Belt fault detection device, system and fault handling method

Abstract

The present invention provides a belt fault detection device, system, and fault handling method, belonging to the field of laser detection technology. The device comprises a sensor module and a fault detection module, wherein the fault detection module comprises a dustproof housing, a camera, and a laser emitter, wherein the camera and laser emitter are mounted on the bottom plate of the dustproof housing, the laser emitter is used to emit laser light onto the belt, the camera is used to capture the laser light irradiated on the belt, and the sensor module is used to detect the signal. By using an industrial camera and a laser emitter, the present invention improves detection accuracy compared to manual detection, avoids false alarms, and increases image exposure time and exposure. The system of the present invention can effectively link detection results with belt position, displaying the existing faults and current fault locations of the entire conveyor belt in real time, historically recording and linking belt replacement information, and displaying faults and location information that occurred during the current belt life cycle, providing a basis for the owner to conduct maintenance.

Description

Technical Field

[0001] The present invention belongs to the technical field of laser detection, and in particular relates to a belt fault detection device, a system and a fault handling method. Background Art

[0002] Belt conveyor systems, with their simple structure and high efficiency, are crucial for the continuous transport of materials over long distances in process industries. However, belt tears are the most critical type of failure affecting conveyor operation. Because conveyors operate at high speeds and over long distances, undetected tears can damage tens or even hundreds of meters of belt. Repairing the belt is not only time-consuming and labor-intensive, but also disrupts normal production, resulting in direct and indirect economic losses for the company. Currently, the prevalent inspection method for belt conveyor systems in various companies relies on regular manual inspections, which lack real-time performance and rely on worker accountability. This presents challenges in the overall system, including a lack of preventative maintenance and numerous safety hazards.

[0003] The current mainstream technical solution is to use line scan cameras for image acquisition and image analysis to determine the shape and location of the fault. A representative example is the fault detector developed by a team from Tianjin University of Technology and Tianjin Hengyi Technology. It uses multiple line scan cameras combined with image fusion and image detection technology to perform fault detection. The system can detect faults to a certain extent, but because line scan camera acquisition requires stable speed feedback to control shooting, it is not suitable for use in relatively harsh environments. Summary of the Invention

[0004] In response to the problems in the background technology, the present invention provides a belt fault detection device, system and fault handling method.

[0005] In order to achieve the above object, the present invention adopts the following technical solutions:

[0006] A conveyor belt fault detection device includes a sensor module and a fault detection module;

[0007] The fault detection module includes a dustproof housing, a camera and a laser transmitter;

[0008] The camera and laser transmitter are mounted on the bottom plate of the dustproof housing;

[0009] The laser emitter is used to emit laser light toward the belt;

[0010] The camera is used to photograph the laser irradiated on the belt;

[0011] The sensor module is used to detect signals when the belt is running.

[0012] Preferably, the dustproof housing is an L-shaped structure, comprising a horizontal section and a vertical section, wherein the vertical section is provided at one end of the horizontal section;

[0013] The camera and laser transmitter are both installed in the horizontal section;

[0014] A shooting hole is provided on a surface of the vertical section facing the horizontal section;

[0015] The lens of the camera faces the shooting hole;

[0016] A glass layer is further installed on the surface of the shooting hole. An air curtain groove is opened in the glass layer. The air curtain groove is provided with an air outlet. The direction of the air outlet is the same as that of the shooting hole.

[0017] Preferably, an adjustment bracket is installed at the bottom of the camera, and the adjustment bracket is installed on the horizontal section;

[0018] The adjusting bracket is used to adjust the shooting angle of the camera.

[0019] Preferably, a box is installed on the top of the vertical section, and a supporting damper structure is installed inside the box, and the damper structure includes a first dust cover plate that is rotatably arranged;

[0020] The first dustproof cover is used to cover the shooting hole.

