A fault detection device and method for underground belt conveyors in coal mines

Abstract

This invention provides a fault detection device and method for underground belt conveyors in coal mines. The fault detection device includes a driving roller and a driven roller, which are fixed to a frame. A conveyor belt is fitted onto the driving roller and the driven roller. It also includes a first detection module, a second detection module, and a control module. The first detection module includes a positioning color strip, a color detection unit, and a first speed detection unit. The positioning color strip is fixed to the center line of the non-load-bearing surface of the conveyor belt. The color detection unit is used to obtain the color type and color value of the positioning color strip. The first speed detection unit is used to detect the conveyor belt's transport speed. The second detection module includes a sensing unit and a second speed detection unit. The sensing unit is fixed to the driven roller, and the second speed detection unit is used to detect the rotational speed of the driven roller. By setting different detection modules, this invention can monitor in real time whether the belt has deviated or slipped, improving the stability of the transport.

Description

Technical Field

[0001] This invention belongs to the field of coal and mineral material conveying technology, and relates to fault detection of belt conveyors, and particularly to a fault detection device and method for underground belt conveyors in coal mines. Background Technology

[0002] Belt conveyors for coal mines are mainly used in coal mining, production, transfer, and processing. They are characterized by large transport capacity, complex working environments, strong load-bearing capacity, and long transport distances. During operation, belt conveyors are prone to belt misalignment or slippage due to factors such as conveyor stability, load, and working environment. If belt misalignment or slippage is not detected in time, and the transport line continues to operate, it will not only affect the quality of the transported materials but also lead to belt wear and even equipment damage, forcing a shutdown for full-line repairs, resulting in low production efficiency and significant economic losses.

[0003] For fault detection of belt conveyors, manual observation is typically used, which is labor-intensive, wastes manpower underground, and has low accuracy. Long-term observation can lead to fatigue and missed detections. Existing technologies have explored image-based recognition methods for efficient operation of belt conveyors. However, extracting the contour of coal on the belt is complex, often ignoring contour fluctuations, resulting in low detection accuracy. Furthermore, these methods are expensive, and their practical application results are not ideal.

[0004] Therefore, accurate real-time monitoring of belt failures during conveyor operation is crucial for stable underground coal mine operations. Summary of the Invention

[0005] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a fault detection device and method for underground belt conveyors in coal mines. By setting different detection modules, it is possible to monitor in real time whether the belt is deviating or slipping, thereby improving the stability of transportation and reducing production risks.

[0006] To achieve this objective, the present invention adopts the following technical solution:

[0007] In a first aspect, the present invention provides a fault detection device for an underground belt conveyor in a coal mine, comprising a driving roller and a driven roller, the driving roller and the driven roller being fixed on a frame, and a conveyor belt being fitted onto the driving roller and the driven roller. The fault detection device comprises a first detection module, a second detection module and a control module, and the control module is electrically connected to the first detection module and the second detection module respectively.

[0008] The first detection module includes a positioning color strip, a color detection unit, and a first speed detection unit. The positioning color strip is fixed on the center line of the non-load-bearing surface of the conveyor belt. The length of the positioning color strip in the width direction of the conveyor belt is the maximum allowable offset of the conveyor belt. The color detection unit is fixed on the vertical projection line of the center line of the conveyor belt onto the frame and is used to obtain the color type and color value of the positioning color strip. The first speed detection unit is fixed on the frame and is used to detect the transport speed of the conveyor belt.

[0009] The second detection module includes a sensing unit and a second speed detection unit. The sensing unit is fixed on the driven roller, and the second speed detection unit is disposed on the frame and is used to detect the rotational speed of the driven roller.

[0010] The fault detection device provided by this invention uses a color detection module to monitor the color value of the positioning color strip located on the center line of the conveyor belt in real time. By obtaining the color value, it can determine whether the belt has deviated, and the detection accuracy is high. The first speed detection unit and the second speed detection unit monitor the speed of the conveyor belt and the driven roller respectively. Based on the comparison of the two speeds, the operating status of the conveyor is determined and the belt slippage is detected, which greatly improves the stability of the conveyor.

[0011] It should be noted that the width direction of the conveyor belt mentioned in this invention refers to the transport direction perpendicular to the conveyor belt.

[0012] As a preferred embodiment of the present invention, the positioning color strip is composed of a plurality of positioning color blocks, which are spaced apart along the transport direction of the conveyor belt. A first color block and a second color block are respectively arranged on both sides of the positioning color block, and the colors of the first color block, the positioning color block and the second color block are different from each other.

[0013] Preferably, the first color block and the second color block extend from the positioning color block in a direction away from each other to the edge of the conveyor belt.

[0014] Preferably, the color detection unit is electrically connected to the control module and is used to transmit the detected color type and color value data to the control module.

