Device and system for judging fault of carrier roller by combining acoustic array and thermal imaging

Abstract

The application discloses a device and system for judging the fault of a supporting roller by combining an acoustic array and thermal imaging, comprising an inspection part, an acoustic array part, a thermal imaging part, a comprehensive processing part and a power supply. The application uses the acoustic array to collect the sound signals of the supporting roller bearing and completes preprocessing, then uses the MVDR algorithm to process the filtered signals, extracts the sound signal power of the supporting roller bearing, and uses the thermal imager to collect the thermal images of the conveying belt. After the preprocessing is completed, the edge detection and feature recognition are used to judge whether the temperature of the supporting roller is faulty. The comprehensive processing part uses the sound-temperature joint analysis algorithm to comprehensively analyze the acoustic array processing signals and the thermal imager processing signals, so as to quickly judge whether the supporting roller bearing is faulty, realizes the sound signal collection and processing of the fault of the supporting roller inner supporting bearing based on the combination of the acoustic array and the thermal imaging technology, and can greatly improve the fault detection accuracy through the analysis of the MVDR algorithm and the sound-temperature joint analysis algorithm.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of idler failure detection, in particular to a device and system for judging idler failure by combining acoustic array and thermal imaging. BACKGROUND

[0002] As an important part of the conveying system, the conveying equipment has the characteristics of long distance, multi-point driving and large capacity. Under the background of fuel transportation transformation, the working environment of the conveying equipment is harsh, the dust concentration in the closed space is high, and the noise is loud, which increases the possibility of machine failure. As the most numerous, most frequently replaced and most prone to failure parts in the conveying equipment, the idler seriously threatens the stable operation of the conveying system. Moreover, it accounts for 35% of the total cost of a belt conveyor and generates more than 70% of the resistance. Therefore, the stability of the idler is particularly important. Long-term operation can cause local temperature to be too high. The reasons for the high temperature of the bearing are as follows: the mechanism is assembled too tightly, the bearing is assembled too tightly; the bearing race rotates on the shaft or in the shell; the quality of the lubricating oil is not up to the requirements or deteriorates, the viscosity of the lubricating oil is too high; the load is too large; the cam bearing retainer or the bone body is broken, etc. Long-term operation of the idler may cause a major safety hazard. The idler often fails during long-term operation. When the idler is being repaired, sound and temperature are important parameters for representing the operating state of the idler. Sound and temperature parameters are also important parts of the maintenance of the conveying belt. If the serious wear of the idler is not discovered in time, it may cause the production line to stop and cause losses, or even cause personnel injury accidents.

[0003] Currently, the fault detection scheme for the conveying equipment has the problems of low efficiency of artificial detection, harm to workers' health, poor environmental adaptability of robot detection, single detection direction of the current detection scheme, inability to detect the fault of the conveying equipment from the combination of sound and temperature, and low accuracy of the fault judgment result. SUMMARY

[0004] The present application provides a device and system for judging idler failure by combining acoustic array and thermal imaging, which can effectively solve the above-mentioned problems in the background art, such as low efficiency of artificial detection, harm to workers' health, poor environmental adaptability of robot detection, single detection direction of the current detection scheme, inability to detect the fault of the conveying equipment from the combination of sound and temperature, and low accuracy of the fault judgment result.

[0005] To achieve the above-mentioned purpose, the present application provides the following technical scheme: a system for judging idler failure by combining acoustic array and thermal imaging, which specifically comprises a patrol part, an acoustic array part, a thermal imaging part, a comprehensive processing part and a power supply. The power supply supplies power to the patrol part, the acoustic array part, the thermal imaging part and the comprehensive processing part.

[0006] The sound array part collects the sound signal of the carrier roller, converts the collected sound signal into an electric signal, realizes the preprocessing of the sound signal, and simultaneously performs algorithm processing on the preprocessed sound signal to obtain its characteristics and find out the abnormal part of the sound signal.

[0007] The inspection part realizes the support of the thermal imager and the sliding of the thermal imager along the slide rail. The thermal imaging part realizes the thermal imaging scanning of the conveying belt based on the thermal imager, measures the point temperature of the carrier roller, and judges whether the temperature is abnormal.

[0008] The comprehensive processing part collects the processing signals of the sound array part and the thermal imaging part through the Ethernet, and completes the display, storage, processing and analysis process. Finally, the analysis result is transmitted to the display module through the Ethernet to judge whether to drive the sound and light alarm module to alarm.