[0021] Preferably, the damper structure includes a bellows, a plurality of fan blades and a transmission shaft; the fan blades are mounted on the transmission shaft, and the transmission shaft is rotatably connected to the bellows; both ends of the transmission shaft extend to the outside of the bellows and are fixedly connected to the first dust cover.

[0022] Preferably, the bellows is further connected to an air duct, and the air duct is used to introduce air into the bellows;

[0023] The air box is also communicated with the air curtain groove.

[0024] Preferably, a laser hole is opened on the surface of the horizontal section, and the laser emitter emits laser through the laser hole.

[0025] Preferably, a substrate is further mounted on the surface of the horizontal section, and the substrate is located around the laser hole;

[0026] The base plate is rotatably connected to a second dust cover plate;

[0027] The second dustproof cover is used to shield the laser hole.

[0028] Preferably, it further comprises a protective shell, wherein the protective shell is wrapped around the outside of the laser emitter;

[0029] The protective shell is also communicated with the laser hole and the air duct.

[0030] Preferably, the fault detection module further comprises a camera, and the camera is installed in the horizontal section;

[0031] The lens of the camera faces the shooting hole and is used for recording and storing the laser irradiated on the belt.

[0032] Preferably, the sensor module includes a conveying roller, a Hall sensor and a magnet;

[0033] The conveying roller is used to support and convey the belt, the magnet is installed on the end surface of the conveying roller, and the Hall sensor is located on one side of the conveying roller and is used to sense the magnet and detect the pulse signal.

[0034] A belt fault detection system includes a fault detection module and a sensor module;

[0035] The system also includes a control room, a distribution box and an alarm module;

[0036] The fault detection device is used to collect the image signal of the belt and send the image signal to the distribution box, wherein the image signal is a line laser image;

[0037] The sensor module is used to detect the pulse signal of the belt and send it to the distribution box;

[0038] The distribution box is used to send image signals and pulse signals to the control room, and is also used to send alarm signals to the alarm module;

[0039] The control room is used to analyze the image signal and determine the fault of the image, combine the pulse signal of the belt, judge the current location information of the fault, and send an alarm signal to the distribution box.

[0040] Preferably, the control room includes a computer and a first optical terminal, and the computer is connected to the first optical terminal;

[0041] The distribution box includes a second optical terminal, a PLC and a power supply, the second optical terminal is connected to the PLC, and the PLC is connected to the sensor module and the alarm module via an RS485 interface;

[0042] The second optical terminal is also connected to the first optical terminal;

[0043] The power supply is connected to the fault detection device and is used to supply power to the fault detection device;

[0044] The second optical terminal is also connected to the fault detection device for transmitting image signals.

[0045] A fault handling method, which is applied to a belt fault detection device, comprises the following steps:

[0046] Obtaining laser profile information on the belt surface;

[0047] Determine the fault type based on the laser profile information;

[0048] If the fault type is the first type, an alarm is issued and a shutdown signal is sent;

[0049] If the fault type is the second type, the belt fault position is located and recorded.

[0050] Preferably, the first type comprises belt tears; and the second type comprises pits.

[0051] Preferably, the belt fault position is located and recorded, and the calculation formula is as follows:

[0052] ;

[0053] When dist At l2, the fault is located at the distance dist from the upper belt on the right side;

[0054] when When the fault is located on the right side of the conveyor belt fault detection device Position the lower belt;

[0055] when When the fault is located on the left side of the conveyor belt fault detection device Position the belt below;

[0056] when When , the fault is located at the upper belt at the D-dist position on the left side of the conveyor belt fault detection device;

[0057] Where Remain represents the remainder; d is the diameter of the conveyor roller; N is the number of pulses measured per belt revolution; M is the pulse position of the fault to be inspected; P is the pulse position at the time of inspection; dist is the current fault distance; l 1 and l 2 is the distance between the conveyor belt fault detection device and the two ends of the belt; D is the total distance of one belt cycle.

