Belt conveyor electronic fence system and working method

Abstract

The present application relates to coal belt conveyor technical field, especially to a kind of belt conveyor electronic fence system, comprising: electronic fence unit, the electronic fence unit is set to both sides of belt conveyor;Acquisition module, the acquisition module is used to collect the running state of belt conveyor;Processing module, the processing module is used to analyze the running state of belt conveyor, and determine the early warning level of belt conveyor;Control module, the control module is connected with the acquisition module and processing module, the control module is used to receive the early warning level of belt conveyor determined by the processing module, and according to the early warning level, the belt conveyor is controlled;Alarm module, the alarm module is connected with the control module, and the alarm module is used to automatically alarm based on the early warning level according to the control of control module.The present application can accurately judge whether the belt of belt conveyor is off tracking, and real-time monitoring belt conveyor running state, ensure normal operation of belt conveyor.

Description

Technical Field

[0001] This invention relates to the field of coal conveyor belt technology, and in particular to an electronic fence system for conveyor belts and its operating method. Background Technology

[0002] A coal conveyor belt is a mechanical device used to transport materials such as coal. It typically consists of a conveyor belt, drive unit, support frame, idlers, and rollers. Through a drive unit, such as an electric motor or reducer, the coal conveyor belt can transport materials from one location to another, achieving continuous material transport. It is widely used in thermal power plants, mines, metallurgy, and other places requiring large-scale coal transportation, and is one of the important pieces of equipment to ensure production efficiency and continuity.

[0003] During operation, belt conveyors often experience belt misalignment or jamming, preventing coal from being transported to the appropriate location in a timely manner. Therefore, it is necessary to monitor the conveyor's transportation process to ensure its normal operation. However, existing monitoring methods have significant limitations in terms of site conditions and are not very accurate or practical. Therefore, there is an urgent need for an electronic fence system for belt conveyors to detect and identify the conveyor's transportation process. Summary of the Invention

[0004] The purpose of this invention is to provide an electronic fence system for belt conveyors, which solves the problem that existing detection methods have significant limitations and cannot accurately determine the operation of belt conveyors.

[0005] To achieve the above objectives, the present invention provides an electronic fence system for belt conveyors, comprising:

[0006] An electronic fence unit is installed on both sides of the belt conveyor;

[0007] The data acquisition module is used to acquire the operating status of the belt conveyor, including the belt temperature and coal temperature, the leakage rate of the belt conveyor, the real-time current value of the belt conveyor, and the coal conveying capacity of the belt conveyor.

[0008] The processing module is used to analyze the operating status of the belt conveyor and determine the warning level of the belt conveyor.

[0009] A control module is connected to the acquisition module and the processing module. The control module is used to receive the warning level of the belt conveyor determined by the processing module and control the belt conveyor according to the warning level.

[0010] An alarm module is connected to the control module and is used to automatically trigger an alarm based on the warning level and under the control of the control module.

[0011] In some embodiments of this application, the electronic fence unit includes an infrared transmitter and an infrared receiver, wherein the infrared transmitter is used to transmit infrared signals and the infrared receiver is used to receive infrared signals;

[0012] The control module is connected to the electronic fence unit. The control module is used to control the external transmitter to emit infrared signals and to determine the abnormal operating status of the electronic fence unit when the infrared receiver does not receive the infrared signals.

[0013] The abnormal operating state includes the duration and frequency of the infrared receiver not receiving an infrared signal.

[0014] In some embodiments of this application, the control module determines the abnormal operating state of the electronic fence unit, and then further includes:

[0015] The abnormal operating status of the electronic fence unit is sent to the processing module;

[0016] The processing module determines whether the belt conveyor is misaligned based on the abnormal operating status of the electronic fence.

[0017] In some embodiments of this application, the processing module determines whether the belt conveyor is misaligned based on the abnormal operating state of the electronic fence, including:

[0018] The time length is compared with the preset time length. If the time length is less than the preset time length, it is determined that the belt of the conveyor belt is not misaligned.

[0019] If the time length is greater than the preset time length and the frequency is less than the preset frequency, then the belt of the conveyor belt is determined to be misaligned.

[0020] In some embodiments of this application, the acquisition module includes:

[0021] An infrared thermal imaging camera is used to photograph a conveyor belt in operation and to obtain the belt temperature and coal temperature values.

[0022] A pressure-sensitive sensor is disposed between the upper and lower belts of the belt conveyor to obtain the pressure difference value after material leakage from the belt conveyor, and to determine the amount of material leakage from the belt conveyor based on the pressure difference value.