[0009] According to the above technical scheme, the inspection part specifically comprises a base, a support, a slide rail, a stepping motor, a universal movable head and a thermal imager holder.

[0010] The base and the slide rail are connected to each other, and the slide rail is arranged in parallel on the conveyor to realize the movement of the support. The support and the base are designed as a whole. The universal movable head is connected with the support. The thermal imager holder is connected with the universal movable head. The thermal imager is connected with the thermal imager holder. The stepping motor is electrically connected with the base to drive the base to move along the slide rail.

[0011] According to the above technical scheme, the sound array part specifically comprises an audio acquisition module, a sound processing module and an interaction module.

[0012] The audio acquisition module specifically comprises a base, an acquisition end and a sound conversion unit. The acquisition end is fixed on the base. The acquisition units on the acquisition end are arranged in a linear manner, and a unit is arranged in a circular manner towards the center of the shaft end. The acquisition unit mainly completes the acquisition of the sound signal. The sound conversion unit completes the A / D conversion and noise reduction processing of the acquisition signal. The sound processing module is connected with the audio acquisition module to complete the processing of the sound signal. The interaction module is mainly used for displaying the processing result of the sound processing module and the estimated fault position judgment result.

[0013] The thermal imaging part specifically comprises an image acquisition module, an image processing module, an image recognition module and a display module.

[0014] The image acquisition module is mainly used for scanning a conveying belt to obtain a thermal infrared sequence image of a carrier roller, the image processing module is mainly used for pre-processing the obtained thermal infrared sequence image of the carrier roller, and the image recognition module is mainly used for edge detection and feature recognition on the thermal infrared sequence image of the carrier roller, so as to find out a point of temperature abnormality of the carrier roller.

[0015] According to the technical scheme, the comprehensive processing part specifically comprises a judgment module, an audible and visual alarm module and a display module;

[0016] The judgment module collects the processing signals of the sound array part and the processing signals of the thermal imaging part through Ethernet, completes display, storage, processing and analysis of the signals, and judges the final fault of the carrier roller through an algorithm;

[0017] The audible and visual alarm module is used for receiving the signals of the judgment module, so as to judge whether to perform an alarm response according to the signals;

[0018] The display module is used for displaying the conveying state of the conveyor and the result of fault judgment.

[0019] According to the technical scheme, the system specifically comprises the following implementation steps:

[0020] S1, sound preprocessing;

[0021] S2, sound signal processing;

[0022] S3, image preprocessing;

[0023] S4, image depth processing;

[0024] S5, temperature state division;

[0025] S6, sound source-temperature joint judgment.

[0026] In S1, the sound preprocessing mainly refers to performing A / D conversion on the collected original sound signals, and because the existence of environmental noise affects the analysis and judgment of the signals in the later stage, the original signals need to be preprocessed once, that is, the sound signals are subjected to noise reduction processing, and the sound sensor unit utilizes DSP to complete the noise reduction processing and then outputs the sound signals.

[0027] In S2, the sound signal processing mainly refers to calculation of the sound signal power of the carrier roller bearing, specifically, a beam forming method is used for sound array measurement, multi-channel spatial information of a microphone array is utilized, an MVDR algorithm is selected to form a narrowband filter in a frequency domain space, and a signal arranged in a direction of an axle end is enhanced, and specific derivation steps are as follows:

[0028] Let uniform linear array be used for M elements, when N signals s1(n), s2(n), …, s N (n) respectively from θ1, θ2, …, θ N incident to the array, by superposition thinking, the received signal can be described as:

[0029] x(n) M×1 = A M×N s N×1 ;

[0030]

[0031] Design a weight, weight coefficient is: w = [w0, w1, … w M-1 ] T ;

[0032] So that the output signal y(n) becomes the target signal;

[0033] The output y(n) can be written as: y(n) = w H x(n);

[0034] The output signal power is:

[0035] Separate the signal s1(n) alone, the rest is written as z(n), so the above formula becomes:

[0036] y(n) = w H x(n) = w H a(θ1) s1(n) + w H z(n);

[0037] The requirement is that the weight vector w makes the signal in the s1 direction pass completely, and z(n) is limited as much as possible, which needs to meet the following conditions:

[0038] w H a(θ1) = 1;

[0039] P = x(n)x(n) H = w H R w ;