[0058] Beneficial effects of the present invention:

[0059] 1. This invention uses an industrial camera and a laser transmitter to perform belt fault detection based on laser triangulation. Compared with manual detection, it improves detection accuracy and can accurately identify situations where there is a lot of dirt under the conveyor belt, avoiding false alarms and increasing image exposure time and exposure.

[0060] 2. In view of the characteristics of large dust and strong vibration on site, the present invention designs a first dustproof cover and a second dustproof cover to prevent dust and water. The outer shell is equipped with an automatically opening and closing baffle and a dustproof air curtain, which is conducive to dust and water prevention;

[0061] 3. The present invention adopts a solution combining a video camera and a still camera, and uses different acquisition and exposure strategies to respectively collect image and video information, thus better assisting workers in fault inspection;

[0062] 4. The system of the present invention can effectively link the detection results with the belt position, and can display the existing faults and current fault locations of the entire conveyor belt in real time, link the historical records with belt replacement information, and display the fault and location information that occurred during the current belt life cycle, providing a basis for the owner to carry out maintenance.

[0063] Other features and advantages of the present invention will be described in the following description, and in part will become apparent from the description, or will be understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures pointed out in the description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0064] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following is a brief introduction to the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0065] Figure 1 A schematic structural diagram of a belt fault detection device according to the present invention is shown;

[0066] Figure 2a shows the external structure diagram of the fault detection module of the present invention;

[0067] Figure 2b A diagram showing the position of a camera in a fault detection module of the present invention;

[0068] Figure 3 shows a structural diagram of the sensor module of the present invention;

[0069] Figure 4 A diagram showing the position of the belt fault detection device and the belt of the present invention is shown;

[0070] Figure 5 A line laser simulation diagram of the laser transmitter of the present invention is shown;

[0071] Figure 6 A true diagram of the line laser of the laser transmitter of the present invention is shown;

[0072] Figure 7 An over-exposed image of the line laser true image of the present invention is shown;

[0073] Figure 8 A schematic diagram showing the belt edge tearing of the present invention is shown;

[0074] Figure 9 A schematic diagram of the belt pits of the present invention is shown;

[0075] Figure 10 Shows a severe longitudinal tear failure diagram of the belt of the present invention;

[0076] Figure 11 A diagram showing a common longitudinal tear failure of the belt of the present invention is shown;

[0077] Figure 12 A coordinate diagram showing a belt of the present invention;

[0078] Figure 13 A structural diagram of a belt fault detection system of the present invention is shown;

[0079] Figure 14 Shown is a workflow diagram of the system of the present invention;

[0080] Figure 15 The figure shows the positional relationship between the system of the present invention and the belt.

[0081] In the figure: 1. Dustproof shell; 101. Horizontal section; 102. Vertical section; 103. Shooting hole; 104. Glass layer; 105. Air curtain slot; 106. Air inlet pipe; 107. Air guide pipe; 2. Camera; 3. Box; 4. Bellows; 401. Fan blade; 402. Drive shaft; 5. First dustproof cover; 6. Second dustproof cover; 7. Laser hole; 8. Base plate; 9. Protective shell; 10. Adjustment bracket; 11. Camera; 12. Laser emitter; 13. Conveyor roller; 14. Hall sensor; 15. Magnet. DETAILED DESCRIPTION

[0082] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts shall fall within the scope of protection of the present invention.

[0083] A belt fault detection device includes a sensor module and a fault detection module, wherein Figure 1As shown, the fault detection module includes a dustproof housing 1, a camera 2 and a laser emitter 12; wherein the camera 2 and the laser emitter 12 are installed on the bottom plate of the dustproof housing 1, the laser emitter 12 is used to emit laser to the belt, and the camera 2 is used to shoot the laser irradiated on the belt.