[0015] The positioning color strip of the present invention consists of several identical positioning color blocks, which are spaced apart along the transport direction of the conveyor belt and fixed to the center line of the conveyor belt to form the positioning color strip. The present invention determines the offset direction of the conveyor belt by setting a first color block and a second color block of different colors on both sides of each positioning color block, and arranging the first color block, the positioning color strip, and the second color block sequentially along the width direction of the conveyor belt. That is, when the color value obtained by the color detection unit is within the range of the first color block, the result is that the conveyor belt is offset in a first direction; when the color value obtained by the color detection unit is within the range of the second color block, the result is that the conveyor belt is offset in a second direction.

[0016] As a preferred embodiment of the present invention, the first speed detection unit includes a rotary sensing component and a connecting rod. The rotary sensing component is located below the conveyor belt and is used to detect the transport speed of the conveyor belt. The connecting rod is fixed to the frame and is used to support the rotary sensing component.

[0017] In this invention, the rotary sensing component is in direct contact with the conveyor belt. During material conveying, the conveyor belt begins to move and generates friction with the rotary sensing component, thereby enabling the detection of conveying speed. To help those skilled in the art better understand the overall technical solution and working process of this invention, the following specific structure of the rotary sensing component is provided as an example:

[0018] The rotary sensing assembly includes a roller mounted on the end of the connecting rod away from the frame. A pulse sensor is mounted on the roller to emit pulse signals. The friction generated by the conveyor belt during transportation drives the roller to rotate, causing the pulse sensor to emit a series of pulses. Each pulse represents a specific distance value, thereby obtaining the translational speed of the conveyor belt.

[0019] Preferably, the first speed detection unit further includes a weight sensing component, which is fixed to the bottom of the connecting rod and is used to detect the weight carried by the conveyor belt.

[0020] In this invention, the weight sensing component is fixed to the bottom of the connecting rod. Since the rotary sensing component is in direct contact with the conveyor belt, the weight of the conveyor belt carrying the material can be transmitted to the weight sensing component through the connecting rod, thus realizing the load-bearing capacity of the conveyor belt and transmitting the weight data to the control module.

[0021] Preferably, the first speed detection unit is electrically connected to the control module and is used to transmit speed data and weight data to the control module.

[0022] As a preferred embodiment of the present invention, the sensing part is a reflective strip, and the second speed detection part includes an optical detection element and a timing element electrically connected. The optical detection element emits light to the surface of the reflective strip and receives the light reflected by the reflective strip to form a photoelectric signal. The timing element is used to measure the time between two consecutive photoelectric signals to obtain the rotational speed data of the driven roller.

[0023] It should be noted that the present invention does not specifically limit the structure of the optical detection element. In order to help those skilled in the art better understand the overall technical solution and working process of the present invention, the present invention provides the following specific structure of the optical detection element by way of example:

[0024] The optical detection element includes a light source assembly, a reflecting lens, a receiving lens, a photosensitive assembly, and a shaping circuit. The light source assembly emits light with a certain wavelength. The light passes through the reflecting lens and hits the surface of the reflective strip, and is reflected to the receiving lens. The photosensitive assembly receives the light transmitted through the receiving lens, converts it into a photoelectric signal, and sends it to the shaping circuit. The shaping circuit processes the photoelectric signal and then sends it to the control module.

[0025] The optical detection element of the present invention is not limited to the operation module with the above structure. Any operation module that can achieve the same or similar function can be arbitrarily replaced, and the technical solution obtained after replacement also falls within the protection scope and disclosure scope of the present invention.

[0026] Preferably, the second speed detection unit is electrically connected to the control module and is used to transmit the rotational speed data of the driven roller to the control module.

[0027] Preferably, the second speed detection unit further includes a support rod for fixing the optical detection element to the frame.

[0028] As a preferred embodiment of the present invention, the control module includes a processor and an alarm electrically connected together. The processor is electrically connected to a color detection unit, a first speed detection unit, and a second speed detection unit, respectively, and is used to analyze and process data signals and trigger the alarm.

[0029] In this invention, the processor receives data signals such as color value data, conveyor belt speed data, weight data, and driven roller rotation speed data from the first detection module and the second detection module, respectively. It converts, processes, analyzes, and stores the received data, and triggers an alarm based on the results.

[0030] Secondly, the present invention provides a method for detecting faults in underground belt conveyors in coal mines. The fault detection method employs the fault detection device for underground belt conveyors in coal mines described in the first aspect, and the fault detection method includes:

[0031] (I) The first speed detection unit monitors the conveyor belt speed and transmits the data to the control module;

[0032] (II) Pre-store standard values, fix the color strip on the center line of the non-load-bearing surface of the conveyor belt, use the color detection unit to obtain the color type and color value data on the conveyor belt, and transmit it to the control module. The control module compares the color type and color value data with the standard values ​​to determine whether the conveyor belt has deviated.