[0040] Generalize θ1 to any angle θ, then the above problem is simplified to an optimization problem with weight vector w as the variable, that is

[0041] minw H R w , st.w H a(θ) = 1

[0042] Use the Lagrange method to construct the cost function J(w) as follows:

[0043] J(w) = w H R w -λ(1-w H a(θ))

[0044] The gradient of the cost function J(w) with respect to the weight vector w is solved and set to 0,

[0045]

[0046] The solution is: w = λR -1 a(θ);

[0047] Under the constraint w H a(θ) = 1, the solution is:

[0048] The above formula is solved together:

[0049] In practice, the w weight can be calculated according to the θ angle, and the sound of the roller is obtained under the constraint condition to reduce the influence of the remaining interference signals;

[0050] The judgment steps are as follows:

[0051] The target angle θ is known;

[0052] (1) Signal reception description:

[0053] Suppose a uniform linear array is used for M array elements, when N signals s1(n), s2(n), …, s N (n) respectively from θ1, θ2, …, θ N incident to the array, according to the superposition principle, the received signal can be described as:

[0054] x(n) M×1 = A M×N s N×1

[0055]

[0056] (2) Weight solution:

[0057]

[0058] (3) Output signal power solution:

[0059] y(n) = w H x(n);

[0060]

[0061] According to the above technical scheme, in the S3, the image preprocessing refers to that the image acquisition module is used for further monitoring of the temperature of the carrier roller on the acquired thermal infrared image, and the preprocessing of the thermal infrared image by the image processing module includes the following steps:

[0062] S3.1, the thermal infrared image acquired by the image acquisition module is subjected to noise reduction processing;

[0063] S3.2, the image subjected to the noise reduction processing is subjected to sharpening processing;

[0064] In the S4, the image depth processing refers to that the image recognition module is used for edge detection, feature recognition division and recognition of abnormal temperature on the image, and specifically includes the following steps:

[0065] S4.1, the preprocessed image is subjected to carrier roller profile acquisition;

[0066] S4.2, the temperature of the carrier roller sampling point is recognized;

[0067] S4.3, the carrier roller final temperature is determined by joint analysis of the carrier roller temperature.

[0068] According to the above technical scheme, in the S5, the temperature state division mainly refers to that the carrier roller temperature is recognized as three states: severe over-temperature work, over-temperature work and normal temperature work by analyzing and judging the carrier roller temperature analysis standard;

[0069] According to the above three states, the specific judgment method is:

[0070] Suppose that there are N carrier roller monitoring points, and the collected temperatures are t1, t2, …, t n , considering that the temperature data of the carrier roller is basically symmetrically distributed or close to symmetrically distributed, the arithmetic mean is adopted, the arithmetic mean is the most commonly used measure value of the trend in the data set, the object is the numerical value type data, and the inevitability characteristics of the data are embodied, and the calculation formula is as follows:

[0071]

[0072] The proportional relative index is used to measure the relationship between the temperature of each sampling point and the average temperature:

[0073]

[0074] When a>30%, the working temperature is in a severe over-temperature working state;

[0075] When 30%>a>10%, the working temperature is in an over-temperature working state;

[0076] When a<10%, the working temperature is in a normal temperature working state.

[0077] According to the technical scheme, in the S6, the standard of the sound source-temperature joint judgment specifically includes the following cases:

[0078] When the processed sound array output signal power exceeds the set serious overload power working threshold, the judgment module of the comprehensive processing part directly outputs an alarm signal to the display module, starts a protection shutdown program, and triggers an audible and light alarm module;

[0079] When the processed thermal imaging image temperature signal exceeds the set serious over-temperature working threshold, the judgment module of the comprehensive processing part directly outputs an alarm signal to the display module, starts a protection shutdown program, and triggers an audible and light alarm module;

[0080] When the sound array output signal power exceeds the set overload power working threshold but does not reach the serious overload power threshold, the judgment module of the comprehensive processing part directly outputs an alarm signal to the display module, and a warning prompt is popped up on the comprehensive display interface;

[0081] When the thermal imaging image temperature signal exceeds the set over-temperature working temperature threshold but does not reach the serious over-temperature working temperature threshold, the judgment module of the comprehensive processing part directly outputs an alarm signal to the display module, and a warning prompt is popped up on the comprehensive display interface;

[0082] When the monitored sound output power is in an upward trend for three consecutive days, and the upward ratio exceeds 20%, the judgment module pops up a warning prompt on the comprehensive display interface of the display part;