[0023] A current sensor is provided, which allows the user to acquire the real-time current value of the belt conveyor.

[0024] In some embodiments of this application, the warning levels of the belt conveyor include general warning level, major warning level, and critical warning level.

[0025] In some embodiments of this application, the processing module analyzes the operating status of the belt conveyor and determines the warning level of the belt conveyor, including:

[0026] Compare the belt temperature value with the belt temperature threshold, and compare the coal temperature value with the coal temperature threshold;

[0027] If the belt temperature value is greater than the belt temperature threshold, or the coal temperature value is greater than the coal temperature threshold, then the warning level of the belt conveyor is determined to be a major warning level.

[0028] Otherwise, the predicted coal conveying capacity of the belt conveyor is determined based on the real-time current value;

[0029] Determine the coal transport difference between the predicted coal transport volume and the actual coal transport volume;

[0030] The warning level of the belt conveyor is determined based on the coal conveying difference.

[0031] In some embodiments of this application, the processing module analyzes the operating status of the belt conveyor and determines the warning level of the belt conveyor, and further includes:

[0032] The predicted leakage amount of the belt conveyor is determined based on the coal conveying volume;

[0033] Determine the leakage difference between the predicted leakage amount and the actual leakage amount;

[0034] The warning level of the belt conveyor is adjusted based on the leakage difference.

[0035] In some embodiments of this application, the control module controls the belt conveyor according to the warning level, including:

[0036] If the warning level is a general warning level, then the warning level is recorded, and a belt conveyor planned maintenance order is generated and sent to the maintenance personnel.

[0037] If the warning level is a major warning level, the belt conveyor will be stopped for a set time, and after the set time, the belt conveyor will be controlled to continue running, and a belt conveyor maintenance plan will be generated and sent to the maintenance personnel.

[0038] If the warning level is a major warning level, the belt conveyor will be stopped and maintenance personnel will be notified to carry out repairs immediately.

[0039] This invention also discloses a method for operating a belt conveyor electronic fence system, applied to the aforementioned belt conveyor electronic fence system, comprising:

[0040] The operating status of the belt conveyor is collected, including the belt temperature and coal temperature, the leakage of the belt conveyor, the real-time current of the belt conveyor, and the coal conveying capacity of the belt conveyor.

[0041] The operating status of the belt conveyor is analyzed, and the warning level of the belt conveyor is determined;

[0042] The receiving and processing module determines the warning level of the belt conveyor and controls the belt conveyor according to the warning level;

[0043] Based on the aforementioned warning level, an automatic alarm will be triggered according to the control module's instructions.

[0044] This invention provides an electronic fence system for a belt conveyor, comprising: an electronic fence unit disposed on both sides of the belt conveyor; a data acquisition module for acquiring the operating status of the belt conveyor, including belt temperature, coal temperature, material leakage, real-time current, and coal conveying capacity; a processing module for analyzing the operating status of the belt conveyor and determining its warning level; a control module connected to the data acquisition and processing modules, receiving the warning level determined by the processing module and controlling the belt conveyor accordingly; and an alarm module connected to the control module for automatically triggering an alarm based on the warning level and the control of the control module.

[0045] This invention can accurately determine whether the belt of a conveyor belt is misaligned by setting up an electronic fence unit. It is equipped with a data acquisition module, a processing module, a control module, and an alarm module to realize real-time monitoring of the belt conveyor's operating status. By analyzing the belt conveyor's operating status, the warning level is determined and an automatic alarm is triggered, enabling self-detection and self-diagnosis of faults, improving management efficiency, reducing overall maintenance costs such as spare parts, accelerating capital turnover, and reducing reliance on the experience of maintenance personnel.

[0046] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0047] Figure 1 This is a schematic diagram of the structure of an electronic fence system for a belt conveyor according to the present invention;

[0048] Figure 2 This is a flowchart illustrating the working method of an electronic fence system for belt conveyors according to the present invention. Detailed Implementation

[0049] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0050] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used herein have the ordinary meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0051] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments of the present invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof, without excluding other elements or objects. The terms "first," "second," and similar words used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "upper," "lower," "left," "right," "front," "rear," "vertical," "horizontal," "side," and "bottom," indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are merely relational terms determined for the convenience of describing the structural relationships of the various components or elements of the present invention, and do not specifically refer to any component or element in the invention, nor should they be construed as limiting the invention. Terms such as "fixed," "connected," and "linked," etc., should be interpreted broadly, indicating that it can be a fixed connection, an integral connection, or a detachable connection; it can be a direct connection or an indirect connection through an intermediate medium. For researchers or technicians in the field, the specific meaning of the above terms in this invention can be determined according to the specific circumstances, and they should not be construed as limitations on this invention.