[0033] (III) The sensing unit is fixed to the surface of the driven roller, and the signal emitted by the sensing unit is collected by the second speed detection unit to obtain the rotational speed data of the driven roller and transmit it to the control module. The control module determines whether the conveyor belt slips based on the rotational speed data and the conveyor belt's transport speed.

[0034] As a preferred technical solution of the present invention, in step (I), during the conveying process of the conveyor belt, the weight of the material carried by the conveyor belt is detected by a weight sensing component and transmitted to the control module. The control module analyzes the current tension state of the conveyor belt based on the weight data.

[0035] In this invention, a rotary sensing component is used to detect the conveyor belt's transport speed. Combined with the weight detected by the weight sensing component, the tension on the conveyor belt can be estimated, which is helpful for assessing the conveyor belt's transport status.

[0036] As a preferred embodiment of the present invention, in step (II), the method for determining whether the conveyor belt has shifted includes:

[0037] S1 provides a mapping data table column generated by the color value of the positioning tape and the tension state of the conveyor belt;

[0038] S2 obtains the color difference amount corresponding to the current stretching state based on the mapped data table columns;

[0039] S3 compares the standard value with the color value data acquired in real time by the color detection unit. When the color value data is within the color difference range of the standard value, the conveyor belt does not deviate. Otherwise, the conveyor belt deviates, the direction of deviation is obtained, and the alarm is triggered.

[0040] During the conveyor belt transport process, the positioning color strip is affected by the stretching of the conveyor belt, resulting in a certain color deviation. This application addresses this by pre-establishing a mapping data table in the processor of the control module. Based on the current stretching state, the corresponding color difference value is obtained, and the color difference value is compared with the standard value to determine whether the conveyor belt has shifted. Furthermore, this invention uses a rotary sensing component to directly contact the conveyor belt at the position corresponding to the color detection unit, obtaining the tension state of the conveyor belt at that position, thus improving the accuracy of the detection.

[0041] As a preferred embodiment of the present invention, in step (II), the method for obtaining the offset direction includes:

[0042] S101 pre-stores the first standard color value and the second standard color value;

[0043] S102 provides a first mapping table and a second mapping table generated according to the stretching state of the first color block and the second color block with the conveyor belt, respectively;

[0044] S103 obtains the first color difference and the second color difference corresponding to the current stretching state based on the first mapping table and the second mapping table;

[0045] S104 compares the first standard color value, the second standard color value, and the color value data acquired in real time by the color detection unit. When the color value data is within the color difference range of the first standard color value, the conveyor belt shifts in the first direction. When the color value data is within the color difference range of the second standard color value, the conveyor belt shifts in the second direction.

[0046] To detect the offset direction of the conveyor belt, this invention sets a first color block and a second color block on both sides of the positioning color block. In addition, the processor presets a standard value corresponding to the color of the positioning color block, a first standard color value corresponding to the color of the first color block, and a second standard color value corresponding to the color of the second color block. A mapping data table column, a first mapping table, and a second mapping table are established respectively. After determining that the color value data acquired in real time exceeds the color difference range of the standard value (i.e., it is determined that the conveyor belt has offset), the offset direction is determined based on the first mapping table and the second mapping table.

[0047] As a preferred embodiment of the present invention, in step (III), the method for determining whether the conveyor belt has slipped includes:

[0048] S201 sets the speed difference limit;

[0049] The S202 control module calculates the difference between the conveyor belt's transport speed and the driven roller's rotational speed.

[0050] S203 compares the difference with the speed difference limit. When the absolute value of the difference is less than the speed difference limit, the conveyor belt does not slip. Otherwise, the conveyor belt slips and an alarm is triggered.

[0051] In this invention, the rotary sensing component transmits the conveyor belt speed to the processor of the control module, the optical detection element transmits photoelectric signals to the control module, the timing element measures the interval between two consecutive photoelectric signals, the processor calculates the rotational speed of the driven roller based on the interval, and compares the conveyor speed with the rotational speed of the driven roller to determine whether the conveyor belt is slipping.

[0052] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0053] This invention provides a fault detection device and method for underground belt conveyors in coal mines. It utilizes a color detection module to monitor the color value of a positioning color strip located on the center line of the conveyor belt in real time. By obtaining the color value, it can determine whether the belt has deviated, achieving high detection accuracy. Furthermore, it employs a first speed detection unit and a second speed detection unit to monitor the speeds of the conveyor belt and driven rollers respectively. Based on the comparison of these speeds, it determines the operating status of the conveyor and detects whether the belt is slipping, greatly improving the stability of the conveyor. Attached Figure Description

[0054] Figure 1 A schematic diagram of a fault detection device for an underground belt conveyor in a coal mine, provided in a specific embodiment of the present invention;

[0055] Figure 2 A schematic diagram of the positioning color strip and color detection unit is provided for a specific embodiment of the present invention;

[0056] Figure 3 A schematic diagram of the structure of the second speed detection unit is provided for a specific embodiment of the present invention;

[0057] Figure 4 A circuit block diagram of the control module is provided for one specific embodiment of the present invention.