[0083] When the monitored temperature is in an upward trend for three consecutive days, and the upward ratio exceeds 15%, the judgment module pops up a warning prompt on the comprehensive display interface;

[0084] When the abnormal point position found by the sound array part positioning and the abnormal temperature point position found by the thermal imaging coincide to 80% or above, the judgment module of the comprehensive processing part determines that the roller has a fault, a warning prompt is popped up on the display module, and an audible and light alarm module is triggered to alarm;

[0085] When the abnormal point position found by the sound array part positioning and the abnormal temperature point position found by the thermal imaging coincide to 70% to 80%, the judgment module of the comprehensive processing part determines that the roller has a fault, and a warning prompt is popped up on the display module.

[0086] An apparatus for jointly judging a roller fault by a sound array and thermal imaging, specifically comprising a memory and a processor, and computer instructions stored on the memory and running on the processor;

[0087] When the computer instructions are run by the processor, the steps of the sound array and temperature joint diagnosis roller fault system are completed.

[0088] Compared with the prior art, the beneficial effects of the present invention are: the present invention has a scientific and reasonable structure and is safe and convenient to use.

[0089] This invention utilizes an acoustic array to collect and preprocess the sound signals of idler roller bearings. The filtered signals are then processed using the MVDR algorithm to extract the sound signal power of the idler roller bearings. A thermal imager acquires thermal images of the conveyor belt. After preprocessing, edge detection and feature recognition are used to determine whether a fault has occurred in the idler roller temperature. The comprehensive processing section employs a sound-temperature joint analysis algorithm to analyze the signals processed by the acoustic array and the thermal imager, thereby quickly determining whether a fault has occurred in the idler roller bearing. This invention achieves sound signal acquisition and processing for faults in the internal support bearings of idlers based on a combination of acoustic array and thermal imaging technologies. Analysis using the MVDR algorithm and the sound-temperature joint analysis algorithm can significantly improve the accuracy of fault detection.

[0090] Furthermore, compared to traditional methods that rely solely on acoustic arrays or temperature measurements, this method features high diagnostic accuracy and fast processing speed. It can effectively solve the problem of misdiagnosis caused by interference from other sound sources or abnormal temperature sources, thus providing stable and accurate diagnosis of conveyor roller bearing faults, avoiding false alarms, and preventing workers from working in environments that are harmful to their health. Attached Figure Description

[0091] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof.

[0092] In the attached diagram:

[0093] Figure 1 This is a flowchart of the diagnostic process for idler roller faults using a combination of acoustic array and thermal imaging, as described in this invention.

[0094] Figure 2 This is a schematic diagram of the acoustic array structure of the present invention;

[0095] Figure 3 This is a schematic diagram of the inspection section of the present invention;

[0096] Figure 4 This is a schematic diagram of the specific interactive interface of the present invention;

[0097] Figure 5 This is a display diagram of the specific comprehensive judgment part of the present invention;

[0098] The following are labeled in the diagram: 1. Slide rail; 2. Base; 3. Bracket; 4. Universal movable head; 5. Thermal imager holder. Detailed Implementation

[0099] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0100] Example 1: As Figures 1-5 As shown, the present invention provides a technical solution, a system for jointly judging roller faults by acoustic array and thermal imaging. The judgment system specifically includes an inspection section, an acoustic array section, a thermal imaging section, a comprehensive processing section and a power supply. The power supply provides power to the inspection section, the acoustic array section, the thermal imaging section and the comprehensive processing section.

[0101] The acoustic array section collects the sound signals from the idler rollers and converts the collected sound signals into electrical signals to preprocess the sound signals. At the same time, it performs algorithmic processing on the preprocessed sound signals to obtain their features and find the abnormal parts of the sound signals.

[0102] The inspection section supports the thermal imager and enables the thermal imager to slide along the slide rail. The thermal imaging section mainly uses the thermal imager to perform thermal imaging scanning on the conveyor belt, measure the point temperature of the idler roller, and determine its temperature condition.

[0103] The integrated processing unit collects the processed signals from the acoustic array and thermal imaging units via Ethernet, and completes the display, storage, processing, and analysis processes. Finally, the analysis results are transmitted to the display module via Ethernet to determine the alarm driving status of the audible and visual alarm module.

