A pipe belt machine inspection device and an inspection method

Abstract

The application discloses a pipe belt machine inspection device and an inspection method, wherein an inspection track is arranged above the pipe belt machine, and an inspection carrier is arranged in the inspection track; the inspection device comprises an inspection host and a driven unit; the driven unit is arranged in the inspection track; the inspection host is arranged in an inspection channel on the two sides of the pipe belt machine; and the inspection track is connected with an external driving unit to drive the inspection carrier to flow. The driving unit of the external inspection device is used, so that the built-in battery of the inspection device does not need to supply power to the driving unit which accounts for most of the power consumption, thereby greatly improving the endurance of the inspection device; the driving force of the inspection device fully utilizes the force transmission of the pipe belt machine driving device, realizes energy saving, and according to the characteristics of the driving carrier of the inspection device, the inspection device has the functions of dust suppression and fire extinguishing along the pipe belt machine.

Description

Technical Field

[0001] This invention relates to the field of material conveying technology, and in particular to a device and method for inspecting conveyor belt systems. Background Technology

[0002] In recent years, in the field of material conveying, belt conveyors have achieved significant development due to their advantages such as long distance, large load capacity, high speed, and minimal environmental impact. However, during long-term, long-distance use, belt conveyors inevitably experience malfunctions such as belt twisting, idler wear, and belt overheating, affecting their normal operation and lifespan. Manual inspection is time-consuming and labor-intensive, making the use of inspection devices (inspection robots) essential.

[0003] Currently, the inspection devices for conveyor belts generally adopt a fixed guide rail type, with the inspection device suspended below the guide rail. The drive unit of the inspection device moves it forward on the guide rail at a certain speed, and the main unit of the inspection device dynamically monitors the equipment and environment along the line, thereby achieving the purpose of inspecting the conveyor belt during standby.

[0004] For conveyor belt systems used in long-distance material transport, considering the excessive voltage drop along the power cables that could affect normal equipment operation, cable-powered inspection devices are unsuitable. Therefore, battery-powered wireless inspection methods are commonly used. For example, patent CN 216036925 U, entitled "An Automatic Detection Device for the Operating Status of Long-Distance Conveying Equipment," proposes a conveyor belt inspection device. This device utilizes a drive unit that travels on a fixed guide rail, with detection units suspended on both sides to inspect the equipment on both sides of the conveyor belt. The drive unit is powered by a built-in battery, and multiple charging points are set along the fixed guide rail. After the inspection device stops at a charging point, it charges the battery at regular intervals. Once charging is complete, it continues to travel on the track to complete the inspection tasks. This type of conveyor belt inspection device typically integrates the battery, inspection host, and drive unit into one unit. During long-distance movement, the battery's endurance inevitably becomes an issue. Existing methods for improving the battery life of inspection devices often involve setting up multiple charging stations along the conveyor belt. When the inspection device reaches a charging station, it stops to charge or has its battery replaced. However, this requires the construction of multiple charging stations or battery replacement devices along the route, resulting in significant economic costs. The stopping process also affects inspection efficiency to some extent, making it particularly unsuitable for applications requiring efficient and non-stop inspection.

[0005] The total weight of the conveyor belt inspection device can reach 30-50KG. According to existing relevant test data, more than 80% of the power consumption of the built-in battery comes from the drive unit. In view of the above, it is necessary to solve the energy consumption problem of the drive unit of the inspection device and significantly improve the endurance of the inspection device.

[0006] Meanwhile, as a type of belt conveyor, the tubular belt conveyor requires the belt to rub against the idlers for extended periods due to its conveying characteristics. This inevitably causes surface heating of both the belt and idlers, which reduces their service life. Furthermore, during the conveying of fine powdery materials, some material inevitably leaks out, causing dust pollution. Therefore, from the perspectives of extending equipment lifespan and environmental protection, there is a need for cooling and dust suppression along the conveyor line.