[0052] Example

[0053] A coal conveyor belt is a mechanical device used to transport materials such as coal. It typically consists of a conveyor belt, drive unit, support frame, idlers, and rollers. Through a drive unit, such as an electric motor or reducer, the coal conveyor belt can transport materials from one location to another, achieving continuous material transport. It is widely used in thermal power plants, mines, metallurgy, and other places requiring large-scale coal transport, and is one of the important pieces of equipment to ensure production efficiency and continuity. However, during operation, belt misalignment or jamming often occurs, preventing coal from being transported to the appropriate location in a timely manner. Therefore, it is necessary to monitor the conveyor belt's transport process to ensure its normal operation.

[0054] This invention provides an electronic fence system for belt conveyors, such as... Figure 1 As shown, it includes:

[0055] An electronic fence unit is installed on both sides of the belt conveyor.

[0056] The data acquisition module is used to acquire the operating status of the belt conveyor, including the belt temperature and coal temperature, the leakage rate, the real-time current, and the coal conveying capacity.

[0057] The processing module is used to analyze the operating status of the belt conveyor and determine the warning level of the belt conveyor.

[0058] A control module is connected to the acquisition module and the processing module. The control module is used to receive the warning level of the belt conveyor determined by the processing module and control the belt conveyor according to the warning level.

[0059] An alarm module is connected to the control module and is used to automatically trigger an alarm based on the warning level and under the control of the control module.

[0060] In some embodiments of this application, the electronic fence unit includes an infrared transmitter and an infrared receiver, wherein the infrared transmitter is used to transmit infrared signals and the infrared receiver is used to receive infrared signals.

[0061] The control module is connected to the electronic fence unit. The control module is used to control the external transmitter to emit infrared signals and to determine the abnormal operating state of the electronic fence unit when the infrared receiver does not receive the infrared signals.

[0062] The abnormal operating state includes the duration and frequency of the infrared receiver not receiving an infrared signal.

[0063] In this embodiment, the electronic fence unit is disposed on the left and right sides of the belt conveyor, and the electronic fence unit includes several groups. Each group of electronic fence units is disposed on the upper and lower sides of the belt conveyor. The electronic fence can be configured such that the external transmitter is disposed on the upper side of the belt conveyor and the infrared receiver is disposed on the lower side of the belt conveyor. The distance between the electronic fence unit and the belt conveyor does not exceed 5% of the belt width.

[0064] In some embodiments of this application, the control module determines the abnormal operating state of the electronic fence unit, and then further includes:

[0065] The abnormal operating status of the electronic fence unit is sent to the processing module.

[0066] The processing module determines whether the belt conveyor is misaligned based on the abnormal operating status of the electronic fence.

[0067] In some embodiments of this application, the processing module determines whether the belt conveyor is misaligned based on the abnormal operating state of the electronic fence, including:

[0068] The time length is compared with the preset time length. If the time length is less than the preset time length, it is determined that the belt of the conveyor belt is not misaligned.

[0069] If the time length is greater than the preset time length and the frequency is less than the preset frequency, then the belt of the conveyor belt is determined to be misaligned.

[0070] In this embodiment, when the belt misalignment is small and it self-corrects to a normal state, the time duration is less than the preset time duration, and the belt is determined to be not misaligned. Only when the time duration is greater than the preset time duration, and the belt does not correct itself after misalignment (i.e., the frequency is less than the preset frequency), is the belt determined to be misaligned.

[0071] In some embodiments of this application, the acquisition module includes:

[0072] An infrared thermal imaging camera is used to photograph a conveyor belt in operation and to acquire the belt temperature and coal temperature values.

[0073] A pressure-sensitive sensor is installed between the upper and lower belts of the belt conveyor to obtain the pressure difference after material leakage, and to determine the amount of material leakage based on the pressure difference.

[0074] A current sensor is provided, which allows the user to acquire the real-time current value of the belt conveyor.

[0075] In this embodiment, an infrared thermal imaging camera is a detection device that detects infrared energy (heat) non-contactly, converts it into electrical signals, and then generates thermal images and temperature values ​​on a display, and can calculate the temperature values. Any object with a temperature emits infrared radiation, and a thermal imager receives this infrared radiation, displaying the temperature distribution on the surface of the measured object through colored images. Based on minute temperature differences, it can determine whether the object has a fault or abnormality. Therefore, it can be used to obtain the belt temperature value of a conveyor belt and the coal temperature value.

