure period is earlier than the second failure period and the second failure period is earlier than the third failure period.

[0065] In the aforementioned fault monitoring device for a belt conveyor, the acquisition unit is used to acquire impact pulse data, vibration data, and temperature data of the transmission mechanism within a predetermined time period. The first determination unit is used to determine whether a fault has occurred in the transmission mechanism based on the impact pulse data, i.e., when a predetermined harmonic frequency appears in the impact pulse spectrum and the impact pulse amplitude is greater than the standard pulse amplitude, the transmission mechanism is determined to have failed. The second determination unit is used to determine the fault occurrence time of the transmission mechanism based on the impact pulse data, vibration data, and temperature data when a fault has occurred. The fault occurrence time includes at least one of the following: a first fault period, a second fault period, and a third fault period, wherein the first fault period is earlier than the second fault period, and the second fault period is earlier than the third fault period. Compared with the prior art method of determining whether a fault has occurred in the transmission mechanism using a single vibration data, a single temperature data, or a combination of vibration data and temperature data, the fault monitoring method of this application determines whether a fault has occurred in the transmission mechanism based on the impact pulse data, thus ensuring a more accurate determination of whether a fault has occurred in the transmission mechanism. In the case of a fault in the transmission mechanism, the fault occurrence time is then determined based on the impact pulse data, vibration data, and temperature data. The fault monitoring method of this application is based on impact pulse data, vibration data and temperature data, and realizes fault monitoring of the transmission mechanism throughout its entire life cycle, thereby solving the problem that it is difficult to accurately monitor the faults of belt conveyors throughout their entire life cycle in the prior art.

[0066] Specifically, an impact pulse is an elastic wave propagating in a rigid material, resulting from the collision between rigid objects. Due to the collision, molecules at the point of impact are accelerated, and this acceleration is transmitted to surrounding molecules through molecules near the impact point until a wavefront (leader wave) is formed. Experiments show that the amplitude of the impact pulse is proportional to the relative velocity of the colliding objects.

[0067] During the operation of belt conveyors, transmission mechanism failures can occur due to wear or improper assembly. This application's belt conveyor fault monitoring method employs three monitoring technologies—impact pulse data, vibration data, and temperature data—to perform composite monitoring of the belt conveyor's transmission mechanism, solving the technical problem of inaccurate monitoring results caused by using only one monitoring method. Furthermore, the effective combination of these three monitoring parameters in this application's belt conveyor fault monitoring method enables full-cycle fault monitoring of the transmission mechanism, from the early stage of fault onset to the middle stage of fault development and the late stage of fault deterioration. The monitored fault frequencies are divided into two bands: 2Hz–10000Hz and 20000Hz–40000Hz. When a transmission mechanism failure is confirmed, the impact pulse data, vibration data, and temperature data are compared laterally, further improving the accuracy of fault monitoring.

[0068] Specifically, the occurrence of a predetermined harmonic in the aforementioned impact pulse spectrum means that, during the operation of the transmission mechanism without any malfunction, the transmission mechanism has a natural operating frequency. If the frequency of the acquired impact pulse spectrum appears to be a predetermined multiple of this natural operating frequency, then the predetermined harmonic is determined to have occurred in the impact pulse spectrum. In one specific embodiment of this application, the predetermined harmonic can be a fourth harmonic. Of course, in practical applications, it is not limited to a fourth harmonic; other harmonics are also possible, such as a second harmonic, a sixth harmonic, etc.

[0069] In practical applications, the first failure period can be considered the early failure period, the second failure period can be considered the mid-term failure period, and the third failure period can be considered the late failure period.