[0104] Based on the above technical solution, the inspection part specifically includes a base, bracket, slide rail, stepper motor, universal movable head and thermal imager holder;

[0105] The base and the slide rail are connected to each other. The slide rail is arranged parallel to the conveyor to realize the movement of the support. The support and the base are designed as one piece. The universal movable head is connected to the support. The thermal imager holder is connected to the universal movable head. The thermal imager is connected to the thermal imager holder. The stepper motor is electrically connected to the base to drive the base to move along the slide rail.

[0106] Based on the above technical solution, the sound array part specifically includes an audio acquisition module, a sound processing module, and an interaction module;

[0107] The audio acquisition module specifically comprises a base, an acquisition end and a sound conversion unit, the acquisition end is fixed on the base, the acquisition units on the acquisition end are linearly arranged, and a unit in the middle is arranged towards the center of the shaft end. The acquisition units mainly complete the acquisition of sound signals, the sound conversion unit completes the A / D conversion and noise reduction processing of the acquisition signals, the sound processing module is connected with the audio acquisition module to complete the processing of the sound signals, and the interaction module is mainly used for displaying the processing results of the sound processing module and the estimated fault position determination results.

[0108] The thermal imaging part specifically comprises an image acquisition module, an image processing module, an image recognition module and a display module.

[0109] The image acquisition module is mainly used for scanning the conveying belt to obtain the thermal infrared sequence image of the carrier roller, the image processing module is mainly used for pre-processing the obtained thermal infrared sequence image of the carrier roller, and the image recognition module is mainly used for edge detection and feature recognition of the thermal infrared sequence image of the carrier roller, so as to find out the point position of the abnormal temperature of the carrier roller.

[0110] Based on the above technical scheme, the comprehensive processing part specifically comprises a judgment module, an audible and visual alarm module and a display module.

[0111] The judgment module collects the processing signals of the sound array part and the processing signals of the thermal imaging part through Ethernet, completes the display, storage, processing and analysis of the signals, and judges the final fault of the carrier roller through an algorithm.

[0112] The audible and visual alarm module is used for receiving the signals of the judgment module, so as to judge whether to perform an alarm response according to the signals.

[0113] The display module is used for displaying the conveying state of the conveyor and the result of the fault judgment.

[0114] Based on the above technical scheme, the system specifically comprises the following implementation steps:

[0115] S1, sound preprocessing;

[0116] S2, sound signal processing;

[0117] S3, image preprocessing;

[0118] S4, image depth processing;

[0119] S5, temperature state division;

[0120] S6, sound source-temperature joint judgment.

[0121] Based on the above technical scheme, in S1, the sound preprocessing mainly refers to completing A / D conversion on the collected original sound signal, and because the existence of environmental noise affects the analysis and judgment of the signal in the later stage, it is necessary to perform a preprocessing on the original signal, which is a noise reduction processing on the sound signal, and the sound sensor unit uses DSP to complete the noise reduction processing and output the sound signal.

[0122] In S2, the sound signal processing mainly refers to the calculation of the sound signal power of the carrier roller bearing. Specifically, it mainly refers to using beam forming method to measure the sound array, using the multi-channel spatial information of the microphone array, selecting MVDR algorithm to form a narrowband filter in the frequency domain space, and enhancing the signal arranged in the direction of the shaft end. The specific derivation steps are as follows:

[0123] Suppose a uniform linear array is used for M array elements, when N signals s1(n), s2(n), …, s N (n) respectively from θ1, θ2, …, θ N incident to the array, according to the superposition principle, the received signal can be described as:

[0124] x(n) M×1 =A M×N s N×1 ;

[0125]

[0126] A weight is designed, and the weight coefficient is: w = [w0, w1, … w M-1 ] T ;

[0127] So that the output signal y(n) becomes the target signal;

[0128] The output y(n) can be written as: y(n) = w H x(n);

[0129] The output signal power is:

[0130] Separate the signal s1(n) alone, and write the rest as z(n), so the above formula becomes:

[0131] y(n) = w H x(n) = w H a(θ1)s1(n) + w H z(n);

[0132] The requirement is that the weight vector w makes the signal in the s1 direction pass completely, and z(n) is limited as much as possible, which needs to meet the following conditions:

[0133] w H a(θ1) = 1;

[0134] P = x(n)x(n) H = w H R w ;

[0135] Generalize θ1 to arbitrary angle θ, then the above problem is simplified to an optimization problem with weight vector w as variable, that is

