A device and method for detecting roller jamming faults

Abstract

This invention relates to a device and method for detecting roller jamming faults, belonging to the field of fault detection. It includes a housing, internal circuitry, and an antenna. The internal circuitry is encapsulated within the housing, which has antenna mounting holes. The antenna is connected to the internal circuitry. The internal circuitry includes a power module, a sensor module, and a controller module. The power module includes a battery and a voltage regulator circuit to supply power to the device. The sensor module includes a MEMS accelerometer chip and its peripheral circuitry. The microcontroller module includes a microcontroller chip, a wireless communication module, and its peripheral circuitry. The accelerometer chip and the microcontroller chip communicate via SPI or I / O. 2 C-protocol communication; the accelerometer is a single-axis or multi-axis accelerometer. This invention uses an accelerometer to detect the rotation angle of the idler roller to determine whether the idler roller is jammed. The method is simple, direct, and highly reliable.

Description

Technical Field

[0001] This invention belongs to the field of fault detection and relates to a device and method for detecting roller jamming faults. Background Technology

[0002] A belt conveyor is a device for transporting materials, and idlers are an important component of it, playing a role in supporting the conveyor belt and the materials. If an idler becomes jammed during operation, the friction between it and the belt changes from rolling friction to sliding friction, increasing the frictional force and generating more heat, which may lead to damage to the belt conveyor or even a fire.

[0003] Currently, the main methods for detecting belt conveyor idler jamming faults include manual inspection, temperature detection, and sound detection. Manual inspection refers to inspectors walking along the belt conveyor and discovering problems through visual inspection, listening, and tapping. This method is labor-intensive, unreliable, and subject to environmental constraints. Temperature detection and sound detection, on the other hand, indirectly detect problems by utilizing the temperature rise and abnormal noise caused by idler jamming. These methods are subject to many interference factors and have poor reliability. Summary of the Invention

[0004] In view of this, the purpose of the present invention is to provide a device and method for detecting idler roller jamming faults, so as to solve the problem of low reliability of idler roller jamming fault detection in the prior art.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] A device for detecting roller jamming faults includes a housing, internal circuitry, and an antenna.

[0007] The internal circuit is encapsulated inside the housing, which has an antenna mounting hole and an antenna connected to the internal circuit.

[0008] The internal circuitry includes a power module, a sensor module, and a controller module.

[0009] The power module includes a battery and a voltage regulator circuit to supply power to the device.

[0010] The sensor module includes a MEMS accelerometer chip and its peripheral circuitry.

[0011] The microcontroller module includes a microcontroller chip, a wireless communication function module, and its peripheral circuitry.

[0012] The accelerometer chip and microcontroller chip are connected via SPI or I... 2 C protocol communication;

[0013] The accelerometer is a single-axis or multi-axis accelerometer.

[0014] Optionally, the device is fixed to the bottom surface of the roller cylinder by adhesive or magnetic attraction, and the presence of jamming fault is determined by detecting the operating status of the roller.

[0015] Optionally, the accelerometer is single-axis or multi-axis;

[0016] During installation, for single-axis and dual-axis accelerometers, the sensing axis is perpendicular to the roller axis; for triaxial accelerometers, one sensing axis is parallel to the roller axis, and the other two sensing axes are perpendicular to the roller axis.

[0017] Optionally, a patrol inspection mode or a scheduled inspection mode can be adopted;

[0018] The inspection work mode is as follows:

[0019] The host computer initiates a round of inspection by sequentially sending start inspection commands to the detection device i, where i = 1, 2, ..., N.

[0020] After receiving the start detection command, the arbitrary detection device i switches from the sleep state to the working state, collects acceleration signals and calculates the detection results, sends the detection results back to the host computer, and then returns to the sleep state until it is woken up again.

[0021] The host computer compiles the results sent back by all the detection devices to obtain the results of this round of inspections.

[0022] The scheduled inspection working mode is as follows:

[0023] Any detection device periodically switches from dormant to active state, collects, calculates, and transmits data to complete a scheduled inspection, and then returns to dormant state.

[0024] The host computer performs real-time statistics and updates on the periodic inspection results of all testing devices.