[0070] To more accurately determine the failure time of the transmission mechanism, in one embodiment of this application, the vibration data includes a vibration spectrum and vibration amplitude, the temperature data includes a temperature amplitude, and the second determining unit includes a first determining module, a second determining module, and a third determining module. The first determining module is used to determine the failure time as the first failure period when the predetermined overtone appears in the impact pulse spectrum, the impact pulse amplitude is greater than the standard pulse amplitude, the difference between the vibration amplitude and the standard vibration amplitude is within a first preset range, and the difference between the temperature amplitude and the standard temperature amplitude is within a second preset range. The second determining module is used to determine the failure time as the first failure period when both the impact pulse spectrum and the vibration spectrum show a predetermined overtone. The third determining module is used to determine the fault occurrence period as the second fault period when the following conditions are met: the predetermined harmonic frequency appears and the rising and falling trends are the same; the impact pulse amplitude is greater than the standard pulse amplitude; the vibration amplitude is greater than the standard vibration amplitude; the impact pulse amplitude and the vibration amplitude have the same rising and falling trend; and the difference between the temperature amplitude and the standard temperature amplitude is within the second preset range.

[0071] Specifically, the first preset range and the second preset range can be adjusted according to the actual situation. In this application, the first preset range and the second preset range are not limited.

[0072] In one specific embodiment of this application, the criteria for determining the first fault period are: the impact pulse spectrum exhibits a fault frequency of 4th harmonic or higher; the impact pulse amplitude is greater than the standard pulse amplitude (i.e., the impact pulse amplitude shows an upward trend); the difference between the vibration amplitude and the standard vibration amplitude is within a first preset range; and the difference between the temperature amplitude and the standard temperature amplitude is within a second preset range (i.e., neither the vibration amplitude nor the temperature amplitude shows significant change). The criteria for determining the second fault period are: both the impact pulse spectrum and the vibration spectrum exhibit predetermined harmonics with the same upward and downward trend (i.e., the impact pulse spectrum and the vibration spectrum remain relatively consistent); the impact pulse amplitude is greater than the standard pulse amplitude, and the vibration amplitude is greater than the standard vibration amplitude (i.e., both the impact pulse amplitude and the vibration amplitude increase); the impact pulse amplitude and the vibration amplitude show the same upward and downward trend (i.e., the impact pulse amplitude and the vibration amplitude remain relatively consistent); and the difference between the temperature amplitude and the standard temperature amplitude is within a second preset range (no significant change in temperature amplitude). The criteria for determining the third fault stage are: the impact pulse amplitude is greater than the standard pulse amplitude, the vibration amplitude is greater than the standard vibration amplitude (i.e., the impact pulse amplitude and vibration amplitude continue to increase), the impact pulse amplitude and vibration amplitude have the same upward and downward trend (i.e., the impact pulse amplitude and vibration amplitude maintain relative consistency), a predetermined harmonic appears in the vibration spectrum (i.e., the vibration spectrum has a fault frequency of 4th harmonic or higher), and the temperature amplitude is greater than the standard temperature amplitude. Of course, in the third fault stage, the fault symptoms in the impact pulse spectrum weaken; that is, due to the increase in vibration amplitude, the change in the impact pulse spectrum is not obvious.

[0073] In another embodiment of this application, such as Figure 2As shown, the acquisition unit comprises a first receiving module, a first processing module, and a second processing module. The first receiving module receives the simulated impact signal transmitted by the composite sensor within the predetermined time period and converts it into a digital impact signal 101. The composite sensor detects the simulated impact signal. The first processing module performs speed fluctuation processing 104 and symptom enhancement processing 105 on the digital impact signal 101 to obtain the impact pulse spectrum 106. The speed fluctuation processing 104 filters out digital impact signals whose speed does not conform to the standard speed range, and the symptom enhancement processing 105 enhances repetitive signals in the digital impact signal. The second processing module performs interference suppression processing 102 on each of the digital impact signals 101 to obtain the impact pulse amplitude 103. In this embodiment, the digital impact signal undergoes speed fluctuation processing and symptom enhancement processing to ensure the accuracy of the obtained impact pulse spectrum. Interference suppression processing is also performed on the digital impact signal to ensure the accuracy of the obtained impact pulse amplitude. This further ensures that the transmission mechanism can be accurately determined based on the impact pulse data, and further ensures that the timing of the transmission mechanism failure can be accurately determined based on the impact pulse data, vibration data, and temperature data.