[0136]

[0137] Use Lagrange method to construct cost function J(w) as follows:

[0138] J(w) = w H R w - λ(1-w H a(θ))

[0139] Take the gradient of cost function J(w) with respect to weight vector w and set it to 0,

[0140]

[0141] Solve to get: w = λR -1 a(θ);

[0142] Under the constraint w H a(θ) = 1, solve to get:

[0143] Solve the above equations to get:

[0144] In practice, the weight w can be calculated according to the angle θ, and the sound of the roller is obtained under the constraint condition to reduce the influence of the remaining interference signals;

[0145] The judgment steps are as follows:

[0146] The target angle θ is known;

[0147] (1) Receive signal description:

[0148] Suppose a uniform linear array is used for M array elements, when N signals s1(n), s2(n), …, s N (n) respectively from θ1, θ2, …, θ N incident to the array, according to superposition thinking, the received signal can be described as:

[0149] x(n) M×1 = A M×N s N×1

[0150]

[0151] (2) Weight solution:

[0152]

[0153] (3) Output signal power solution:

[0154] y(n)=w H x(n);

[0155]

[0156] Based on the above technical solution, in S3, the image preprocessing refers to the image acquisition module for further monitoring of the temperature of the carrier roller, and the pre-processing of the thermal infrared image by the image processing module includes the following steps:

[0157] S3.1, the thermal infrared image acquired by the image acquisition module is denoised;

[0158] S3.2, the image after denoising is sharpened;

[0159] In S4, the image depth processing refers to the image recognition module for edge detection, feature recognition division, and identification of abnormal temperature, which specifically includes the following steps:

[0160] S4.1, the pre-processed image is acquired for the carrier roller profile;

[0161] S4.2, identify the temperature of the carrier roller sampling point;

[0162] S4.3, determine the final temperature of the carrier roller by joint analysis of the carrier roller temperature.

[0163] Based on the above technical solution, in S5, the temperature state division mainly refers to identifying the carrier roller temperature as three states: severe over-temperature operation, over-temperature operation, and normal temperature operation through the analysis and judgment standard of the carrier roller temperature;

[0164] According to the above three states, the specific judgment method is:

[0165] Let the carrier roller monitoring points be N, and the collected temperatures be t1, t2, …, t n , considering that the temperature data of the carrier roller is basically symmetrically distributed or close to symmetrically distributed, the arithmetic mean is used, which is the most commonly used measure of data trend, and the object is numerical data, which reflects the certainty characteristics of the data, and its calculation formula is as follows:

[0166]

[0167] The proportional relative index is used to measure the relationship between the temperature of each sampling point and the average temperature:

[0168]

[0169] Example 2: When a > 30%, the working temperature is in a serious over-temperature working state;

[0170] Example 3: When 30% > a > 10%, the working temperature is in an over-temperature working state;

[0171] Example 4: When a < 10%, the working temperature is in a normal temperature working state.

[0172] In S6, the standard of the sound source-temperature joint judgment specifically includes the following cases:

[0173] Example 5: When the processed sound array output signal power exceeds the set serious overload power working threshold, the judgment module of the comprehensive processing part directly outputs an alarm signal to the display module, starts the protection shutdown program, and triggers the sound and light alarm module;

[0174] Example 6: When the processed thermal imaging temperature signal exceeds the set serious over-temperature working threshold, the judgment module of the comprehensive processing part directly outputs an alarm signal to the display module, starts the protection shutdown program, and triggers the sound and light alarm module;

[0175] Example 7: When the sound array output signal power exceeds the set overload power working threshold without reaching the serious overload power threshold, the judgment module of the comprehensive processing part directly outputs an alarm signal to the display module, and a warning prompt is popped up on the comprehensive display interface;

[0176] Example 8: When the thermal imaging temperature signal exceeds the set over-temperature working temperature threshold without reaching the serious over-temperature working temperature threshold, the judgment module of the comprehensive processing part directly outputs an alarm signal to the display module, and a warning prompt is popped up on the comprehensive display interface;

[0177] Example 9: When the monitored sound output power is in an upward trend for three consecutive days, and the upward ratio exceeds 20%, the judgment module pops up a warning prompt on the comprehensive display interface of the display part;

[0178] Example 10: When the monitored temperature is in an upward trend for three consecutive days, and the upward ratio exceeds 15%, the judgment module pops up a warning prompt on the comprehensive display interface;

[0179] Example 11: When the sound array part positioning finds that the coincidence degree of the abnormal point position and the temperature abnormal point position found by the thermal imaging reaches 80% or above, the judgment module of the comprehensive processing part determines that the roller has a fault, a warning prompt is popped up on the display module, and the sound and light alarm module is triggered to alarm;

[0180] In the embodiment 12, when the coincidence degree between the abnormal point position found by the acoustic array positioning and the temperature abnormal point position found by the thermal imaging reaches 70% to 80%, the judgment module of the comprehensive processing part determines that the roller is in failure, and a warning prompt is popped up in the display module.