[0007] Furthermore, due to the complexity of materials transported by conveyor belts, especially fine, powdery, flammable materials, friction inevitably occurs between the conveyor belt and idlers, and between the conveyor belt and the material during long-distance, high-speed transport. This friction generates static electricity or heat, which can easily cause spontaneous combustion of the belt and material, creating safety hazards such as smoke or fire along the conveyor belt line. Therefore, fire protection along the line is essential. Currently, the industry generally uses water-based fire protection, installing fire pipes, detection devices, and sprinkler systems along the conveyor belt line. Through the coordinated control of the detection devices and sprinkler systems, fire protection along the line is achieved, and the spray can also serve the purpose of cooling and dust suppression. For conveyor belts used for long-distance material transport, this fire protection method inevitably results in huge fire protection investment, such as increasing the selection of fire pipes and related cables for fire protection devices along the line. It also faces problems such as insufficient water pressure over long distances and large cable investment, making it technically and economically infeasible. Summary of the Invention

[0008] The purpose of this invention is to provide a conveyor belt inspection device and method. By changing the drive unit of the inspection device, the endurance of the inspection device is greatly improved, and the inspection device is equipped with bidirectional and dual-channel inspection capabilities, reducing energy consumption. At the same time, the inspection device is equipped with cooling, dust suppression and fire protection functions along the conveyor belt.

[0009] The technical problem solved by this invention can be achieved by the following technical solutions:

[0010] A conveyor belt inspection device includes a conveyor belt and a conveyor belt. The conveyor belt is equipped with an idler frame. The device is characterized in that: an inspection track is provided above the idler frame, inspection channels are provided on both sides of the conveyor belt, an inspection device is movably mounted on the inspection track, and an external drive unit is provided at one end of the inspection track.

[0011] The inspection track is an open water tank with a closed bottom, and its path is the same as the layout direction of the conveyor belt. The inspection track is divided into two layers by a partition: an upper drive layer and a lower return layer, both of which are equipped with flowing inspection carriers. The drive layer and the return layer are connected at the head and tail sections of the conveyor belt, and the inspection carriers circulate within the inspection track.

[0012] The inspection device includes two inspection hosts and two driven units. The inspection hosts are located in the inspection channels on both sides of the conveyor belt, and serve as the control hosts for the inspection device. Each host has a built-in control system that is wirelessly connected to an external inspection server. The driven units are located in the middle of the inspection device, within the drive layer. Each driven unit has a battery unit above it, and both are connected to the control system of the inspection hosts. The driven units are connected to the two inspection hosts via side arms.

[0013] The external drive unit includes a conveyor belt drive device, a transmission shaft, a speed change device, and an inspection carrier drive device. The conveyor belt drive device is connected to the inspection carrier drive device through the transmission shaft and the speed change device, and drives the inspection carrier drive device to drive the inspection carrier to flow.

[0014] Furthermore, the top of both sides of the water tank of the inspection track is provided with a side track groove, which is an open U-shaped groove; a support device is provided below the two side arms of the inspection device, and the two support devices are slidably arranged in the side track grooves.

[0015] Furthermore, the support device includes a driven wheel, an elastic link, and a brake lever; the driven wheel is placed in the side track groove and has a built-in speed measuring unit that is connected to the control system of the inspection host; the driven wheel has a wheel frame that is connected to the lower end of the elastic link, and the upper end of the elastic link is connected to the side arm; the elastic link has an automatic extension and retraction function and has a built-in stroke sensor that is connected to the control system of the inspection host; there are two brake levers installed on both sides of the driven wheel.

[0016] Furthermore, the inspection track is equipped with a carrier replenishment unit. The stroke sensor of the elastic link of the support device outputs stroke data to determine the liquid level status and feeds it back to the inspection host. When the liquid level of the inspection carrier in the inspection track is low, the inspection host remotely issues a carrier replenishment command to control the start and stop of the replenishment unit of the inspection track.

[0017] Furthermore, the inspection device is equipped with an extraction unit, including an extraction module and a steering nozzle, both of which are connected to the control system of the inspection host. The extraction module is equipped with a pump body and pipelines. There are two sets of steering nozzles, which are respectively installed at the lower part of the inspection host and connected to the pipelines of the extraction module. The pump body extracts the inspection carrier from the drive layer and delivers it to the steering nozzles through the pipelines.

[0018] Furthermore, the pipeline is composed of a main pipeline and two branch pipelines, and the steering module is installed at the branch point of the pipeline to control the flow direction of the inspection carrier.

[0019] Furthermore, the transmission device is connected to the conveyor belt drive device and the inspection carrier drive device through transmission shafts at both ends, and the transmission device has a built-in forward gear D, neutral gear N and reverse gear R.

[0020] An inspection method based on the aforementioned conveyor belt inspection device includes an inspection working mode, an inspection cooling and dust suppression function, a fire-fighting function, and an inspection carrier replenishment function. The specific steps are as follows:

[0021] The inspection device is placed in the drive layer of the inspection track, and the inspection track is pre-filled with inspection carrier. When the stroke sensor of the elastic link of the inspection device detects that the liquid level of the inspection carrier is normal, the inspection host remotely sends a wireless signal to the external inspection server, namely the inspection ready signal. The external inspection server starts the inspection working mode upon receiving this signal.