[0074] In one specific embodiment of this application, the speed fluctuation processing involves synchronous and continuous updating of the speed signal and the impact pulse result, with the sampling rate adjusted according to the speed. A standard speed range is set during data acquisition, with a default speed fluctuation of + / -20% and a maximum fluctuation of + / -50%. If the maximum speed fluctuation is exceeded, the measurement terminates, and a remeasurement is attempted.

[0075] In another specific embodiment of this application, symptom enhancement involves identifying recurring impulse pulse signals in the time-domain signal and enhancing these signals to suppress random signals, thus obtaining a time-domain signal. An impulse pulse spectrum is then generated based on the enhanced time-domain signal.

[0076] In another specific embodiment of this application, interference suppression can be based on the number of revolutions of the transmission mechanism. For example, one strong pulse is processed every 10 revolutions; if the default measurement time of 50 revolutions is used, then 5 strong pulses are processed.

[0077] In another specific embodiment of this application, the aforementioned composite sensor is a composite sensor of pulse and vibration. This composite sensor of pulse and vibration can be used to detect simulated impact signals and simulated vibration signals of a transmission.

[0078] To ensure the accuracy of the obtained vibration spectrum and vibration amplitude, in another embodiment of this application, the vibration data includes a vibration spectrum and vibration amplitude. The acquisition unit further includes a second receiving module, a third processing module, and a fourth processing module. The second receiving module is used to receive the analog vibration signal within the predetermined time period sent by the composite sensor and convert the analog vibration signal into a digital vibration signal. The composite sensor is used to detect the analog vibration signal. The third processing module is used to perform at least filtering and symptom enhancement processing on the digital vibration signal to obtain the vibration spectrum. The symptom enhancement processing enhances the repetitive signals in the digital vibration signal. The fourth processing module performs smoothing and noise reduction processing and interference suppression processing on the digital vibration signal to obtain the vibration amplitude. The smoothing and noise reduction processing ensures that a predetermined rotational speed corresponds to a predetermined number of the digital vibration signals.

[0079] Specifically, an analog-to-digital converter (ADC) can be used to convert the received analog vibration signal into a digital vibration signal. Alternatively, a 24-bit analog-to-digital converter (ADC) combined with a fixed sampling frequency of 102400 Hz can be used to convert the analog vibration signal into a digital vibration signal.

[0080] Specifically, the above-mentioned smoothing and denoising process (with a fixed smoothing filter) maintains a constant number of samples per revolution. By continuously tracking the rotational speed (in parallel with vibration data acquisition), even if the rotational speed changes significantly during data acquisition, the number of samples is adjusted according to the changes in rotational speed.

[0081] In practical applications, due to the complex operating conditions of the transmission mechanism, the collected analog vibration signals contain a lot of interference signals. Therefore, in order to further ensure the accuracy of the obtained vibration spectrum, in another embodiment of this application, the third processing module includes a filtering submodule, an adjustment submodule, and an enhancement processing module. The filtering submodule is used to perform the filtering process on the digital vibration signal using an envelope filter to obtain the filtered digital vibration signal. The adjustment submodule is used to adjust the negative amplitude of the filtered digital vibration signal to a positive amplitude to obtain a preset vibration signal. The enhancement processing module is used to perform the symptom enhancement process on the preset vibration signal to obtain the vibration spectrum.

[0082] In one specific embodiment of this application, the envelope filter removes high-energy low-frequency signals generated by imbalance and misalignment, while retaining low-energy high-frequency signals from the belt conveyor's drive mechanism. As the belt conveyor's drive mechanism deteriorates due to failure, energy shifts from higher frequencies to lower frequencies. In the early stages of failure, the increase in mechanical background noise at higher frequencies (i.e., frequencies > 5–10 kHz) is more significant, while at lower frequencies (i.e., frequencies < 5–10 kHz), the development of later-stage failures is more pronounced. By applying filters of different frequencies at different frequencies, early signs of failure can be captured and the failure process can be tracked.

[0083] In practical applications, the preset vibration signal is subjected to symptom enhancement processing, which can enhance the repetitive signal in the time domain signal and suppress the random signal, thus further ensuring that the obtained vibration spectrum is more accurate.