[0058] Among them, 1-conveyor belt; 2-drive roller; 3-driven roller; 4-frame; 5-positioning color belt; 6-center line; 7-color detection unit; 8-first color block; 9-second color block; 10-rotary sensing component; 11-weight sensing component; 12-connecting rod; 13-sensing unit; 14-optical detection element; 15-timing element; 16-support rod. Detailed Implementation

[0059] It should be understood that in the description of this invention, the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0060] It should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "set," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0061] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0062] In one specific implementation, the present invention provides a fault detection device for underground belt conveyors in coal mines, such as... Figure 1 As shown, it includes a driving roller 2 and a driven roller 3, which are fixed on the frame 4. A conveyor belt 1 is fitted on the driving roller 2 and the driven roller 3.

[0063] The fault detection device further includes a first detection module, a second detection module, and a control module, wherein the control module is electrically connected to the first detection module and the second detection module respectively.

[0064] The first detection module includes a positioning color strip 5, a color detection unit 7, and a first speed detection unit. The positioning color strip 5 is fixed on the center line 6 of the non-load-bearing surface of the conveyor belt 1. The length of the positioning color strip 5 in the width direction of the conveyor belt 1 is the maximum allowable offset of the conveyor belt 1. The color detection unit 7 is fixed on the vertical projection line of the center line 6 of the conveyor belt 1 onto the frame 4 and is used to obtain the color type and color value of the positioning color strip 5. The first speed detection unit is fixed on the frame 4 and is used to detect the transport speed of the conveyor belt 1.

[0065] The second detection module includes a sensing unit 13 and a second speed detection unit. The sensing unit 13 is fixed on the driven roller 3, and the second speed detection unit is disposed on the frame 4 for detecting the rotational speed of the driven roller 3.

[0066] The fault detection device provided by this invention uses a color detection module to monitor the color value of the positioning color strip 5 located on the center line 6 of the conveyor belt 1 in real time. By obtaining the color value, it can determine whether the belt has deviated, and the detection accuracy is high. The first speed detection unit and the second speed detection unit respectively monitor the speed of the conveyor belt 1 and the driven roller 3. Based on the comparison of the two speeds, the operating status of the conveyor is determined and the belt slippage is detected, which greatly improves the stability of the conveyor.

[0067] In some implementations, such as Figure 2 As shown, the positioning color belt 5 is composed of several positioning color blocks, which are spaced apart along the transport direction of the conveyor belt 1. A first color block 8 and a second color block 9 are respectively arranged on both sides of the positioning color block, and the colors of the first color block 8, the positioning color block and the second color block 9 are different from each other.

[0068] In some embodiments, the first color block 8 and the second color block 9 extend from the positioning color block in a direction away from each other to the edge of the conveyor belt 1.

[0069] The color detection unit 7 of this invention is electrically connected to the control module and is used to transmit the detected color type and color value data to the control module. The positioning color belt 5 is composed of several identical positioning color blocks, which are spaced apart along the transport direction of the conveyor belt 1 and fixed on the center line 6 of the conveyor belt 1 to form the positioning color belt 5. This invention determines the offset direction of the conveyor belt 1 by setting a first color block 8 and a second color block 9 of different colors on both sides of each positioning color block, i.e., the first color block 8, the positioning color belt 5, and the second color block 9 are arranged sequentially along the width direction of the conveyor belt 1: when the color value obtained by the color detection unit 7 is within the range of the first color block 8, the result is that the conveyor belt 1 is offset in the first direction; when the color value obtained by the color detection unit 7 is within the range of the second color block 9, the result is that the conveyor belt 1 is offset in the second direction.

[0070] In some implementations, such as Figure 1As shown, the first speed detection unit includes a rotary sensing component 10 and a connecting rod 12. The rotary sensing component 10 is located below the conveyor belt 1 and is used to detect the transport speed of the conveyor belt 1. The connecting rod 12 is fixed to the frame 4 and is used to support the rotary sensing component 10. In this invention, the rotary sensing component 10 is in direct contact with the conveyor belt 1. During material conveying, the conveyor belt 1 begins to move and generates friction with the rotary sensing component 10, thereby realizing the detection of the transport speed. To help those skilled in the art better understand the overall technical solution and working process of this invention, the present invention provides the following specific structure of the rotary sensing component 10:

[0071] The rotary sensing assembly 10 includes a rolling wheel located at the end of the connecting rod 12 away from the frame 4. A pulse sensor is installed on the rolling wheel to emit pulse signals. The friction generated by the conveyor belt 1 during transportation drives the rolling wheel to rotate, causing the pulse sensor to emit a series of pulses. Each pulse represents a specific distance value, thereby obtaining the translational speed of the conveyor belt 1.