[0084] It should be noted that, combined with Figure 4 It can be seen that the belt fault detection device is located on the lower side of the belt, and the laser emitter 12 emits laser vertically toward the bottom of the belt. At the same time, the camera 2 shoots the laser on the belt diagonally upward to perform laser triangulation. In addition, the camera 2 uses a high-precision line laser and an industrial camera equipped with an ultra-wide-angle lens, which can enable a single device to cover a larger belt width, and can identify and detect faults through a smart recognition algorithm.

[0085] Furthermore, if Figure 3 As shown, the sensor module is used to detect the signal when the belt is running, and includes a conveyor roller 13, a Hall sensor 14 and a magnet 15; the conveyor roller 13 is used to support and convey the belt; the magnet 15 is installed on the end face of the conveyor roller 13, and the Hall sensor 14 is located on one side of the conveyor roller 13 for sensing the magnet 15.

[0086] It should be noted that when the Hall sensor 14 approaches the magnet 15, the Hall sensor 14 returns a signal of 1, and when the Hall sensor 14 moves away from the magnet 15, the signal returned is 0. Thus, when the conveyor roller 13 rotates, the return signal from the Hall sensor 14 is a series of pulse signals. By calculating the pulse signals and combining them with the diameter of the conveyor roller 13, the speed and start / stop signals of the conveyor roller 13 can be calculated. By placing two or more Hall sensors 14 on the conveyor roller 13 near the detection system, it is possible to accurately obtain the speed information and position information of the belt near the installation location. At the same time, multiple Hall sensors 14 can be cross-verified to ensure that the speed detection system is not working properly.

[0087] Further, in Figure 1 and Figure 2a In the figure, the dustproof shell 1 is L-shaped, including a horizontal section 101 and a vertical section 102, and the vertical section 102 is installed at one end of the horizontal section 101, and the two are connected to each other. The camera 2 and the laser emitter 12 are both installed on the horizontal section 101, and a shooting hole 103 is provided on a surface of the vertical section 102 facing the horizontal section 101. The lens of the camera 2 faces the shooting hole 103, which is convenient for capturing the laser on the belt; a glass layer 104 is also installed on the surface of the shooting hole 103, and an air curtain groove 105 is opened in the glass layer 104. The air curtain groove 105 is provided with an air outlet, and the direction of the air outlet is the same as that of the shooting hole 103.

[0088] It should be noted that if Figure 2bAs shown, the belt fault detection device can also be provided with a camera 11, which is installed in the horizontal section 101, specifically on one side of the camera 2, and the lens of the camera 11 faces the shooting hole 103, for recording and storing the laser irradiated on the belt.

[0089] Furthermore, an adjustment bracket 10 is installed at the bottom of the camera 2 . The adjustment bracket 10 is installed on the horizontal section 101 . The adjustment bracket 10 is used to adjust the shooting angle of the camera 2 .

[0090] It should be noted that the camera 11 also needs to be equipped with an adjustment bracket 10 to control the angle.

[0091] Furthermore, a box body 3 is installed on the top of the vertical section 102, and a damper structure is installed inside the box body 3. The damper structure includes a first dust cover plate 5 that is rotatably arranged, and the first dust cover plate 5 is used to cover the shooting hole 103; in addition, the damper structure includes a bellows 4, a plurality of fan blades 401 and a transmission shaft 402; the fan blades 401 are installed on the transmission shaft 402, and the transmission shaft 402 is rotatably connected to the bellows 4; both ends of the transmission shaft 402 extend to the outside of the bellows 4 and are fixedly connected to the first dust cover plate 5. The bellows 4 is also connected to an air duct 107, which is used to introduce air flow into the bellows 4. The bellows 4 is also connected to the air curtain groove 105.

[0092] It should be noted that the airflow enters the box 3 and then enters the damper structure. The airflow drives the fan blade 401 to rotate, thereby rotating the transmission shaft 402. The transmission shaft 402 then drives the first dust cover 5 to open. The first dust cover 5 opens under the action of wind and can generate a protective air curtain at the same time to prevent dust from falling onto the camera 2 and the camera 11. At this time, the camera 2 and the camera 11 can work.