[0025] Optionally, the acquisition, calculation, and transmission specifically include: acquiring the accelerometer signal once at times t1 and t2 respectively and calculating the rotation angles θ1 and θ2;

[0026] When the idler roller is in normal operation, the rotation angle Δθ from time t1 to time t2 is 360°×(t2-t1)×60 / r, where r represents the normal rotation speed of the idler roller, in r / min;

[0027] If θ2-θ1 equals Δθ, it means that the actual rotational speed is consistent with the theoretical rotational speed, and the idler roller is operating normally.

[0028] If θ2-θ1 is approximately equal to 0 or much less than Δθ, it indicates that the idler roller is jammed.

[0029] Optionally, when the accelerometer is single-axis, the formula for calculating the rotation angle θ is: When it is a dual-axis or tri-axis Where g is a gravitational acceleration, and AX and AY are the accelerations along the X and Y axes, respectively.

[0030] The fault detection method based on the device according to any one of claims 1 to 7 is characterized in that: the method includes a patrol inspection mode or a scheduled inspection mode;

[0031] The inspection work mode is as follows:

[0032] The host computer initiates a round of inspection by sequentially sending start inspection commands to the detection device i, where i = 1, 2, ..., N.

[0033] After receiving the start detection command, the arbitrary detection device i switches from the sleep state to the working state, collects acceleration signals and calculates the detection results, sends the detection results back to the host computer, and then returns to the sleep state until it is woken up again.

[0034] The host computer compiles the results sent back by all the detection devices to obtain the results of this round of inspections.

[0035] The scheduled inspection working mode is as follows:

[0036] Any detection device periodically switches from dormant to active state, collects, calculates, and transmits data to complete a scheduled inspection, and then returns to dormant state.

[0037] The host computer performs real-time statistics and updates on the periodic inspection results of all testing devices.

[0038] Optionally, the accelerometer signal is collected once at time t1 and t2 respectively, and the rotation angles θ1 and θ2 are calculated.

[0039] When the idler roller is in normal operation, the rotation angle Δθ from time t1 to time t2 is 360°×(t2-t1)×60 / r, where r represents the normal rotation speed of the idler roller, in r / min;

[0040] If θ2-θ1 equals Δθ, it means that the actual rotational speed is consistent with the theoretical rotational speed, and the idler roller is operating normally.

[0041] If θ2-θ1 is approximately equal to 0 or much less than Δθ, it indicates that the idler roller is jammed.

[0042] The beneficial effects of this invention are as follows: This invention uses an acceleration sensor to detect the rotation angle of the idler roller to determine whether the idler roller has a jamming fault. The method is simple, direct, and highly reliable.

[0043] Other advantages, objectives, and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination, or may be learned from practice of the invention. The objectives and other advantages of the invention can be realized and obtained through the following description. Attached Figure Description

[0044] To make the objectives, technical solutions, and advantages of the present invention clearer, the preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, wherein:

[0045] Figure 1 This is a schematic diagram of the structure of the idler roller jamming fault detection device according to an embodiment of the present invention;

[0046] Figure 2 This is a schematic diagram of the installation direction of the accelerometer according to an embodiment of the present invention;

[0047] Figure 3 This is a flowchart of the inspection work mode according to an embodiment of the present invention;

[0048] Figure 4 This is a flowchart of the scheduled inspection working mode according to an embodiment of the present invention;

[0049] Figure 5 This is a schematic diagram of the rotation angle when the accelerometer is a single axis in an embodiment of the present invention;

[0050] Figure 6 This is a schematic diagram of the rotation angle when the accelerometer is a dual-axis sensor in an embodiment of the present invention.

[0051] Figure 7 This is a schematic diagram of the rotation angle when the accelerometer is triaxial in an embodiment of the present invention.