[0084] In one embodiment of this application, the fault monitoring method further includes a low-pass filtering unit and a sampling processing unit. The low-pass filtering unit is used to perform low-pass filtering on the preset vibration signal before performing the symptom enhancement processing on the preset vibration signal to obtain the vibration spectrum, thereby obtaining the filtered preset vibration signal. The low-pass filtering is used to filter out the preset vibration signal outside the preset frequency range. The sampling processing unit is used to sample the filtered preset vibration signal to obtain the target vibration signal, and determine the vibration spectrum based on the target vibration signal, thus further ensuring that the obtained vibration spectrum is more accurate.

[0085] In practical applications, the cutoff frequency of the above low-pass filtering is 20Hz.

[0086] Specifically, the filtered preset vibration signal is sampled to obtain the target vibration signal. Specifically: at a low-pass filter frequency of 40kHz, the sampling rate is 102,400 samples / second, and all samples are selected. At a low-pass filter frequency of 20kHz, the sampling rate is 51,200 samples / second, and one sample is selected from every two samples. At a low-pass filter frequency of 5kHz, the sampling rate is 12,800 samples / second, and one sample is selected from every eight samples. At a low-pass filter frequency of 10Hz, the sampling rate is 25.6 samples / second, and one sample is selected from every 4,000 samples.

[0087] In one specific embodiment of this application, such as Figure 3As shown, after receiving the analog vibration signal from the transmission mechanism 100 transmitted by the composite sensor within a predetermined time, the analog vibration signal is first converted into a digital vibration signal 107. Then, an envelope filter 108 is used to filter the digital vibration signal 107 to obtain a filtered digital vibration signal 107. Next, the negative amplitude values ​​in the filtered digital vibration signal 107 are adjusted to positive amplitude values ​​(i.e., rectification 109) to obtain a preset vibration signal. Then, the preset vibration signal is subjected to low-pass filtering 110 to obtain a filtered preset vibration signal. The filtered preset vibration signal is then subjected to sampling processing 111 and symptom enhancement processing 105 to obtain a target vibration signal. Finally, the vibration spectrum 112 is determined based on the target vibration signal.

[0088] In another specific embodiment of this application, such as Figure 3 As shown, after receiving the analog vibration signal from the transmission mechanism 100 transmitted by the composite sensor within a predetermined time, the analog vibration signal is converted into a digital vibration signal 107. Then, an envelope filter 108 is used to filter the digital vibration signal 107 to obtain the filtered digital vibration signal 107. Next, the filtered digital vibration signal 107 undergoes smoothing and noise reduction processing 113 and interference suppression processing 102 to obtain the vibration amplitude 114.

[0089] In order to obtain the temperature amplitude more easily, in another embodiment of this application, the temperature data includes the temperature amplitude. Obtaining the temperature data of the transmission mechanism within a predetermined time period includes: receiving an analog temperature signal sent by a temperature sensor within the predetermined time period, and converting the analog temperature signal into a digital temperature signal; and obtaining the temperature amplitude based on the digital temperature signal.

[0090] The fault monitoring device for the belt conveyor mentioned above includes a processor and a memory. The acquisition unit, the first determination unit, and the second determination unit are all stored in the memory as program units. The processor executes the program units stored in the memory to realize the corresponding functions.

[0091] The processor contains a kernel, which retrieves the corresponding program units from memory. One or more kernels can be configured, and adjusting kernel parameters can address the challenges of accurately monitoring faults throughout the entire lifecycle of belt conveyors, a problem that is difficult to solve in existing technologies.

[0092] The memory may include non-permanent memory in computer-readable media, such as random access memory (RAM) and / or non-volatile memory, such as read-only memory (ROM) or flash RAM, and the memory includes at least one memory chip.

[0093] This invention provides a computer-readable storage medium storing a program that, when executed by a processor, implements the aforementioned fault monitoring method for belt conveyors.

[0094] This invention provides a processor for running a program, wherein the program executes the fault monitoring method for the belt conveyor.