[0093] Furthermore, if Figure 1 As shown, a laser hole 7 is opened on the surface of the horizontal section 101, and the laser emitter 12 emits laser through the laser hole 7; in addition, a base plate 8 is also installed on the surface of the horizontal section 101, and the base plate 8 is located around the laser hole 7. The base plate 8 is hinged with a second dust cover 6, and the second dust cover 6 is used to cover the laser hole 7; in addition, there is a protective shell 9 outside the laser emitter 12, and the air guide tube 107 is also connected to the protective shell 9.

[0094] It should be noted that the function of the second dust cover 6 is to prevent dust from entering the laser hole 7 and to prevent dust from falling on the laser emitter 12. When working, the second dust cover 6 is opened, and then the laser of the laser emitter 12 can be emitted through the laser hole 7. The second dust cover 6 can be closed when idle; specifically, the airflow of the air duct 107 can be blown out through the laser hole 7, and the second dust cover 6 is opened by wind force, and the air duct 107 is connected to the air inlet pipe 106, and the airflow can enter the air duct 107 through the air inlet pipe 106.

[0095] like Figure 5 As shown, the images captured by camera 2 or camera 11 primarily observe the morphological characteristics of the laser line streaks for subsequent analysis. Due to the narrow installation location in this project, the laser brightness uniformity across the measurement surface is relatively poor. This results in conventional methods for extracting laser line color information being ineffective, resulting in underexposure at the edges and overexposure in the center.

[0096] like Figure 6 As shown in the figure, the system uses a green high-precision line laser with a wavelength of 532mm as the light source and uses a 5-megapixel high-speed industrial camera to capture the image of the belt with the laser mark. Figure 7 As shown, an overexposed image with all three RGB channels at 255 is clearly visible in the middle area. Specifically, an overexposed image with all three RGB channels at 255 appears at coordinates 793, 644, and 41, 255, and 42 at coordinates 842, 666. The present invention uses a method of fusing color features and multiple verifications of brightness information to perform line laser extraction. By combining the color features with the brightness channel linear features for comprehensive judgment, the mask at the location of the laser line can be effectively extracted. To increase the detection and extraction speed, the system uses a method of manually pre-marking the mask area. After verification, the system's detection time for each frame of image is less than 20ms.

[0097] like Figures 8-11 As shown in Figure 2, when the fault image is collected, different fault types will cause different changes in the line laser characteristics, among which Figure 8 The failure is the belt edge tearing off, Figure 9 The fault is that the belt has pits. Figure 10 The fault is that the belt is severely torn. Figure 11 The most common fault is belt tearing.

[0098] A system using a belt fault detection device, such as Figure 13 As shown, it includes a control room, a distribution box, a fault detection device, a sensor module and an alarm module; wherein the fault detection device is used for image signals and sends the image signals to the distribution box, and the image signals are line laser images; the sensor module is used to detect the pulse signals of the belt and send them to the distribution box; the distribution box is used to send the image signals and pulse signals to the control room, and is also used to send alarm signals to the alarm module; the control room is used to analyze the image signals and determine the fault of the image, and combine the pulse signals of the belt to judge the current location information of the fault and send an alarm signal to the distribution box.

[0099] It should be noted that this system utilizes the principle of line laser triangulation for measurement. Installed between the upper and lower conveyor belts, it uses a wide-angle linear laser to project light onto the belt, while an area array industrial camera captures images. The image signal is transmitted via a network cable to the distribution box. From there, it passes through a second optical terminal within the distribution box and is then transmitted to the control room via optical fiber for analysis. The PLC in the distribution box also collects the conveyor belt's operating signals and transmits them to the control room computer. The control room computer analyzes the line laser image for any faults and, combined with the conveyor belt's pulse signals, determines the fault's current location and sends an alarm to the on-site personnel.