[0072] In some embodiments, the first speed detection unit further includes a weight sensing component 11, which is fixed to the bottom of the connecting rod 12. The weight sensing component 11 is used to detect the weight carried by the conveyor belt 1. The first speed detection unit is electrically connected to the control module and is used to transmit speed data and weight data to the control module. In this invention, the weight sensing component 11 is fixed to the bottom of the connecting rod 12. Since the rotary sensing component 10 is in direct contact with the conveyor belt 1, the gravity of the conveyor belt 1 carrying material can be transmitted to the weight sensing component 11 through the connecting rod 12, thus realizing the load-bearing capacity of the conveyor belt 1 and transmitting the weight data to the control module.

[0073] In some implementations, such as Figure 3 As shown, the sensing part 13 is a reflective strip, and the second speed detection part includes an optical detection element 14 and a timing element 15 that are electrically connected. The optical detection element 14 emits light to the surface of the reflective strip and receives the light reflected by the reflective strip to form a photoelectric signal. The timing element 15 is used to measure the time between two consecutive photoelectric signals to obtain the rotational speed data of the driven roller 3.

[0074] To help those skilled in the art better understand the overall technical solution and working process of the present invention, the present invention provides the following specific structure of the optical detection element 14 by way of example:

[0075] The optical detection element 14 includes a light source assembly, a reflecting lens, a receiving lens, a photosensitive assembly, and a shaping circuit. The light source assembly emits light with a certain wavelength. The light passes through the reflecting lens and hits the surface of the reflective strip, and is reflected to the receiving lens. The photosensitive assembly receives the light transmitted through the receiving lens, converts it into a photoelectric signal, and sends it to the shaping circuit. The shaping circuit processes the photoelectric signal and sends it to the control module.

[0076] In some embodiments, the second speed detection unit is electrically connected to the control module for transmitting the rotational speed data of the driven roller 3 to the control module. The second speed detection unit also includes a support rod 16 for fixing the optical detection element 14 to the frame 4.

[0077] In some implementations, such as Figure 4 As shown, the control module includes a processor and an alarm electrically connected. The processor is electrically connected to the color detection unit 7, the first speed detection unit, and the second speed detection unit, respectively, and is used to analyze and process data signals and trigger the alarm. In this invention, the processor receives data signals such as color value data, conveyor belt 1 transport speed data, weight data, and driven roller 3 rotation speed data from the first and second detection modules, respectively. It converts, processes, analyzes, and stores the received data, and triggers the alarm based on the results.

[0078] In another specific embodiment, the present invention provides a fault detection method for underground belt conveyors in coal mines. The fault detection method employs a fault detection device for underground belt conveyors in coal mines as described in a specific embodiment. The fault detection method includes:

[0079] (1) The first speed detection unit monitors the transport speed of the conveyor belt 1 and transmits it to the control module;

[0080] (2) Pre-store standard values, fix the color belt 5 on the center line 6 of the non-load-bearing surface of the conveyor belt 1, use the color detection unit 7 to obtain the color type and color value data on the conveyor belt 1, and transmit it to the control module. The control module compares the color type and color value data with the standard values ​​to determine whether the conveyor belt 1 has deviated.

[0081] (3) The sensing unit 13 is fixed to the surface of the driven roller 3, and the signal emitted by the sensing unit 13 is collected by the second speed detection unit to obtain the rotational speed data of the driven roller 3 and transmit it to the control module. The control module determines whether the conveyor belt 1 slips based on the rotational speed data and the transport speed of the conveyor belt 1.

[0082] In some implementations, in step (1), during the conveying process of the conveyor belt 1, the weight of the material carried by the conveyor belt 1 is detected by the weight sensing component 11 and transmitted to the control module. The control module analyzes the current tension state of the conveyor belt 1 based on the weight data.

[0083] In this invention, a rotary sensing component 10 is used to detect the transport speed of the conveyor belt 1. Combined with the weight currently carried by the conveyor belt 1 detected by the weight sensing component 11, the tension on the conveyor belt 1 can be estimated, which is helpful for evaluating the transport status of the conveyor belt 1.

[0084] In some implementations, step (2) of determining whether the conveyor belt 1 has shifted includes:

[0085] S1 provides a mapping data table column generated by the color value of the positioning color strip 5 and the tension state of the conveyor belt 1;

[0086] S2 obtains the color difference amount corresponding to the current stretching state based on the mapped data table columns;

[0087] S3 compares the standard value with the color value data acquired in real time by the color detection unit 7. When the color value data is within the color difference range of the standard value, the conveyor belt 1 does not deviate. Otherwise, the conveyor belt 1 deviates, the direction of deviation is obtained, and the alarm is triggered.