[0181] In the embodiment 13, the device for judging the roller failure by combining the acoustic array and the thermal imaging specifically comprises a memory, a processor, and computer instructions stored in the memory and running on the processor.

[0182] When the computer instructions are run by the processor, the steps of the system for jointly diagnosing the roller failure by combining the acoustic array and the temperature are completed.

[0183] Finally, it should be noted that the above description is only the preferred examples of the present application and is not used to limit the present application. Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions recorded in the foregoing embodiments or equivalently replace some technical features. Any modification, equivalent replacement, improvement, etc. within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A system for jointly determining idler roller faults using acoustic array and thermal imaging, characterized in that: The system specifically includes an inspection section, an acoustic array section, a thermal imaging section, an integrated processing section, and a power supply, wherein the power supply provides power to the inspection section, the acoustic array section, the thermal imaging section, and the integrated processing section; The acoustic array section collects the sound signals from the idler rollers, converts the collected sound signals into electrical signals, preprocesses the sound signals, and performs algorithmic processing on the preprocessed sound signals to obtain their features and identify abnormal parts of the sound signals. The inspection section supports the thermal imager and enables the thermal imager to slide along the slide rail. The thermal imaging section uses the thermal imager to perform thermal imaging scanning on the conveyor belt, measure the point temperature of the idler roller, and determine whether its temperature is abnormal. The integrated processing section specifically includes a judgment module, an audible and visual alarm module, and a display module; The judgment module collects the processed signals from the acoustic array section and the thermal imaging section via Ethernet, and completes the display, storage, processing and analysis of the signals, and uses algorithms to judge the final fault of the idler roller. The audible and visual alarm module is used to receive signals from the judgment module, and then determine whether to trigger an alarm response based on the signals. The display module is used to display the conveying status of the conveyor and the results of fault diagnosis; The integrated processing unit collects the processed signals from the acoustic array and the thermal imaging unit via Ethernet, and completes the display, storage, processing and analysis processes. The judgment module finally transmits the analysis results to the display module via Ethernet, and the judgment module determines whether to activate the audible and visual alarm module. The system specifically includes the following implementation steps: S1, Sound preprocessing; S2, Audio signal processing; S3, Image Preprocessing; S4, Image Depth Processing; S5, Temperature State Classification; S6. Sound source-temperature joint judgment; In S6, the criteria for joint judgment of sound source and temperature specifically include the following situations: When the power of the processed acoustic array output signal exceeds the set severe overload power threshold, the judgment module of the integrated processing section directly outputs an alarm signal to the display module, starts the protection shutdown procedure, and triggers the audible and visual alarm module. When the temperature signal of the processed thermal image exceeds the set severe over-temperature threshold, the judgment module of the integrated processing section directly outputs an alarm signal to the display module, starts the protection shutdown procedure, and triggers the audible and visual alarm module. When the output signal power of the acoustic array exceeds the set overload power threshold but does not reach the severe overload power threshold, the judgment module of the integrated processing section directly outputs an alarm signal to the display module, and a warning prompt pops up on the integrated display interface. When the temperature signal of the thermal imaging image exceeds the set over-temperature operating temperature threshold but does not reach the severe over-temperature operating temperature threshold, the judgment module of the integrated processing section directly outputs an alarm signal to the judgment module, and a warning prompt pops up on the integrated display interface. If the sound output power is on an upward trend for three consecutive days and the increase exceeds 20%, the judgment module will display a warning message on the integrated display interface of the display module. When the monitored temperature shows an upward trend for three consecutive days, with an increase exceeding 15%, the judgment module will display a warning message on the integrated display interface of the display module. When the overlap between the abnormal points detected by the acoustic array and the abnormal temperature points detected by the thermal imaging exceeds 80%, the judgment module of the integrated processing section determines that the idler roller has malfunctioned, pops up a warning message on the display module, and triggers the audible and visual alarm module. When the overlap between the abnormal points detected by the acoustic array and the abnormal temperature points detected by the thermal imaging reaches 70% to 80%, the judgment module of the integrated processing section determines that the idler roller has malfunctioned and displays a warning message on the display module.