[0076] In some embodiments of this application, the warning levels of the belt conveyor include general warning level, major warning level, and critical warning level.

[0077] In some embodiments of this application, the processing module analyzes the operating status of the belt conveyor and determines the warning level of the belt conveyor, including:

[0078] The belt temperature value is compared with the belt temperature threshold, and the coal temperature value is compared with the coal temperature threshold.

[0079] If the belt temperature value is greater than the belt temperature threshold, or the coal temperature value is greater than the coal temperature threshold, then the warning level of the belt conveyor is determined to be a major warning level.

[0080] Otherwise, the predicted coal conveying capacity of the belt conveyor is determined based on the real-time current value.

[0081] Determine the coal transport difference between the predicted coal transport volume and the actual coal transport volume.

[0082] The warning level of the belt conveyor is determined based on the coal conveying difference.

[0083] In this embodiment, prolonged operation of the belt conveyor can lead to belt overheating, thus affecting its normal operation. Therefore, when both the belt temperature and the coal temperature are excessively high, it indicates that the belt conveyor has been running for too long or there are other problems. Furthermore, if both the belt temperature and the coal temperature are excessively high, heat cannot be released, which can easily lead to hazards such as fires. Therefore, when either the belt temperature or the coal temperature exceeds the belt temperature threshold, it indicates a serious problem, and the belt conveyor's warning level is set to a critical warning level.

[0084] In some embodiments of this application, the processing module analyzes the operating status of the belt conveyor and determines the warning level of the belt conveyor, and further includes:

[0085] The predicted leakage amount of the belt conveyor is determined based on the coal conveying volume.

[0086] Determine the leakage difference between the predicted leakage amount and the actual leakage amount.

[0087] The warning level of the belt conveyor is adjusted based on the leakage difference.

[0088] In this embodiment, when the belt of the conveyor belt tears, coal will fall from the tear. Therefore, the more coal falls, the greater the leakage difference, indicating that the belt tear is serious and the warning level of the conveyor belt needs to be adjusted.

[0089] In some embodiments of this application, the control module controls the belt conveyor according to the warning level, including:

[0090] If the warning level is a general warning level, then the warning level is recorded, and a belt conveyor planned maintenance order is generated and sent to the maintenance personnel.

[0091] If the warning level is a major warning level, the belt conveyor will be stopped for a set time, and after the set time has elapsed, the belt conveyor will be controlled to resume operation, and a belt conveyor maintenance plan will be generated and sent to the maintenance personnel.

[0092] If the warning level is a major warning level, the belt conveyor will be stopped and maintenance personnel will be notified to carry out repairs immediately.

[0093] This invention also discloses a method for operating a belt conveyor electronic fence system, applicable to the aforementioned belt conveyor electronic fence system, such as... Figure 2 As shown, it includes:

[0094] S1, collect the operating status of the belt conveyor, including the belt temperature and coal temperature, the leakage of the belt conveyor, the real-time current of the belt conveyor, and the coal conveying capacity of the belt conveyor.

[0095] S2, Analyze the operating status of the belt conveyor and determine the warning level of the belt conveyor.

[0096] S3, receive the warning level of the belt conveyor determined by the receiving and processing module, and control the belt conveyor according to the warning level.

[0097] S4, based on the warning level, automatically trigger an alarm according to the control of the control module.

[0098] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. 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 still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

[0099] The system provided in the above embodiments is only illustrated by the division of the above functional modules. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the modules or steps in the embodiments of the present invention can be further decomposed or combined. For example, the modules in the above embodiments can be merged into one module, or further divided into multiple sub-modules to complete all or part of the functions described above. The names of the modules and steps involved in the embodiments of the present invention are only for distinguishing the various modules or steps and are not considered as an improper limitation of the present invention.

[0100] Those skilled in the art will recognize that the modules and method steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. The programs corresponding to the software modules and method steps can be placed in random access memory (RAM), main memory, read-only memory (ROM), electrically programmable ROM, electrically erasable programmable ROM, registers, hard disks, removable disks, CD-ROMs, or any other form of storage medium known in the art. To clearly illustrate the interchangeability of electronic hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in electronic hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of the invention.