[0022] In the inspection mode, the external inspection server remotely sends a start signal to the external drive unit. After receiving the start signal, the transmission device in the external drive unit switches from neutral to forward or reverse gear. The conveyor belt drive device drives the inspection carrier drive device to generate fluid driving force, causing the inspection carrier to start flowing in one direction, thereby driving the inspection device to operate.

[0023] Furthermore, during the operation of the inspection device, the speed measuring unit supporting the driven wheel provides real-time speed feedback signals, which are then sent to a remote external inspection server via the inspection host. When the external inspection server needs to adjust the inspection speed based on the actual feedback speed, it sends a speed adjustment signal to the speed change device in the external drive unit. The speed change device switches between different speed gears to adjust the speed of the inspection carrier drive device based on the received speed adjustment signal, thereby changing the flow velocity of the inspection carrier and thus adjusting the travel speed of the inspection device.

[0024] Furthermore, in the inspection working mode, the external inspection server synchronously activates the inspection cooling and dust suppression function; after the inspection cooling and dust suppression function is activated, the extraction unit of the inspection device is triggered to perform atomized spraying, and the inspection device can execute the cooling and dust suppression command for the equipment along the pipeline without stopping.

[0025] Furthermore, in the inspection mode, the external inspection server simultaneously activates the inspection and fire-fighting function; after the inspection and fire-fighting function is activated, the inspection host of the inspection device determines the fire hazard that occurs along the conveyor belt, and simultaneously triggers the extraction unit and brake lever of the inspection device to execute the stop fire-fighting command of the inspection device; after the fire hazard is dealt with, the inspection host resets the extraction unit and brake lever, and the inspection device continues to move forward.

[0026] Furthermore, in the inspection mode, the external inspection server simultaneously activates the inspection carrier replenishment function. After the inspection carrier replenishment function is activated, the liquid level status of the inspection carrier in the inspection track is determined based on the extension stroke feedback from the stroke sensor of the elastic link of the inspection device. When the liquid level of the inspection carrier is too low, the inspection host sends a liquid level signal and a replenishment request command to the external inspection server. The external inspection server calculates the replenishment amount and replenishment time based on the carrier liquid level data and sends the replenishment data to the replenishment unit of the inspection track. The replenishment unit runs for a specific time based on the replenishment data to complete the replenishment of the inspection carrier.

[0027] Furthermore, the inspection host of the inspection device has a built-in positioning module, which can send the specific location information of the inspection device within the inspection track to the inspection server in real time. When the inspection device moves and approaches the end of the inspection track, the inspection server calculates the inertial distance and hysteresis time based on the current inspection speed of the inspection device and the distance to the end of the track, and sends a reversal command to the external drive unit in advance. After receiving the reversal command, the external drive unit stops and runs in reverse. During the hysteresis time, the inspection carrier does not immediately change direction, and the inspection device continues to move towards the end of the inspection track due to inertia. When the inspection device reaches the end of the track, the hysteresis of the inspection carrier has disappeared, and the inspection carrier flows in reverse at normal speed, so that the inspection device can complete the inspection reversal without stopping and continue to move in reverse at normal inspection speed.

[0028] Compared with the prior art, the present invention has the following advantages:

[0029] 1. This invention applies fluid drive technology to a conveyor belt inspection device. A fluid drive channel is installed on the existing conveyor belt truss structure, utilizing fluid buoyancy to reduce the operating resistance of the inspection device. By controlling and changing the drive force supply method of the inspection device, the built-in battery of the inspection device does not need to supply power to the drive unit, which accounts for the majority of the power consumption, thus significantly improving the endurance of the inspection device. Furthermore, it satisfies dual-channel inspection along the left and right sides of the conveyor belt, greatly improving inspection efficiency.

[0030] 2. This invention incorporates an extraction unit within the inspection device, utilizing the flow, atomization, and fire extinguishing characteristics of the driving carrier. Combined with the detection and linkage functions of the inspection device, it provides cooling, dust suppression, and firefighting capabilities. This eliminates the need for additional cooling, dust suppression, and firefighting devices along the conveyor belt line, solving the problems of cooling and dust suppression related to belt / roller heating and material dust generation, as well as firefighting in case of fire, along long-distance conveyor belt lines. Simultaneously, the driving carrier of the inspection device adopts a trough structure for collection and circulation, allowing for natural replenishment using rainwater. Furthermore, it eliminates the need to consider fire water pressure along the conveyor belt line, enhancing its engineering applicability. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the installation of the inspection device of the present invention along the pipeline conveyor.