[0095] This invention provides a device including a processor, a memory, and a program stored in the memory and executable on the processor. When the processor executes the program, it performs at least the following steps:

[0096] Step S101: Obtain the impact pulse data, vibration data and temperature data of the transmission mechanism within a predetermined time period. The impact pulse data includes the impact pulse spectrum and the impact pulse amplitude.

[0097] Step S102: If a predetermined harmonic frequency appears in the above-mentioned impact pulse spectrum and the amplitude of the above-mentioned impact pulse is greater than the amplitude of the standard pulse, it is determined that the above-mentioned transmission mechanism has malfunctioned.

[0098] Step S103: In the event of a failure in the transmission mechanism, the failure time of the transmission mechanism is determined based on the impact pulse data, the vibration data, and the temperature data. The failure time includes at least one of the following: a first failure period, a second failure period, and a third failure period, wherein the first failure period is earlier than the second failure period, and the second failure period is earlier than the third failure period.

[0099] The devices mentioned in this article can be servers, PCs, tablets, mobile phones, etc.

[0100] This application also provides a computer program product, which, when executed on a data processing device, is suitable for executing an initialization program having at least the following method steps:

[0101] Step S101: Obtain the impact pulse data, vibration data and temperature data of the transmission mechanism within a predetermined time period. The impact pulse data includes the impact pulse spectrum and the impact pulse amplitude.

[0102] Step S102: If a predetermined harmonic frequency appears in the above-mentioned impact pulse spectrum and the amplitude of the above-mentioned impact pulse is greater than the amplitude of the standard pulse, it is determined that the above-mentioned transmission mechanism has malfunctioned.

[0103] Step S103: In the event of a failure in the transmission mechanism, the failure time of the transmission mechanism is determined based on the impact pulse data, the vibration data, and the temperature data. The failure time includes at least one of the following: a first failure period, a second failure period, and a third failure period, wherein the first failure period is earlier than the second failure period, and the second failure period is earlier than the third failure period.

[0104] In the above embodiments of the present invention, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0105] In the several embodiments provided in this application, it should be understood that the disclosed technical content can be implemented in other ways. The device embodiments described above are merely illustrative; for example, the division of units described above can be a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between units or modules may be electrical or other forms.

[0106] The units described above as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0107] Furthermore, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0108] If the aforementioned integrated units are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, read-only memory (ROM), random access memory (RAM), portable hard drives, magnetic disks, or optical disks.

[0109] As can be seen from the above description, the embodiments of this application achieve the following technical effects:

[0110] 1) In the fault monitoring method for a belt conveyor of this application, firstly, impact pulse data, vibration data, and temperature data of the transmission mechanism are acquired within a predetermined time period. Then, based on the impact pulse data, it is determined whether a fault has occurred in the transmission mechanism, i.e., a fault is determined when a predetermined harmonic frequency appears in the impact pulse spectrum and the impact pulse amplitude is greater than the standard pulse amplitude. Finally, in the case of a fault in the transmission mechanism, the fault occurrence time of the transmission mechanism is determined based on the impact pulse data, vibration data, and temperature data. The fault occurrence time includes at least one of the following: a first fault period, a second fault period, and a third fault period, wherein the first fault period is earlier than the second fault period, and the second fault period is earlier than the third fault period. Compared with the prior art method of determining whether a fault has occurred in the transmission mechanism by using a single vibration data, a single temperature data, or a combination of vibration data and temperature data, the fault monitoring method of this application determines whether a fault has occurred in the transmission mechanism based on the impact pulse data, thus ensuring a more accurate determination of whether a fault has occurred in the transmission mechanism. In the case of a fault in the transmission mechanism, the fault occurrence time of the transmission mechanism is determined based on the impact pulse data, vibration data, and temperature data. The fault monitoring method of this application is based on impact pulse data, vibration data and temperature data, and realizes fault monitoring of the transmission mechanism throughout its entire life cycle, thereby solving the problem that it is difficult to accurately monitor the faults of belt conveyors throughout their entire life cycle in the prior art.