[0100] like Figure 12 As shown in the figure, the system automatically extracts the fault location and fault severity information by analyzing the change information of the laser stripes. The system's detection scheme is mainly divided into the following steps:

[0101] The laser line image is processed using the corresponding multi-scale Hessian matrix to obtain the main direction of the gradient feature after Hessian filtering. The tangent and normal directions of the laser line center point at each position are extracted. The laser line eigenvalues ​​are extracted. Since each point on the x-axis corresponds to a unique laser point, data dimensionality reduction can be performed to calculate the curve of each eigenvalue in the x-direction of the belt. By analyzing the changes in eigenvalues, the fault location is extracted. After detecting the fault in the image, the actual tear length and width are calculated based on parameters such as the fault location on the image, the current belt speed, and the number of frames the fault lasted. The results are displayed in a table, and the video information of the network video recorder at that time is saved.

[0102] Further, in Figure 13 The central control room includes a computer and a first optical terminal, and the computer is connected to the first optical terminal; the distribution box includes a second optical terminal, a PLC programmable controller and a power supply, and the second optical terminal is connected to the PLC, and the PLC is connected to the sensor module and the alarm module through the RS485 interface; the second optical terminal is also connected to the first optical terminal; the power supply is connected to the fault detection device for powering the fault detection device; the second optical terminal is also connected to the fault detection device for transmitting image signals; in addition, the sensor module includes a speed sensor and a position sensor; the speed sensor and the position sensor are both connected to the PLC.

[0103] It should be noted that the first optical terminal and the second optical terminal are connected via optical fiber, the second optical terminal and the fault detection device are connected via a network cable, and the PLC and the sensor module are connected via an RS485 interface.

[0104] like Figure 14 As shown, the process of the system of the present invention when working is as follows:

[0105] First, the fault detection device collects the image signal of the laser on the belt, and then sends the image signal to the first optical terminal through the second optical terminal in the distribution box, and finally reaches the computer;

[0106] The computer analyzes the image signal, extracts the laser line, and then detects the laser line. If the laser line indicates no fault, the list is updated; if the laser line indicates a fault, the following steps are performed:

[0107] 1. Check whether there is any fault in this frame image. If so, record it as "fault in detection" and then record the running position of the belt;

[0108] 1.1. Determine whether this frame image is a serious fault. If so, stop the machine and alarm. If not, update the list.

[0109] 2. If there is no fault in this frame, determine whether the fault is recorded as "fault in detection";

[0110] 2.1. If yes, update the fault to "Detected Faults", clear the corresponding "Detecting Faults", and finally update the list;

[0111] After updating the list, the faults one turn earlier are deleted according to the running position of the belt, and finally the fault data is updated on the computer display interface in the control room. When querying the fault, the system calculates the actual position of the fault on the belt conveyor at that moment by counting the accumulated pulses of the speed measuring device.

[0112] A fault handling method, applied to a conveyor belt fault detection device, comprises the following steps:

[0113] Obtaining laser profile information on the belt surface;

[0114] Determine the fault type based on laser profile information;

[0115] If the fault type is the first type (such as belt tearing), an alarm will be issued and a shutdown signal will be sent;

[0116] If the fault type is the second type (such as a pit), the belt fault position is located and recorded.

[0117] It should be noted that the present invention performs the following specific operations when processing image failures:

[0118] When the system detects that the belt is started (i.e. the speed and pulse signal are not 0), the damper mechanism starts to work, the damper is opened, and the laser is irradiated on the surface of the lower belt to form a surface contour line, which is collected into the system through camera 2 and photographed and stored by camera 11.

[0119] The length of a longitudinal tear can be calculated as: number of frames with the fault at the same location / frame rate * conveyor belt speed. Therefore, manually setting thresholds allows the control system to classify the severity of a fault and determine subsequent system actions based on the severity level. For example, in the event of a severe tear, the system will alert the central control room and immediately send an emergency shutdown signal. However, for a moderate tear, a fault record and maintenance reminder will be generated in the software.