[0032] Figure 2 This is a structural diagram of the inspection device and inspection track.

[0033] Figure 3 This is a schematic diagram of the support structure for the inspection device.

[0034] Figure 4 This is a schematic diagram of the fluid-driven connection for inspection.

[0035] Figure 5 This is a schematic diagram of the external drive unit.

[0036] Figure 6 This is a schematic diagram of the inspection method.

[0037] In the diagram, 1-conveyor belt, 2-belt conveyor, 21-idler frame, 22-inspection channel;

[0038] 3-Inspection track, 31-Drive layer, 32-Return layer, 33-Inspection carrier, 34-Side track groove, 35-Carrier replenishment unit;

[0039] 4-Inspection device, 41-Inspection host, 42-Driven unit, 421-Battery unit, 43-Side arm, 44-Support device, 441-Support driven wheel, 442-Elastic linkage, 443-Brake lever, 444-Wheel frame, 45-Extraction unit, 451-Extraction module, 452-Steering module, 453-Steering nozzle;

[0040] 5-External drive unit, 51-Belt conveyor drive device, 52-Transmission coupling, 53-Speed ​​change device, 54-Inspection carrier drive device, 511-Drive motor, 512-First coupling, 513-Reducer, 514-Second coupling, 515-Drum. Detailed Implementation

[0041] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments, but the implementation of the present invention is not limited thereto.

[0042] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They 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" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. The terms "first position" and "second position" refer to two different positions.

[0043] The purpose of this invention is to provide an inspection device and method for conveyor belts, which can significantly improve the endurance of the inspection device and enable it to have functions such as cooling, dust suppression and fire fighting along the conveyor belt. Figures 1-6 This is a preferred embodiment of the present invention, as shown in the appendix. Figures 1-5 As shown, the inspection device of the present invention includes a conveyor belt 1, a conveyor belt machine 2, an inspection track 3, an inspection device 4, and an external drive unit 5. The conveyor belt machine 2 is provided with a roller frame 21, and inspection channels 22 are provided on both sides of the conveyor belt machine 2; the inspection track 3 is fixedly set above the roller frame 21, the inspection device 4 is movably installed on the inspection track 3, and an external drive unit 5 is provided at one end of the inspection track 3.

[0044] The inspection track 3 is an open water tank with a closed bottom and raised sides. It is installed using structural components above the conveyor roller frame, meaning the path of the inspection track 3 is the same as the layout direction of the conveyor 2. The inspection track 3 is divided into upper and lower layers by a partition, both containing flowing inspection carriers 33 (which can be liquid or other flowable substances such as water). The upper layer is the drive layer 31 of the inspection device 4, where the flow direction of the inspection carriers 33 is the same as the inspection direction, and the driven unit 42 of the inspection device 4 is placed in this layer. The lower layer is the return layer 32 of the inspection carriers, where the flow direction of the inspection carriers 33 is opposite to the inspection direction. The inspection carriers 33 in the drive layer 31 drive the inspection device 4 forward, and the inspection carriers 33 in the return layer 32 return to the inspection starting point. The drive layer 31 and the return layer 32 are separated along the conveyor 2, but connected at the beginning and end of the conveyor 2, thus realizing the circulation of the inspection carriers within the inspection track 3. The inspection carrier 33 flows within the inspection track 3, driven by the inspection carrier drive device 54 at one end of the inspection track (the conveyor drive end), generating fluid driving force to propel the inspection carrier 33 at a certain speed, thereby causing the inspection device 4 to move forward synchronously at a certain speed. Side track grooves 34, which are U-shaped grooves with upward openings, are also provided at the top of both sides of the water tank above the inspection track 3. The inspection track 3 is also equipped with a carrier replenishment unit 35 to replenish the carrier when the liquid level of the inspection carrier 33 is low.

[0045] The inspection device 4 employs a dual-sided inspection method, comprising two inspection hosts 41 and driven units 42. The inspection hosts 41 are located in the inspection channels 22 on both sides of the conveyor belt 2, serving as the control hosts for the inspection device 4. Structurally, they are integrated, with a built-in control system and various detection modules such as infrared, ultrasonic, visual recognition, and sound modules. They utilize non-contact detection, primarily detecting abnormal conditions along the conveyor belt 2, such as idler roller jamming or detachment, belt twisting or deviation, idler roller overheating, smoke, fire, and environmental data like temperature and humidity. The control system of the inspection host 41 is wirelessly connected to other parts of the inspection device 4, achieving local control through internally integrated circuit boards and microcontrollers. The control system of the inspection host 41 is also wirelessly connected to an external inspection server.