[0111] 2) In the fault monitoring device for the belt conveyor of this application, the acquisition unit is used to acquire impact pulse data, vibration data, and temperature data of the transmission mechanism within a predetermined time period. The first determining unit is used to determine whether the transmission mechanism has failed based on the impact pulse data, that is, when a predetermined harmonic frequency appears in the impact pulse spectrum and the impact pulse amplitude is greater than the standard pulse amplitude, the transmission mechanism is determined to have failed. The second determining unit is used to determine the failure time of the transmission mechanism based on the impact pulse data, vibration data, and temperature data when the transmission mechanism fails. The failure time includes at least one of the following: a first failure period, a second failure period, and a third failure period, wherein the first failure period is earlier than the second failure period, and the second failure period is earlier than the third failure period. Compared with the prior art method of determining whether the transmission mechanism has failed by using a single vibration data, a single temperature data, or a combination of vibration data and temperature data, the fault monitoring method of this application determines whether the transmission mechanism has failed based on the impact pulse data, thus ensuring that the failure of the transmission mechanism can be determined more accurately. When the transmission mechanism fails, the failure time of the transmission mechanism is determined based on the impact pulse data, vibration data, and temperature data. The fault monitoring method of this application is based on impact pulse data, vibration data and temperature data, and realizes fault monitoring of the transmission mechanism throughout its entire life cycle, thereby solving the problem that it is difficult to accurately monitor the faults of belt conveyors throughout their entire life cycle in the prior art.

[0112] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A fault monitoring method for a belt conveyor, wherein the belt conveyor includes a transmission mechanism, characterized in that, The fault monitoring method includes: Acquire impact pulse data, vibration data, and temperature data of the transmission mechanism within a predetermined time period. The impact pulse data includes the impact pulse spectrum and the impact pulse amplitude. If a predetermined harmonic frequency appears in the impact pulse spectrum and the impact pulse amplitude is greater than the standard pulse amplitude, it is determined that the transmission mechanism has malfunctioned. The vibration data includes a vibration spectrum and vibration amplitude, and the temperature data includes a temperature amplitude. When the predetermined overtone appears in the impact pulse spectrum, the impact pulse amplitude is greater than the standard pulse amplitude, the difference between the vibration amplitude and the standard vibration amplitude is within a first preset range, and the difference between the temperature amplitude and the standard temperature amplitude is within a second preset range, the fault occurrence time is determined as the first fault period. When the predetermined overtone appears in both the impact pulse spectrum and the vibration spectrum with the same upward and downward trend, the impact pulse amplitude is greater than the standard pulse amplitude, the vibration amplitude is greater than the standard vibration amplitude, and the impact pulse amplitude... When the value and the vibration amplitude have the same upward and downward trend, and the difference between the temperature amplitude and the standard temperature amplitude is within the second preset range, the time of occurrence of the fault is determined to be the second fault period; when the impact pulse amplitude is greater than the standard pulse amplitude, the vibration amplitude is greater than the standard vibration amplitude, the impact pulse amplitude and the vibration amplitude have the same upward and downward trend, the predetermined harmonic appears in the vibration spectrum, and the temperature amplitude is greater than the standard temperature amplitude, the time of occurrence of the fault is determined to be the third fault period, wherein the first fault period is earlier than the second fault period, and the second fault period is earlier than the third fault period.

2. The fault monitoring method according to claim 1, characterized in that, Acquiring impact pulse data of the transmission mechanism within a predetermined time period includes: The composite sensor receives a simulated impact signal within the predetermined time period sent by the composite sensor and converts the simulated impact signal into a digital impact signal. The composite sensor is used to detect the simulated impact signal. The digital impact signal is subjected to speed fluctuation processing and symptom enhancement processing to obtain the impact pulse spectrum. The speed fluctuation processing is to filter out the digital impact signal whose speed does not conform to the standard speed range, and the symptom enhancement processing is to enhance the repetitive signals in the digital impact signal. Interference suppression processing is performed on each of the digital impulse signals to obtain the impulse pulse amplitude.