[0088] During the conveyor belt 1's transport process, the positioning color belt 5 is affected by the stretching of the conveyor belt 1, resulting in a certain color deviation. This application pre-establishes a mapping data table in the processor of the control module, obtains the corresponding color difference value based on the current stretching state, and compares the color difference value with the standard value to determine whether the conveyor belt 1 has shifted. Furthermore, this invention directly contacts the rotary sensing component 10 with the conveyor belt 1 at the position corresponding to the color detection unit 7 to obtain the tension state of the conveyor belt 1 at the corresponding position, improving the accuracy of detection.

[0089] In some implementations, step (2) of obtaining the offset direction includes:

[0090] S101 pre-stores the first standard color value and the second standard color value;

[0091] S102 provides a first mapping table and a second mapping table generated according to the stretching state of the first color block 8 and the second color block 9 with the conveyor belt 1, respectively;

[0092] S103 obtains the first color difference and the second color difference corresponding to the current stretching state based on the first mapping table and the second mapping table;

[0093] S104 compares the first standard color value, the second standard color value, and the color value data acquired in real time by the color detection unit 7. When the color value data is within the color difference range of the first standard color value, the conveyor belt 1 shifts in the first direction. When the color value data is within the color difference range of the second standard color value, the conveyor belt 1 shifts in the second direction.

[0094] In order to detect the offset direction of the conveyor belt 1, the present invention sets a first color block 8 and a second color block 9 on both sides of the positioning color block. In addition, the processor presets a standard value corresponding to the color of the positioning color block, a first standard color value corresponding to the color of the first color block 8, and a second standard color value corresponding to the color of the second color block 9. A mapping data table column, a first mapping table, and a second mapping table are established respectively. After determining that the color value data acquired in real time exceeds the color difference range of the standard value (that is, determining that the conveyor belt 1 has offset), the offset direction is determined based on the first mapping table and the second mapping table.

[0095] In some implementations, step (3) of determining whether the conveyor belt 1 has slipped includes:

[0096] S201 sets the speed difference limit;

[0097] The S202 control module calculates the difference between the conveyor belt 1's transport speed and the driven roller 3's rotational speed.

[0098] S203 compares the difference with the speed difference limit. When the absolute value of the difference is less than the speed difference limit, the conveyor belt 1 does not slip. Otherwise, the conveyor belt 1 slips and triggers the alarm.

[0099] In this invention, the rotary sensing component 10 transmits the transport speed of the conveyor belt 1 to the processor of the control module, the optical detection element 14 transmits photoelectric signals to the control module, the timing element 15 measures the interval between two consecutive photoelectric signals, the processor calculates the rotational speed of the driven roller 3 based on the interval, and compares the transport speed with the rotational speed of the driven roller 3 to determine whether the conveyor belt 1 has slipped.

[0100] Example

[0101] This embodiment provides a fault detection device for an underground belt conveyor in a coal mine, including a driving roller 2 and a driven roller 3 fixed on a frame 4, with a conveyor belt 1 mounted on the driving roller 2 and the driven roller 3. The fault detection device also includes a first detection module, a second detection module, and a control module.

[0102] The first detection module includes a positioning color strip 5 and a color detection unit 7. The positioning color strip 5 is fixed on the center line 6 of the non-load-bearing surface of the conveyor belt 1, and the length of the positioning color strip 5 in the width direction of the conveyor belt 1 is the maximum allowable offset of the conveyor belt 1. The positioning color strip 5 is composed of positioning color blocks, which are spaced apart along the transport direction of the conveyor belt 1. A first color block 8 and a second color block 9 are respectively arranged on the left and right sides of the positioning color blocks, and the colors of the first color block 8, the positioning color blocks, and the second color block 9 are different from each other.

[0103] The color detection unit 7 is fixed to the vertical projection line of the center line 6 of the conveyor belt 1 onto the frame 4 and is electrically connected to the control module. It is used to acquire the color type and color value of the positioning color belt 5 and then transmit it to the control module. In this embodiment, the color detection unit 7 can perform color recognition and sensing. It detects the color by comparing the color of the object with the previously taught reference color. When the two colors match within a certain error range, the detection result is output.

[0104] The first detection module also includes a first speed detection unit for monitoring the conveyor belt 1's conveying speed. The first speed detection unit includes a rotary sensor assembly 10, a weight sensor assembly 11, and a connecting rod 12. The rotary sensor assembly 10 is located below the conveyor belt 1, and the connecting rod 12 is fixed to the frame 4 to support the rotary sensor assembly 10. The rotary sensor assembly 10 includes a rolling wheel located at the end of the connecting rod 12 away from the frame 4. A pulse sensor is mounted on the rolling wheel to emit pulse signals. The friction generated by the conveyor belt 1 during transport drives the rolling wheel to rotate, causing the pulse sensor to emit a series of pulses. Each pulse represents a specific distance value, thus allowing the translational speed of the conveyor belt 1 to be obtained. The weight sensor assembly 11 is fixed to the bottom of the connecting rod 12 and is used to detect the weight carried by the conveyor belt 1. The first speed detection unit is electrically connected to the control module to transmit speed and weight data to the control module.

