Method for monitoring the deviation of a belt conveyor and device therefor

Abstract

A belt conveyor deviation monitoring method and device, comprising: a detection switch (1), a counting module (2), a display module (3), a power supply (4), a reset button (5), the detection switch (1) comprising: a vertical roller (11), a connecting rod mechanism (12), a first micro switch (13) and a second micro switch (14); when the belt deviates, the belt presses the vertical roller (11), drives the connecting rod mechanism, triggers the first micro switch and the second micro switch to send an alarm signal, the first micro switch is used for detecting a first-level belt deviation alarm, one normally closed contact point thereof is used for being connected in series with normally closed contact points of other detection switches, and is sent to an alarm relay of a belt conveyor control system and is used for alarm of slight deviation; the second micro switch is used for alarm and shutdown of severe deviation. The present application solves the problem of rapid positioning of intermittent deviation fault points and false signals.

Description

Technical Field

[0001] This invention relates to the field of belt conveyor monitoring, specifically to a belt conveyor misalignment monitoring switch. Background Technology

[0002] A belt conveyor is a friction-driven mechanical device that transports materials continuously. During the operation of the belt conveyor, irregular stacking of materials can cause the conveyor belt to deviate. The detection switch is mainly used to detect the amount of deviation during the operation of the belt conveyor and output alarm or stop signals according to the actual amount of deviation, effectively preventing safety accidents such as roller shaft misalignment and idler bearing damage caused by conveyor belt deviation.

[0003] In practical applications, belt conveyors are typically equipped with a number of detection switches on both sides. These switches usually have two levels of alarm signals: a primary misalignment alarm for minor misalignment and a secondary misalignment shutdown for severe misalignment. Because belt conveyor systems require a large number of detection switches, the normally closed contacts of the primary and secondary misalignment signals from multiple switches are usually connected in series to centrally send minor and severe misalignment detection signals to the control system. However, the current method of using these detection switches for misalignment monitoring generally suffers from the following problems:

[0004] During operation, belt conveyors may experience intermittent belt misalignment, or erroneous signals from detection switches. Often, by the time maintenance personnel arrive, the conveyor belt has returned to its normal position, but the detection switch signals no longer indicate any abnormality. Therefore, it is difficult to quickly locate the source of the misalignment. Maintenance personnel must repeatedly inspect the long stretch of the conveyor belt while it is running, or open each detection switch junction box and measure and troubleshoot individually. This is neither safe for maintenance personnel nor conducive to quickly identifying the fault, resulting in prolonged troubleshooting time and impacting production and maintenance efficiency.

[0005] A search of relevant literature revealed the following publicly available technology in the same field: a detection switch with a field indicator light, application number: 20130237475.8. According to this document, this detection switch can indicate the real-time signal status of the detection switch, but its disadvantage is that it cannot solve the problem of quickly locating intermittent deviation fault points and false signals. Summary of the Invention

[0006] To address the aforementioned problem of rapidly locating intermittent belt misalignment faults and erroneous signals, the present invention aims to provide a belt misalignment monitoring switch. This switch can automatically record the location and frequency of belt misalignment faults while monitoring belt misalignment anomalies, thus solving the problem of difficulty in diagnosing intermittent misalignment faults. This allows maintenance personnel to quickly locate the fault point, reduce the time spent troubleshooting misalignment faults, and improve the maintenance efficiency of belt conveyor systems.

[0007] To achieve the above objectives, the technical solution of the present invention is as follows:

[0008] 1. A method for monitoring belt conveyor misalignment, characterized in that the method comprises:

[0009] 1) Detection switches are configured on both sides of the belt conveyor. The detection switch (1) includes: a vertical roller (11), a linkage mechanism (12), a first micro switch (13), and a second micro switch (14). When the belt deviates, it presses against the vertical roller (11), which is driven by the linkage mechanism (12) to trigger the first micro switch or the second micro switch. The first micro switch and the second micro switch each include a normally open contact and a normally closed contact.

[0010] 2) When the belt conveyor runs slightly off track, the vertical roller (11) of the detection switch deflects, triggering the first micro switch to act. Its normally closed contact sends a first-level deviation alarm signal to the control system. The normally closed contact is connected in series with the normally closed contacts of other detection switches and sent to the alarm relay of the belt conveyor control system.