[0046] The driven unit 42 is located in the middle of the inspection device 4 and is placed in the drive layer 31 of the inspection track 3. The battery unit 421 of the inspection device is located above the driven unit 42. The driven unit 42 is connected to the two inspection hosts 41 through the two side arms 43, so that the inspection hosts 41 and the driven unit 42 move synchronously. Both the driven unit 42 and the battery unit 421 are connected to the control system of the inspection hosts 41. In order to ensure that the inspection device remains stable during the movement and avoids lateral tilting, support devices 44 are provided below the two side arms 43. The two support devices 44 are slidably installed in the side track grooves 34.

[0047] The support device 44 includes a driven wheel 441, an elastic connecting rod 442, and a brake lever 443, all of which are connected to the control system signal of the inspection host 41. The driven wheel 441 is placed in the side track groove 34 and has a built-in speed measuring unit (not shown in the figure). The speed measuring unit sends a speed signal to the inspection host 41, which calculates the current walking speed of the inspection device 4. The driven wheel 441 has a wheel frame 444 that is connected to the lower end of the elastic connecting rod 442, and the upper end of the elastic connecting rod 442 is connected to the side arm 43. The elastic link 442 has an automatic telescopic function and a built-in stroke sensor (not shown in the figure). It can calculate the telescopic stroke and send an analog electrical signal proportional to the stroke change to the control system. The stroke sensor is connected to the control system signal of the inspection host 41. The elastic link 442 can monitor the liquid level of the inspection carrier 33 on the drive layer 31 of the inspection track 3, preventing the driven unit 42 of the inspection device 4 from contacting the bottom of the drive layer 31 when the liquid level of the inspection carrier 33 is too low, and preventing the inspection carrier 33 from overflowing from the inspection track when the liquid level of the inspection carrier 33 is too high. When the liquid level of the inspection carrier 33 decreases, the elastic link 442 is affected by the weight of the inspection device 4 and compresses downward; when the liquid level of the inspection carrier 33 increases, the elastic link 442 is affected by the buoyancy of the inspection carrier 33 and expands upward. The stroke sensor of the elastic connecting rod 442 outputs stroke data to determine the liquid level status and feeds it back to the inspection host 41. The inspection host 41 then remotely issues a carrier replenishment command, adjusting and controlling the water replenishment volume through the start and stop time of the replenishment unit 35 of the inspection track 3, thereby ensuring that the liquid level of the inspection carrier 33 on the inspection track 3 is in a reasonable state. There are two brake levers 443, installed on both sides of the supporting driven wheel 441. They can be hydraulic push rod type elastic telescopic rods. When the inspection device 4 needs to be temporarily stopped, such as in the case of autonomous obstacle avoidance or fire fighting, the inspection host 41 controls the brake levers 443 to extend. The brake levers 443 make close contact with the groove wall of the side track groove 34 on the side of the inspection track to achieve the purpose of braking.

[0048] The inspection device 4 is also equipped with an extraction unit 45, including an extraction module 451, a steering module 452, and a steering nozzle 453, all of which are connected to the control system of the inspection host 41. The extraction module 451 is equipped with a pump body and pipelines (not shown in the figure). The pump body is connected to the drive layer 31, and the pipelines connect the pump body and the steering nozzles 453. There are two sets of steering nozzles 453, which are respectively set at the lower part of the two inspection hosts 41, avoiding the various detection modules of the inspection hosts 41 during installation. The pump body extracts the inspection carrier 33 from the drive layer 31 and outputs it to the steering nozzles 453 through the pipelines. The pipelines are composed of a main pipeline and two branch pipelines. The steering module 452 is set at the bifurcation of the pipeline and can be an electromagnetic reversing valve with two working valve positions, which can control the inspection carrier 33 to output to the left, right, or both pipelines. The steering nozzles 453 can be rotated to a certain angle according to the instructions of the inspection host 41 and can be set to atomization or spray mode.

[0049] The external drive unit 5 includes a conveyor belt drive device 51, a transmission shaft 52, a speed change device 53, and an inspection carrier drive device 54. The inspection carrier drive device 54 cannot generate driving force itself; instead, it is generated by the conveyor belt drive device 51. The conveyor belt drive device 51 includes a drive motor 511, a first coupling 512, a reducer 513, a second coupling 514, and a roller 515 connected in sequence, which is a common structure for conveyors. The conveyor belt drive device 51 is connected to the inspection carrier drive device 54 via the transmission shaft 52 and the speed change device 53 to drive the inspection carrier drive device 54. The transmission shaft 52 is coaxially connected to the conveyor belt drive device 51 via gear transmission.