[0120] For non-emergency faults, which do not require emergency shutdown to troubleshoot, the system is designed to locate and remind the fault. The positioning solution is to first measure the number of pulses of the Hall sensor 14 when the conveyor belt system travels one cycle. Combined with the diameter of the installed conveyor roller 13, the total distance D of the belt cycle can be calculated. During calibration, by setting marking points, the distance from one end of the belt is manually measured. Since the lengths of the upper and lower belts are equal, the distance to the other end can be calculated. When a fault is detected, the pulse position corresponding to each fault midpoint is recorded. The location information of the fault at that time can be accurately marked during maintenance to assist maintenance.

[0121] like Figure 15 As shown in the figure, assuming that the conveyor roller 13 of the belt to be tested rotates clockwise and the upper belt moves to the right, the diameter of the conveyor roller 13 is known to be d, the number of pulses measured per belt cycle is N, the pulse position of the fault to be inspected is M, and the pulse position at the time of inspection is P, then the current fault distance dist can be calculated as:

[0122] ;

[0123] Where Remain represents the remainder.

[0124] The system output location is written as:

[0125] When dist At l2, the fault is located at the distance dist from the upper belt on the right side;

[0126] when When the fault is located on the right side of the conveyor belt fault detection device Position the lower belt;

[0127] when When the fault is located on the left side of the conveyor belt fault detection device Position the belt below;

[0128] when When , the fault is located at the upper belt at the D-dist position on the left side of the conveyor belt fault detection device;

[0129] The system also effectively prevents duplicate fault alarms based on the fault pulse location and distance. The system's shielding principle is: when two faults are close in image location and the difference in pulse position is close to the total pulse number N, the system identifies them as the same fault and updates them to the fault log. The fault log in the software interface only displays faults detected within the past week.

[0130] Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A belt fault detection device for measuring belt fault types using a line laser triangulation method, characterized in that: It includes a sensor module, a fault detection module and a damper structure; The fault detection module comprises a dustproof housing (1), a camera (2) and a laser emitter (12); The camera (2) and the laser emitter (12) are mounted on the bottom plate of the dustproof housing (1); The laser emitter (12) is a wide-angle linear laser, used for emitting laser light toward the belt; The camera (2) is used to photograph the laser irradiated on the belt; The sensor module is used to detect the signal when the belt is running; A shooting hole (103) is provided on one surface of the dustproof housing (1), a glass layer (104) is further installed on the surface of the shooting hole (103), an air curtain groove (105) is provided in the glass layer (104), and an air outlet is provided in the air curtain groove (105), and the direction of the air outlet is the same as that of the shooting hole (103); A box body (3) is installed on the top of the dustproof housing (1), and the damper structure is installed inside the box body (3); The damper structure comprises a bellows (4), a plurality of blades (401), a transmission shaft (402) and a first dust cover (5); the blades (401) are mounted on the transmission shaft (402), and the transmission shaft (402) is rotatably connected to the bellows (4); both ends of the transmission shaft (402) extend to the outside of the bellows (4) and are fixedly connected to the first dust cover (5), and the first dust cover (5) is used to shield the shooting hole (103); The sensor module includes a conveying roller (13), a Hall sensor (14) and a magnet (15); The conveying roller (13) is used to support and convey the belt, the magnet (15) is installed on the end surface of the conveying roller (13), and the Hall sensor (14) is located on one side of the conveying roller (13) and is used to sense the magnet (15) and detect the pulse signal.

2. A belt fault detection device according to claim 1, characterized in that: The dustproof housing (1) is an L-shaped structure, comprising a horizontal section (101) and a vertical section (102), wherein the vertical section (102) is arranged at one end of the horizontal section (101); The camera (2) and the laser emitter (12) are both installed on the horizontal section (101); The shooting hole (103) is provided on a surface of the vertical section (102) facing the horizontal section (101); The lens of the camera (2) faces the shooting hole (103).