[0105] The second detection module includes a sensing unit 13 and a second speed detection unit. The sensing unit 13 is a reflective strip that adheres to the surface of the driven roller 3. The second speed detection unit includes an optical detection element 14 and a timing element 15 that are electrically connected. The optical detection element 14 includes a light source assembly, a reflecting lens, a receiving lens, a photosensitive component, and a shaping circuit. The light source assembly emits light of a certain wavelength. The light passes through the reflecting lens and hits the surface of the reflective strip, and is reflected to the receiving lens. The photosensitive component receives the light transmitted through the receiving lens, converts it into a photoelectric signal, and sends it to the shaping circuit. The shaping circuit processes the photoelectric signal and sends it to the control module. The timing element 15 measures the time between two consecutive photoelectric signals to obtain the rotational speed data of the driven roller 3.

[0106] The control module includes an electrically connected processor and an alarm. The processor is electrically connected to the color detection unit 7, the first speed detection unit, and the second speed detection unit, respectively. It is used to receive data signals such as color value data, conveyor belt 1 transport speed data, weight data, and driven roller 3 rotation speed data. It converts, processes, analyzes, and stores the received data, and triggers the alarm based on the results.

[0107] Application examples

[0108] This application example uses the fault detection device for underground belt conveyors in coal mines provided in the embodiment to detect faults in belt conveyors, specifically including the following steps:

[0109] (1) The rotary sensing component 10 is used to monitor the translation speed of the conveyor belt 1 and transmit it to the processor of the control module. At the same time, the weight sensing component 11 is used to detect the weight of the material carried by the conveyor belt 1 and transmit it to the processor. The processor analyzes the speed data and weight data to obtain the current tension state of the conveyor belt 1.

[0110] (2) Fix the color strip 5, the first color block 8 and the second color block 9 on the center line 6 of the non-load-bearing surface of the conveyor belt 1, and use the color detection unit 7 to obtain the color type and color value data on the conveyor belt 1 and transmit it to the processor.

[0111] (3) The standard value, the first standard color value and the second standard color value are pre-stored in the processor, and the mapping data table, the first mapping table and the second mapping table are generated according to the stretching state of the positioning color strip 5, the first color block 8 and the second color block 9 and the conveyor belt 1, respectively.

[0112] (4) Based on the mapping data table, obtain the color difference corresponding to the current stretching state, compare the standard value with the color value data obtained in real time by the color detection unit 7, and when the color value data is within the color difference range of the standard value, the conveyor belt 1 does not shift; otherwise, the conveyor belt 1 shifts.

[0113] (5) After determining that the conveyor belt 1 has deviated, based on the first mapping table and the second mapping table, the first color difference and the second color difference corresponding to the current stretching state are obtained. The first standard color value, the second standard color value and the color value data acquired in real time by the color detection unit 7 are compared. When the color value data is within the color difference range of the first standard color value, the conveyor belt 1 deviates in the first direction (left side). When the color value data is within the color difference range of the second standard color value, the conveyor belt 1 deviates in the second direction (right side) and triggers the alarm.

[0114] (6) Fix the reflective strip to the surface of the driven roller 3, use the second speed detection unit to collect the signal emitted by the reflective strip, obtain the rotational speed data of the driven roller 3, and transmit it to the processor;

[0115] (7) Set a speed difference limit in the processor, calculate the difference between the transport speed of the conveyor belt 1 and the rotation speed of the driven roller 3, compare the difference with the speed difference limit, and when the absolute value of the difference is less than the speed difference limit, the conveyor belt 1 does not slip; otherwise, the conveyor belt 1 slips and triggers the alarm.

[0116] The applicant declares that the above description is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Those skilled in the art should understand that any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention fall within the protection and disclosure scope of the present invention.