[0052] Reference numerals: 1. Housing; 2. Internal circuit; 3. Antenna; 4. Antenna mounting hole; 21. Power module; 22. Sensor module; 23. Controller module. Detailed Implementation

[0053] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0054] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual pictures. They should not be construed as limiting the invention. To better illustrate the embodiments of the invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0055] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "front," and "rear" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and 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, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present invention. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0056] A schematic diagram of a roller jamming fault detection device according to this embodiment is shown below. Figure 1 As shown, it mainly includes a housing 1, an internal circuit 2, and an antenna 3; wherein, the internal circuit 2 is encapsulated inside the housing 1, and the housing has an antenna mounting hole 4, and the antenna 3 is connected to the internal circuit 2.

[0057] The internal circuit 2 includes a power supply module 21, a sensor module 22, and a controller module 23.

[0058] The power module includes a battery and a voltage regulator circuit to supply power to the system.

[0059] The sensor module includes a MEMS accelerometer chip and its peripheral circuitry.

[0060] The controller module includes a microcontroller chip that integrates a ZegBee wireless communication function module and its peripheral circuitry.

[0061] The accelerometer chip and microcontroller chip are connected via SPI or I... 2 C protocol communication.

[0062] The accelerometer is a single-axis or multi-axis accelerometer.

[0063] In specific implementation, such as Figure 2As shown, when manufacturing and installing the idler roller jamming fault detection device, if a single-axis (X-axis) accelerometer is used, the X-axis should be perpendicular to the idler roller axis; if a dual-axis (X, Y-axis) accelerometer is used, the X and Y axes should be perpendicular to the idler roller axis; if a three-axis (X, Y, Z-axis) accelerometer is used, the X and Y axes should be perpendicular to the idler roller axis, and the Z-axis should be parallel to the idler roller axis.

[0064] This embodiment of the idler roller jamming fault detection device adopts a patrol inspection or scheduled inspection working mode to reduce system power consumption.

[0065] When adopting the inspection work mode, the workflow diagram is as follows: Figure 3 As shown: After starting work, the system first initializes and establishes a network, then enters a sleep state, waiting for the start detection command signal from the host computer. When the host computer starts a round of inspection, it sends the start detection command to all detection devices in sequence. After receiving the signal, the detection device switches from the sleep state to the working state. After three steps, it collects acceleration signals, calculates the detection results, and sends the detection results back to the host computer, and then returns to the sleep state, waiting to be woken up again. The host computer statistically analyzes the results sent back by all detection devices to obtain the inspection results for this round.

[0066] When using the scheduled inspection work mode, the workflow diagram is as follows: Figure 4 As shown: After starting work, the system first initializes, establishes the network, and starts the scheduled inspection timer, and then enters the sleep state; when the scheduled inspection timer expires, it switches from the sleep state to the working state, and after three steps of collecting acceleration signals, calculating the test results, and sending the test results back to the host computer, it returns to the sleep state to wait for the next scheduled inspection; the host computer performs real-time statistics and updates on the scheduled inspection results of all testing devices.

[0067] In specific implementation, such as Figure 3 and Figure 4 As shown, when sending the detection result, if it fails to send the result m times, the current detection result will be abandoned.

[0068] In practice, the inspection cycle or scheduled inspection cycle should be longer than the time required for the device to complete one test.

[0069] In specific implementation, the method for the device to collect acceleration signals and calculate the detection results is as follows: at times t1 and t2, the acceleration sensor signals are collected once and the rotation angles θ1 and θ2 are calculated. When the idler is in normal operation, the rotation angle Δθ in the time interval Δt = t2 - t1 is 360° × Δt × 60 / r, where r represents the normal rotation speed of the idler in r / min. If Δθ ≈ θ2 - θ1, it means that the actual rotation speed is consistent with the theoretical rotation speed and the idler is operating normally. If θ1 and θ2 detected at times t1 and t2 remain unchanged or the change θ2 - θ1 is much smaller than Δθ, it means that the idler is jammed.

[0070] In specific implementation, such as Figure 5 and Figure 6 As shown, when the accelerometer is a single axis, the formula for calculating the rotation angle θ is: When the accelerometer is dual-axis or tri-axis Where g is a gravitational acceleration, A X A Y These are the accelerations along the X and Y axes.