3. A belt fault detection device according to claim 2, characterized in that: An adjustment bracket (10) is installed at the bottom of the camera (2), and the adjustment bracket (10) is installed on the horizontal section (101); The adjustment bracket (10) is used to adjust the shooting angle of the camera (2).

4. A belt fault detection device according to claim 2, characterized in that: The box (3) is installed on the top of the vertical section (102).

5. A belt fault detection device according to claim 2, characterized in that: The bellows (4) is also connected to an air guide pipe (107), and the air guide pipe (107) is used to introduce air flow into the bellows (4); The wind box (4) is also in communication with the air curtain groove (105).

6. A belt fault detection device according to claim 5, characterized in that: A laser hole (7) is provided on the surface of the horizontal section (101), and the laser emitter (12) emits laser light through the laser hole (7).

7. A belt fault detection device according to claim 6, characterized in that: A substrate (8) is also mounted on the surface of the horizontal section (101), and the substrate (8) is located around the laser hole (7); The base plate (8) is rotatably connected to a second dust cover plate (6); The second dustproof cover (6) is used to shield the laser hole (7).

8. A belt fault detection device according to claim 7, characterized in that: It also includes a protective shell (9), wherein the protective shell (9) is wrapped around the outside of the laser emitter (12); The protective housing (9) is also in communication with the laser hole (7) and the air guide tube (107).

9. A belt fault detection device according to claim 2, characterized in that: The fault detection module further comprises a camera (11), wherein the camera (11) is installed on the horizontal section (101); The lens of the camera (11) faces the shooting hole (103) and is used to record and store the laser light irradiated on the belt.

10. A belt fault detection system, characterized in that: A belt fault detection device comprising any one of claims 1 to 9; The system also includes a control room, a distribution box and an alarm module; The fault detection device is used to collect the image signal of the belt and send the image signal to the distribution box, wherein the image signal is a line laser image; The sensor module is used to detect the pulse signal of the belt and send it to the distribution box; The distribution box is used to send image signals and pulse signals to the control room, and is also used to send alarm signals to the alarm module; The control room is used to analyze the image signal and determine the fault of the image, combine the pulse signal of the belt, judge the current location information of the fault, and send an alarm signal to the distribution box.

11. A belt fault detection system according to claim 10, characterized in that: The control room includes a computer and a first optical terminal, and the computer is connected to the first optical terminal; The distribution box includes a second optical terminal, a PLC and a power supply, the second optical terminal is connected to the PLC, and the PLC is connected to the sensor module and the alarm module via an RS485 interface; The second optical terminal is also connected to the first optical terminal; The power supply is connected to the fault detection device and is used to supply power to the fault detection device; The second optical terminal is also connected to the fault detection device for transmitting image signals.

12. A fault handling method, characterized in that: The method is applied to the belt fault detection device according to any one of claims 1 to 9, comprising the following steps: Obtaining laser profile information on the belt surface; Determine the fault type based on the laser profile information; If the fault type is the first type, an alarm is issued and a shutdown signal is sent; If the fault type is the second type, the belt fault position is located and recorded.

13. A fault handling method according to claim 12, characterized in that: The first type includes belt tears; the second type includes pits.

14. A fault handling method according to claim 12, characterized in that: Locate and record the belt fault position. The calculation formula is as follows: ； When dist< l2, the fault is located at the distance dist from the upper belt on the right side; when When the fault is located on the right side of the conveyor belt fault detection device Position the lower belt; when When the fault is located on the left side of the conveyor belt fault detection device Position the belt below; when When , the fault is located at the upper belt at the D-dist position on the left side of the conveyor belt fault detection device; Where Remain represents the remainder; d is the diameter of the conveyor roller (13); N is the number of pulses measured per belt revolution; M is the pulse position where the fault to be inspected is located; P is the pulse position at the inspection time; dist is the current fault distance; l 1 and l 2 is the distance between the conveyor belt fault detection device and the two ends of the belt; D is the total distance of one belt cycle.

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