Claims

1. A method for fault detection of underground belt conveyors in coal mines, characterized in that, The method employs a fault detection device for underground belt conveyors in coal mines, comprising a driving roller and a driven roller, both fixed to a frame. A conveyor belt is fitted onto the driving roller and driven roller. The fault detection device includes a first detection module, a second detection module, and a control module, with the control module electrically connected to both the first and second detection modules. The first detection module includes a positioning color strip, a color detection unit, and a first speed detection unit. The positioning color strip is fixed to the centerline of the non-load-bearing surface of the conveyor belt, and its length in the width direction of the conveyor belt is the maximum allowable offset of the conveyor belt. Composed of several positioning color blocks, these color blocks are spaced apart along the transport direction of the conveyor belt. A first color block and a second color block are respectively positioned on both sides of each positioning color block. The colors of the first color block, the positioning color block, and the second color block are all different. A color detection unit is fixed to the vertical projection line of the center line of the conveyor belt onto the frame, used to obtain the color type and color value of the positioning color block. A first speed detection unit is fixed to the frame, used to detect the transport speed of the conveyor belt. A second detection module includes a sensing unit and a second speed detection unit. The sensing unit is fixed to the driven roller, and the second speed detection unit is disposed on the frame, used to detect the rotational speed of the driven roller. The fault detection method includes: (I) The first speed detection unit monitors the conveyor belt speed and transmits the data to the control module; (II) Pre-store standard values, fix the color strip on the center line of the non-load-bearing surface of the conveyor belt, use the color detection unit to obtain the color type and color value data on the conveyor belt, and transmit it to the control module. The control module compares the color type and color value data with the standard values ​​to determine whether the conveyor belt has deviated. (III) The sensing unit is fixed to the surface of the driven roller, and the signal emitted by the sensing unit is collected by the second speed detection unit to obtain the rotational speed data of the driven roller and transmit it to the control module. The control module determines whether the conveyor belt slips based on the rotational speed data and the conveyor belt's transport speed. The method for determining whether the conveyor belt has shifted includes: S1 provides a mapping data table column generated by the color value of the positioning tape and the tension state of the conveyor belt; S2 obtains the color difference amount corresponding to the current stretching state based on the mapped data table columns; S3 compares the standard value with the color value data acquired in real time by the color detection unit. When the color value data is within the color difference range of the standard value, the conveyor belt does not deviate. Otherwise, the conveyor belt deviates, the direction of deviation is obtained, and the alarm is triggered. After determining that the conveyor belt is misaligned, the method for obtaining the offset direction includes: S101 pre-stores the first standard color value and the second standard color value; S102 provides a first mapping table and a second mapping table generated according to the stretching state of the first color block and the second color block with the conveyor belt, respectively; S103 obtains the first color difference and the second color difference corresponding to the current stretching state based on the first mapping table and the second mapping table; S104 compares the first standard color value, the second standard color value, and the color value data acquired in real time by the color detection unit. When the color value data is within the color difference range of the first standard color value, the conveyor belt shifts in the first direction. When the color value data is within the color difference range of the second standard color value, the conveyor belt shifts in the second direction.

2. The fault detection method according to claim 1, characterized in that, The first color block and the second color block extend from the positioning color block in a direction away from each other to the edge of the conveyor belt; The color detection unit is electrically connected to the control module and is used to transmit the detected color type and color value data to the control module.

3. The fault detection method according to claim 1 or 2, characterized in that, The first speed detection unit includes a rotary sensing component and a connecting rod. The rotary sensing component is located below the conveyor belt and is used to detect the transport speed of the conveyor belt. The connecting rod is fixed to the frame and is used to support the rotary sensing component.

4. The fault detection method according to claim 3, characterized in that, The first speed detection unit also includes a weight sensing component, which is fixed to the bottom of the connecting rod and is used to detect the weight carried by the conveyor belt. The first speed detection unit is electrically connected to the control module and is used to transmit speed data and weight data to the control module.

5. The fault detection method according to claim 1, characterized in that, The sensing part is a reflective strip, and the second speed detection part includes an optical detection element and a timing element that are electrically connected. The optical detection element emits light to the surface of the reflective strip and receives the light reflected by the reflective strip to form a photoelectric signal. The timing element is used to measure the time between two consecutive photoelectric signals to obtain the rotational speed data of the driven roller. The second speed detection unit is electrically connected to the control module and is used to transmit the rotational speed data of the driven roller to the control module.

6. The fault detection method according to claim 5, characterized in that, The second speed detection unit also includes a support rod for fixing the optical detection element to the frame.

7. The fault detection method according to claim 1, characterized in that, The control module includes a processor and an alarm that are electrically connected. The processor is electrically connected to a color detection unit, a first speed detection unit, and a second speed detection unit, respectively, and is used to analyze and process data signals and trigger the alarm.

8. The fault detection method according to claim 1, characterized in that, In step (I), during the conveying process of the conveyor belt, the weight of the material carried by the conveyor belt is detected by the weight sensor component and transmitted to the control module. The control module analyzes the weight data to obtain the current tension state of the conveyor belt.

9. The fault detection method according to claim 1, characterized in that, In step (III), the method for determining whether the conveyor belt has slipped includes: S201 sets the speed difference limit; The S202 control module calculates the difference between the conveyor belt's transport speed and the driven roller's rotational speed. S203 compares the difference with the speed difference limit. When the absolute value of the difference is less than the speed difference limit, the conveyor belt does not slip. Otherwise, the conveyor belt slips and an alarm is triggered.

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