2. The system for jointly determining idler roller faults using acoustic array and thermal imaging according to claim 1, characterized in that: The inspection section specifically includes a base, bracket, slide rail, stepper motor, universal movable head, and thermal imager holder; The base and the slide rail are connected to each other. The slide rail is arranged parallel to the conveyor to realize the movement of the support. The support and the base are set as one unit. The universal movable head is connected to the support. The thermal imager holder is connected to the universal movable head. The thermal imager is connected to the thermal imager holder. The stepper motor is electrically connected to the base to drive the base to move along the slide rail.

3. The system for jointly determining idler roller faults using acoustic array and thermal imaging according to claim 1, characterized in that: The sound array section specifically includes an audio acquisition module, a sound processing module, and an interaction module; The audio acquisition module specifically includes a base, an acquisition end, and a sound conversion unit. The acquisition end is fixed on the base, and the acquisition units on the acquisition end are arranged linearly, with one acquisition unit in the middle arranged towards the center of the axis. The acquisition units complete the acquisition of sound signals, and the sound conversion unit completes the A / D conversion and noise reduction processing of the acquired signals. The sound processing module is connected to the audio acquisition module and completes the processing of sound signals. The interaction module is used to display the processing results of the sound processing module and the estimated fault location determination results. The thermal imaging component specifically includes an image acquisition module, an image processing module, an image recognition module, and a display module; The image acquisition module is used to scan the conveyor belt to obtain thermal infrared sequence images of the idlers. The image processing module is used to preprocess the obtained thermal infrared sequence images of the idlers. The image recognition module is used to perform edge detection and feature recognition on the thermal infrared sequence images of the idlers, thereby finding the locations of abnormal idler temperatures.

4. The system for jointly determining idler roller faults using acoustic array and thermal imaging according to claim 1, characterized in that: In S1, sound preprocessing refers to the process of preprocessing the original sound signal after A / D conversion because the presence of environmental noise affects the subsequent analysis and judgment of the signal. This preprocessing is to reduce the noise of the sound signal and output the sound signal after the noise reduction is completed by the sound sensor unit using DSP. In S2, sound signal processing refers to the calculation of the sound signal power of the idler roller bearing. Specifically, it refers to using beamforming to perform sound array measurement, using the multi-channel spatial information of the microphone array, and using the MVDR algorithm to form a narrowband filter in the frequency domain space to enhance the signal in the direction of the shaft end.

5. The system for jointly determining idler roller faults using acoustic array and thermal imaging according to claim 3, characterized in that: In step S3, image preprocessing refers to the image acquisition module using the acquired thermal infrared image for monitoring the temperature of the idler roller. The image processing module's preprocessing of the thermal infrared image includes the following steps: S3.

1. Perform noise reduction processing on the thermal infrared image acquired by the image acquisition module; S3.2 Sharpen the image after noise reduction; In step S4, image depth processing refers to the image recognition module performing edge detection, feature recognition and segmentation, and identifying abnormal temperatures on the generated image. Specifically, it includes the following steps: S4.1 Obtain the roller profile from the preprocessed image; S4.2 Identify the temperature of the idler roller sampling point; S4.

3. Determine the final temperature of the idler rollers by conducting joint analysis of the idler roller temperature.

6. The system for jointly determining idler roller faults using acoustic array and thermal imaging according to claim 1, characterized in that: In S5, temperature state classification refers to identifying the idler temperature into three states based on the analysis and judgment criteria of the idler temperature: severe over-temperature operation, over-temperature operation, and normal temperature operation. Based on the above three states, the specific judgment method is as follows: Suppose there are N monitoring points on the idler roller, and the recorded temperatures are t1, t2, ..., t3. n The arithmetic mean is used, and its calculation formula is as follows: The relationship between the temperature at each sampling point and the average temperature is measured using a proportional relative index: When a>30%, the operating temperature is in a state of severe overheating. When 30% > a > 10%, the operating temperature is in an over-temperature operating state. When a < 10%, the operating temperature is within the normal operating range.

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