[0050] To meet the requirements of bidirectional inspection, a speed change device 53 is installed between the conveyor belt drive unit 51 and the inspection carrier drive unit 54. The speed change device 53 connects the conveyor belt drive unit 51 and the inspection carrier drive unit 54 through transmission shafts 52 at both ends. The speed change device 53 has a forward gear (D), a neutral gear (N), and a reverse gear (R). When the inspection device needs to inspect forward, the speed change device 53 is switched to the forward gear (D), and the conveyor belt drive unit 51 drives the inspection carrier drive unit 54 to rotate forward, causing the inspection carrier to flow forward. When the inspection device needs to inspect backward, the speed change device 53 is switched to the reverse gear (R), and the conveyor belt drive unit 51 drives the inspection carrier drive unit 54 to rotate backward, causing the inspection carrier to flow backward. When the inspection device needs to stop, the speed change device 53 is switched to the neutral gear (N), disconnecting the mechanical connection between the conveyor belt drive unit 51 and the inspection carrier drive unit 54, causing the inspection carrier to stop flowing.

[0051] To meet the inspection requirements at different speeds, the transmission device 53 can have multiple forward and reverse gears, as shown in the attached diagram. Figure 3As shown, the forward gears are D1 to D3, and the reverse gears are R1 to R3. By controlling the transmission device 53 in different gears, multi-level speed regulation can be achieved. This embodiment only illustrates three gears (fast, medium, and slow), but the transmission device 53 is not limited to adding more gears.

[0052] An inspection method based on this inspection device includes an inspection working mode, inspection cooling and dust suppression functions, fire protection functions, and inspection carrier replenishment functions: the specific method is as follows:

[0053] The inspection device 4 is placed in the drive layer 31 of the inspection track 3, and the inspection carrier 33 is pre-filled into the inspection track 3. When the stroke sensor of the elastic connecting rod 442 of the inspection device 4 detects that the liquid level of the inspection carrier 33 is normal, the inspection host 41 remotely sends a wireless signal to the external inspection server, namely the inspection ready signal. The external inspection server can start the inspection working mode upon receiving this signal.

[0054] In the inspection mode, the external inspection server remotely sends a start signal to the external drive unit 5. Specifically, after receiving the start signal, the speed change device 53 in the external drive unit 5 switches from neutral to forward or reverse gear, causing the conveyor belt drive device 51 to drive the inspection carrier drive device 54 to generate fluid driving force, causing the inspection carrier 33 to start flowing in one direction, thereby driving the inspection device 4 to run.

[0055] During the operation of the inspection device 4, the speed measuring unit supporting the driven wheel 441 provides real-time speed feedback signals, which are then remotely transmitted to an external inspection server via the inspection host 41. When the external inspection server needs to adjust the inspection speed based on the actual feedback speed, it sends a speed adjustment signal to the speed change device 53 in the external drive unit 5. The speed change device 53, based on the received speed adjustment signal, switches between different speed gears to adjust the speed of the inspection carrier drive device 54, thereby changing the flow velocity of the inspection carrier 33 and thus adjusting the travel speed of the inspection device 4.

[0056] In the inspection mode, the external inspection server simultaneously activates three functions: inspection cooling and dust suppression, fire protection, and inspection carrier replenishment. After the inspection cooling and dust suppression function is activated, the extraction unit 45 of the inspection device 4 is triggered to perform atomized spraying. The inspection device 4 can execute the cooling and dust suppression command for the equipment along the conveyor belt 2 without stopping. After the inspection fire protection function is activated, the inspection host 41 of the inspection device 4 determines the fire hazard along the conveyor belt 2 and simultaneously triggers the extraction unit 45 and the brake lever 443 of the inspection device 4 to execute the stop fire protection command for the inspection device 4. After the fire hazard is dealt with, the inspection host 41 resets the extraction unit 45 and the brake lever 443, and the inspection device 4 continues to move forward.

[0057] After the inspection carrier replenishment function is activated, the liquid level status of the inspection carrier 33 in the inspection track 3 is determined based on the extension stroke feedback from the stroke sensor of the elastic connecting rod 442 of the inspection device 4. When the liquid level of the inspection carrier 33 is too low, the inspection host 41 sends a liquid level signal and a replenishment request command to the external inspection server. The external inspection server calculates the replenishment amount and replenishment time based on the carrier liquid level data and sends the replenishment data to the replenishment unit 35 of the inspection track 3. The replenishment unit 35 runs for a specific time according to the replenishment data to complete the replenishment of the inspection carrier 33.