3. The fault monitoring method according to claim 1, characterized in that, The vibration data includes the vibration spectrum and vibration amplitude. Obtaining the vibration data of the transmission mechanism within a predetermined time period includes: The composite sensor receives analog vibration signals within the predetermined time period sent by the composite sensor and converts the analog vibration signals into digital vibration signals. The composite sensor is used to detect the analog vibration signals. The digital vibration signal is subjected to at least filtering and symptom enhancement processing to obtain the vibration spectrum. The symptom enhancement processing is to enhance the repetitive signals in the digital vibration signal. The digital vibration signal is subjected to smoothing and noise reduction processing and interference suppression processing to obtain the vibration amplitude. The smoothing and noise reduction processing is to make a predetermined number of digital vibration signals correspond to a predetermined rotational speed.

4. The fault monitoring method according to claim 3, characterized in that, At least the digital vibration signal is filtered and its symptom enhancement is performed to obtain the vibration spectrum, including: The digital vibration signal is filtered using an envelope filter to obtain the filtered digital vibration signal. The negative amplitude values ​​in the filtered digital vibration signal are adjusted to positive amplitude values ​​to obtain the preset vibration signal; The vibration spectrum is obtained by performing the symptom enhancement processing on the preset vibration signal.

5. The fault monitoring method according to claim 4, characterized in that, Before performing the symptom enhancement processing on the preset vibration signal to obtain the vibration spectrum, the fault monitoring method further includes: The preset vibration signal is subjected to low-pass filtering to obtain the filtered preset vibration signal. The low-pass filtering is used to filter out the preset vibration signal outside the preset frequency range. The filtered preset vibration signal is sampled to obtain the target vibration signal, and the vibration spectrum is determined based on the target vibration signal.

6. The fault monitoring method according to any one of claims 1 to 4, characterized in that, The temperature data includes temperature amplitude. Obtaining the temperature data of the transmission mechanism within a predetermined time period includes: Receives analog temperature signals within the predetermined time period sent by a temperature sensor, and converts the analog temperature signals into digital temperature signals; The temperature amplitude is obtained based on the digital temperature signal.

7. A fault monitoring device for a belt conveyor, the belt conveyor including a transmission mechanism, characterized in that, The fault monitoring device includes: The acquisition unit is used to acquire the impact pulse data, vibration data and temperature data of the transmission mechanism within a predetermined time period. The impact pulse data includes the impact pulse spectrum and the impact pulse amplitude, the vibration data includes the vibration spectrum and the vibration amplitude, and the temperature data includes the temperature amplitude. The first determining unit is configured to determine that the transmission mechanism has malfunctioned when a predetermined harmonic frequency appears in the spectrum of the impact pulse and the amplitude of the impact pulse is greater than the amplitude of a standard pulse. The second determining unit is configured to determine the fault occurrence period as a first fault period when the predetermined overtone appears in the impact pulse spectrum, the impact pulse amplitude is greater than the standard pulse amplitude, the difference between the vibration amplitude and the standard vibration amplitude is within a first preset range, and the difference between the temperature amplitude and the standard temperature amplitude is within a second preset range; to determine the fault occurrence period as a second fault period when the predetermined overtone appears in both the impact pulse spectrum and the vibration spectrum and have the same rising and falling trend, the impact pulse amplitude is greater than the standard pulse amplitude, the vibration amplitude is greater than the standard vibration amplitude, the impact pulse amplitude and the vibration amplitude have the same rising and falling trend, and the difference between the temperature amplitude and the standard temperature amplitude is within the second preset range; and to determine the fault occurrence period as a third fault period when the impact pulse amplitude is greater than the standard pulse amplitude, the vibration amplitude is greater than the standard vibration amplitude, the impact pulse amplitude and the vibration amplitude have the same rising and falling trend, the predetermined overtone appears in the vibration spectrum, and the temperature amplitude is greater than the standard temperature amplitude, wherein the first fault period is earlier than the second fault period, and the second fault period is earlier than the third fault period.

8. A computer-readable storage medium, characterized in that, The computer-readable storage medium includes a stored program, wherein, The program executes the fault monitoring method for belt conveyors as described in any one of claims 1 to 6.

9. A processor, characterized in that, The processor is used to run a program, wherein the program executes the fault monitoring method for the belt conveyor according to any one of claims 1 to 6.

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