Claims

1. An electronic fence system for belt conveyors, characterized in that, include: An electronic fence unit is installed on both sides of the belt conveyor; The data acquisition module is used to acquire the operating status of the belt conveyor, including the belt temperature and coal temperature, the leakage rate of the belt conveyor, the real-time current value of the belt conveyor, and the coal conveying capacity of the belt conveyor. The processing module is used to analyze the operating status of the belt conveyor and determine the warning level of the belt conveyor. A control module is connected to the acquisition module and the processing module. The control module is used to receive the warning level of the belt conveyor determined by the processing module and control the belt conveyor according to the warning level. An alarm module is connected to the control module, and the alarm module is used to automatically sound an alarm based on the warning level and under the control of the control module. The warning levels for the belt conveyor include general warning level, major warning level, and severe warning level; The processing module analyzes the operating status of the belt conveyor and determines the warning level of the belt conveyor, including: Compare the belt temperature value with the belt temperature threshold, and compare the coal temperature value with the coal temperature threshold; If the belt temperature value is greater than the belt temperature threshold, or the coal temperature value is greater than the coal temperature threshold, then the warning level of the belt conveyor is determined to be a major warning level. Otherwise, the predicted coal conveying capacity of the belt conveyor is determined based on the real-time current value; Determine the coal transport difference between the predicted coal transport volume and the actual coal transport volume; The warning level of the belt conveyor is determined based on the coal conveying difference; The processing module analyzes the operating status of the belt conveyor and determines the warning level of the belt conveyor, and also includes: The predicted leakage amount of the belt conveyor is determined based on the coal conveying volume; Determine the leakage difference between the predicted leakage amount and the actual leakage amount; The warning level of the belt conveyor is adjusted based on the leakage difference.

2. The belt conveyor electronic fence system according to claim 1, characterized in that, The electronic fence unit includes an infrared transmitter and an infrared receiver. The infrared transmitter is used to transmit infrared signals, and the infrared receiver is used to receive infrared signals. The control module is connected to the electronic fence unit. The control module is used to control the infrared transmitter to emit infrared signals and to determine the abnormal operating status of the electronic fence unit when the infrared receiver does not receive the infrared signals. The abnormal operating state includes the duration and frequency of the infrared receiver not receiving an infrared signal.

3. The belt conveyor electronic fence system according to claim 2, characterized in that, The control module determines the abnormal operating state of the electronic fence unit, and then further includes: The abnormal operating status of the electronic fence unit is sent to the processing module; The processing module determines whether the belt conveyor is misaligned based on the abnormal operating status of the electronic fence.

4. The belt conveyor electronic fence system according to claim 3, characterized in that, The processing module determines whether the belt conveyor is misaligned based on the abnormal operating status of the electronic fence, including: The time length is compared with the preset time length. If the time length is less than the preset time length, it is determined that the belt of the conveyor belt is not misaligned. If the time length is greater than the preset time length and the frequency is less than the preset frequency, then the belt of the conveyor belt is determined to be misaligned.

5. The belt conveyor electronic fence system according to claim 1, characterized in that, The acquisition module includes: An infrared thermal imaging camera is used to photograph a conveyor belt in operation and to obtain the belt temperature and coal temperature values. A pressure-sensitive sensor is disposed between the upper and lower belts of the belt conveyor to obtain the pressure difference value after material leakage from the belt conveyor, and to determine the amount of material leakage from the belt conveyor based on the pressure difference value. A current sensor is provided, which allows the user to acquire the real-time current value of the belt conveyor.

6. The belt conveyor electronic fence system according to claim 1, characterized in that, The control module controls the belt conveyor according to the warning level, including: If the warning level is a general warning level, then the warning level is recorded, and a belt conveyor planned maintenance order is generated and sent to the maintenance personnel. If the warning level is a major warning level, the belt conveyor will be stopped for a set time, and after the set time, the belt conveyor will be controlled to continue running, and a belt conveyor maintenance plan will be generated and sent to the maintenance personnel. If the warning level is a major warning level, the belt conveyor will be stopped and maintenance personnel will be notified to carry out repairs immediately.

7. A method for operating a belt conveyor electronic fence system, applied to the belt conveyor electronic fence system of claim 1, characterized in that, include: The operating status of the belt conveyor is collected, including the belt temperature and coal temperature, the leakage of the belt conveyor, the real-time current of the belt conveyor, and the coal conveying capacity of the belt conveyor. The operating status of the belt conveyor is analyzed, and the warning level of the belt conveyor is determined; The receiving and processing module determines the warning level of the belt conveyor and controls the belt conveyor according to the warning level; Based on the aforementioned warning level, an automatic alarm will be triggered according to the control module's instructions.

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