[0058] The inspection device 4 needs to travel back and forth within the section between the beginning and end of the inspection track 3. Because the inspection carrier 33 is liquid, there is a lag. That is, after the inspection carrier 33 drives the inspection device 4 to work for a certain period of time, the inspection carrier 33 can start flowing at a certain speed from a standstill; after the inspection carrier 33 drives the inspection device 4 to change direction, it also takes a certain amount of time for the flow direction of the inspection carrier 33 to change from flowing to a standstill, and then to flowing in the opposite direction.

[0059] Based on the hysteresis characteristics of the inspection carrier 33, and to avoid the inspection device 4 from lingering for too long during the return journey and affecting inspection efficiency, this invention proposes an inertial hysteresis compensation method. The inspection host 41 of the inspection device 4 has a built-in positioning module that can send the specific position information of the inspection device 4 within the inspection track 3 to the inspection server in real time. When the inspection device 4 moves and approaches the end of the inspection track 3, the inspection server calculates the inertial distance and hysteresis time based on the current inspection speed of the inspection device 4 and the distance to the end of the track, and sends a reversal command to the external drive unit 5 in advance. After receiving the reversal command, the external drive unit 5 stops and runs in reverse. During the hysteresis time, the inspection carrier 33 does not immediately change direction, and the inspection device 4 continues to move towards the end of the inspection track 3 due to inertia. When the inspection device 3 reaches the end of the track, the sluggishness of the inspection carrier 33 has disappeared. The inspection carrier 33 flows in the opposite direction at the normal speed, so that the inspection device 4 can complete the inspection reversal without stopping and continue to move in the opposite direction at the normal inspection speed, thereby ensuring the smoothness and inspection efficiency of the inspection device 4 when reversing.

[0060] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the technical scope of the present invention. Therefore, any minor modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the protection scope of the present invention.

Claims

1. A conveyor belt inspection device, comprising a conveyor belt and a conveyor belt, wherein the conveyor belt is equipped with an idler frame, characterized in that: An inspection track is provided above the idler frame, and inspection channels are located on both sides of the conveyor belt. An inspection device is movably mounted on the inspection track, and an external drive unit is provided at one end of the inspection track. The inspection track is an open water tank with a closed bottom, and its path is the same as the layout direction of the conveyor belt. The inspection track is divided into two layers by a partition: an upper drive layer and a lower return layer, both of which are equipped with flowing inspection carriers. The drive layer and the return layer are connected at the head and tail sections of the conveyor belt, and the inspection carriers circulate within the inspection track. The inspection device includes an inspection host and a driven unit. There are two inspection hosts, which are respectively installed in the inspection channels on both sides of the conveyor belt. They are the control hosts of the inspection device and have a built-in control system. The control system is wirelessly connected to an external inspection server. The driven unit is located in the middle of the inspection device and is placed in the drive layer. A battery unit is provided above the driven unit. Both are connected to the control system of the inspection host. The driven unit is connected to the two inspection hosts through two side arms. The external drive unit includes a pipe conveyor drive device, a transmission shaft, a speed change device, and an inspection carrier drive device. The pipe conveyor drive device is connected to the inspection carrier drive device through the transmission shaft and the speed change device, and drives the inspection carrier drive device to drive the inspection carrier to flow. The inspection track has side track grooves on both sides of the water tank. Each side track groove is a U-shaped groove with an open top. Support devices are located below the two side arms of the inspection device and are slidably mounted within the side track grooves. Each support device includes a driven wheel, an elastic connecting rod, and a brake rod. The driven wheel is placed within the side track groove and has a built-in speed measuring unit connected to the control system of the inspection host. The driven wheel has a wheel frame connected to the lower end of the elastic connecting rod, and the upper end of the elastic connecting rod is connected to the side arm. The elastic connecting rod has an automatic extension / retraction function and a built-in stroke sensor connected to the control system of the inspection host. Two brake rods are installed on the outer sides of the driven wheel.

2. The conveyor belt inspection device according to claim 1, characterized in that: The inspection track is equipped with a carrier replenishment unit. The stroke sensor of the elastic link of the support device outputs stroke data to determine the liquid level status and feeds it back to the inspection host. When the liquid level of the inspection carrier in the inspection track is low, the inspection host remotely issues a carrier replenishment command to control the start and stop of the replenishment unit of the inspection track.