[0071] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A device for detecting roller jamming faults, characterized in that: Includes the housing, internal circuitry, and antenna; The internal circuit is encapsulated inside the housing, which has an antenna mounting hole and an antenna connected to the internal circuit. The internal circuitry includes a power module, a sensor module, and a controller module. The power module includes a battery and a voltage regulator circuit to supply power to the device. The sensor module includes a MEMS accelerometer chip and its peripheral circuitry. The controller module includes a microcontroller chip, a wireless communication function module, and its peripheral circuits. The accelerometer chip and microcontroller chip are connected via SPI or I... 2 C protocol communication; The acceleration sensor is a single-axis or multi-axis acceleration sensor; Adopt either a patrol inspection mode or a scheduled inspection mode; The inspection work mode is as follows: The host computer initiates a round of inspections, sequentially sending data to the detection devices. i Send the start detection command. i =1,2… N ; After receiving the start detection command, the arbitrary detection device i switches from the sleep state to the working state, collects acceleration signals and calculates the detection results, sends the detection results back to the host computer, and then returns to the sleep state until it is woken up again. The host computer compiles the results sent back by all the detection devices to obtain the results of this round of inspections. The scheduled inspection working mode is as follows: Any detection device periodically switches from dormant to active state, collects, calculates, and transmits data to complete a scheduled inspection, and then returns to dormant state. The host computer performs real-time statistics and updates on the periodic inspection results of all testing devices; The acquisition, calculation, and transmission specifically include: acquiring accelerometer signals once at times t1 and t2 and calculating rotation angles θ1 and θ2 respectively; When the idler roller is in normal operation, the rotation angle from time t1 to time t2 , where r represents the normal rotational speed of the idler roller, in r / min; If θ2-θ1 equals This indicates that the actual rotational speed is consistent with the theoretical rotational speed, and the idler roller is operating normally; If θ2-θ1 is approximately equal to 0 or much smaller This indicates that the idler roller is stuck.

2. The idler roller jamming fault detection device according to claim 1, characterized in that: The device is fixed to the bottom surface of the roller cylinder by adhesive or magnetic attraction, and determines whether a jamming fault has occurred by detecting the operating status of the roller.

3. The idler roller jamming fault detection device according to claim 1, characterized in that: The accelerometer sensor may be single-axis or multi-axis. During installation, for single-axis and dual-axis accelerometers, the sensing axis is perpendicular to the roller axis; for triaxial accelerometers, one sensing axis is parallel to the roller axis, and the other two sensing axes are perpendicular to the roller axis.

4. The idler roller jamming fault detection device according to claim 3, characterized in that: When the accelerometer is a single axis, the formula for calculating the rotation angle θ is: When the accelerometer is a dual-axis or tri-axis sensor Where g is a gravitational acceleration, and AX and AY are the accelerations along the X and Y axes, respectively.

5. A fault detection method based on the device according to any one of claims 1 to 4, characterized in that: This method includes either a patrol inspection mode or a scheduled inspection mode; The inspection work mode is as follows: The host computer initiates a round of inspections, sequentially sending data to the detection devices. i Send the start detection command. i =1,2… N ; After receiving the start detection command, the arbitrary detection device i switches from the sleep state to the working state, collects acceleration signals and calculates the detection results, sends the detection results back to the host computer, and then returns to the sleep state until it is woken up again. The host computer compiles the results sent back by all the detection devices to obtain the results of this round of inspections. The scheduled inspection working mode is as follows: Any detection device periodically switches from dormant to active state, collects, calculates, and transmits data to complete a scheduled inspection, and then returns to dormant state. The host computer performs real-time statistics and updates on the periodic inspection results of all testing devices; The acquisition, calculation and transmission are specifically as follows: at times t1 and t2, the accelerometer signal is acquired once and the rotation angles θ1 and θ2 are calculated respectively; When the idler roller is in normal operation, the rotation angle from time t1 to time t2 , where r represents the normal rotational speed of the idler roller, in r / min; If θ2-θ1 equals This indicates that the actual rotational speed is consistent with the theoretical rotational speed, and the idler roller is operating normally; If θ2-θ1 is approximately equal to 0 or much smaller This indicates that the idler roller is stuck.

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