3. The conveyor belt inspection device according to claim 1, characterized in that: The inspection device is equipped with an extraction unit, including an extraction module, a steering module, and steering nozzles, all of which are connected to the control system of the inspection host. The extraction module includes a pump body and pipelines. There are two sets of steering nozzles, which are respectively installed at the lower part of the inspection host and connected to the pipelines of the extraction module. The pump body extracts the inspection carrier from the drive layer and delivers it to the steering nozzles through the pipelines. The pipelines are composed of a main pipeline and two branch pipelines. The steering module is installed at the branch point of the pipeline to control the flow direction of the inspection carrier.

4. The conveyor belt inspection device according to claim 1, characterized in that: The transmission device is connected to the conveyor belt drive device and the inspection carrier drive device through transmission shafts at both ends. The transmission device has a built-in forward gear D, neutral gear N and reverse gear R.

5. An inspection method based on the conveyor belt inspection device according to any one of claims 1-4, characterized in that: The specific steps are as follows: The inspection device is placed in the drive layer of the inspection track, and the inspection track is pre-filled with inspection carrier. When the stroke sensor of the elastic link of the inspection device detects that the liquid level of the inspection carrier is normal, the inspection host remotely sends a wireless signal to the external inspection server, namely the inspection ready signal. The external inspection server starts the inspection working mode upon receiving this signal. In the inspection mode, the external inspection server remotely sends a start signal to the external drive unit. After receiving the start signal, the transmission device in the external drive unit switches from neutral to forward or reverse gear. The conveyor belt drive device drives the inspection carrier drive device to generate fluid driving force, causing the inspection carrier to start flowing in one direction, thereby driving the inspection device to operate.

6. The inspection method according to claim 5, characterized in that: During the operation of the inspection device, the speed measuring unit supporting the driven wheel provides real-time speed feedback signals, which are then sent to a remote external inspection server via the inspection host. When the external inspection server needs to adjust the inspection speed based on the actual feedback speed, it sends a speed adjustment signal to the speed change device in the external drive unit. The speed change device switches between different speed gears to adjust the speed of the inspection carrier drive device based on the received speed adjustment signal, thereby changing the flow velocity of the inspection carrier and thus adjusting the travel speed of the inspection device.

7. The inspection method according to claim 5, characterized in that: In the inspection mode, the external inspection server synchronously activates the inspection cooling and dust suppression function; after the inspection cooling and dust suppression function is activated, the extraction unit of the inspection device is triggered to perform atomized spraying. The inspection device can execute the cooling and dust suppression command for the equipment along the pipeline without stopping. In the inspection mode, the external inspection server synchronously activates the inspection and fire protection function. After the inspection and fire protection function is activated, the inspection host of the inspection device determines the fire hazard that occurs along the pipeline conveyor and simultaneously triggers the extraction unit and brake lever of the inspection device to execute the stop fire protection command of the inspection device. After the fire hazard is dealt with, the inspection host resets the extraction unit and brake lever, and the inspection device continues to move forward. In the inspection mode, the external inspection server synchronously activates the inspection carrier replenishment function. After the replenishment function is activated, the liquid level of the inspection carrier in the inspection track is determined based on the extension stroke feedback from the stroke sensor of the elastic link of the inspection device. When the liquid level of the inspection carrier is too low, the inspection host sends a liquid level signal and a replenishment request command to the external inspection server. The external inspection server calculates the replenishment amount and replenishment time based on the carrier liquid level data and sends the replenishment data to the replenishment unit of the inspection track. The replenishment unit runs for a specific time based on the replenishment data to complete the replenishment of the inspection carrier.

8. The inspection method according to claim 5, characterized in that: The inspection host of the inspection device has a built-in positioning module, which can send the specific location information of the inspection device within the inspection track to the inspection server in real time. When the inspection device moves and approaches the end of the inspection track, the inspection server calculates the inertial distance and hysteresis time based on the current inspection speed of the inspection device and the distance to the end of the track, and sends a reversal command to the external drive unit in advance. After receiving the reversal command, the external drive unit stops and runs in reverse. During the hysteresis time, the inspection carrier does not immediately change direction, and the inspection device continues to move towards the end of the inspection track due to inertia. When the inspection device reaches the end of the track, the hysteresis of the inspection carrier has disappeared, and the inspection carrier flows in reverse at normal speed, so that the inspection device can complete the inspection reversal without stopping and continue to move in reverse at normal inspection speed.

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