[0011] 3) The normally open contact of the first micro switch (13) is connected to the counting module (2) to trigger the counting of slight deviation signals;

[0012] 4) When the belt conveyor runs off track severely, the vertical roller (11) of the detection switch continues to deflect, triggering the second micro switch (14) to operate. One normally closed contact of the second micro switch (14) is connected in series with the normally closed contacts of other detection switches and sent to the emergency stop relay (7) of the belt conveyor control system for alarm and shutdown of severe deviation.

[0013] 5) The normally open contact of the second micro switch (14) is connected to the counting module (2) and is used to trigger the counting of severe deviation signals;

[0014] 6) Regularly test the detection switch to quickly diagnose the location of minor and major deviation faults, accumulate and count the minor and major deviation signals, and record the number of minor and major deviation faults that occur.

[0015] 7) Based on the diagnosis in 6) above,

[0016] For minor belt misalignment issues, the first step is to observe the belt's operation to maintain production, and then make adjustments during a temporary shutdown.

[0017] 8) Based on the diagnosis in 6) above,

[0018] For severe deviation faults, immediate action must be taken:

[0019] First, to ensure the belt runs smoothly, any blockages must be cleared or the faulty bearing replaced before attempting to start the belt to see if it still runs off track.

[0020] 9) After dealing with the location of the minor or severe deviation fault, activate the reset button (5) connected to the counting module (2) to initialize and reset the accumulated value of the counter in the counting module (2) for subsequent deviation monitoring.

[0021] According to the present invention, slight belt misalignment refers to the allowable amount of belt misalignment within a controllable range without touching the frame or support. Generally, it is about 30 degrees of rotation angle after the belt contactor of the belt misalignment switch rod comes into contact with the belt.

[0022] Severe misalignment refers to a misalignment fault that causes material to fall, contact the support or frame, or cause the belt to roll up, resulting in excessive load and tripping the thermal relay, making it impossible to continue operation. Generally, the misalignment switch vertical roller contacts the belt at an angle of about 45 degrees.

[0023] The purpose of a slight belt misalignment indicator is to alert the manufacturer to any belt deviation, allowing them to determine if adjustments are necessary and preventing severe misalignment that could lead to shutdowns and production disruptions. Generally, the process involves first observing the belt's operation to maintain production, and then making adjustments in the event of a temporary shutdown.

[0024] Using a belt conveyor that is severely misaligned can easily cause even greater malfunctions (such as belt edge tearing or failure to operate normally).

[0025] First, to ensure belt operation, any blockages must be cleared or damaged bearings replaced before attempting to start the belt to see if it still runs off-track. If it still cannot be corrected, a guide wheel can be installed to force the belt to turn off-track. The fastest and most direct way is to install a guide wheel to force the belt to turn off-track. If the belt runs off-track due to a misalignment of the material feeding position, a plate can be welded inside the material tube to adjust the feeding angle and concentrate the material falling in the middle of the belt as much as possible.

[0026] According to the present invention, a method for monitoring belt conveyor misalignment is characterized in that,

[0027] The counting module (2) includes a first counter and a second counter, which are connected to the first micro switch (13) and the second micro switch (14) respectively. They are used to accumulate and count the slight deviation signal and the severe deviation signal, and record the number of times the slight and severe deviation faults occur.

[0028] According to the present invention, a method for monitoring belt conveyor misalignment is characterized in that,

[0029] The display module is connected to the counting module (2) and is used to display the accumulated value of the two counters on the display module, so that maintenance personnel can quickly diagnose the location and frequency of the fault.

[0030] According to the present invention, a method for monitoring belt conveyor misalignment is characterized in that,

[0031] 7) For minor deviation faults, the following procedures should be followed:

[0032] For unidirectional belts, the amount of belt misalignment is adjusted by adjusting the tension on both sides of the belt.

[0033] Because reversible belts can rotate in both directions, they may run to one side when rotating in the forward direction and to the other side when rotating in the reverse direction. In such cases, it is necessary to install a guide wheel to force the belt to deviate. This should be done after the machine has had a downtime.

[0034] According to the present invention, a method for monitoring belt conveyor misalignment is characterized in that,

[0035] For severe deviation faults, such as material blockage, clearing the blockage, or replacing the faulty bearing and then attempting to start the machine but still experiencing deviation, directly install a guide wheel to force correction, or

[0036] If the material deviation is caused by the offset of the feeding position, weld a plate inside the material tube and adjust the feeding angle.

[0037] According to the present invention, a method for monitoring belt conveyor misalignment is characterized in that,

[0038] The detection switches are installed in pairs on both the beginning and end sides of a conveyor belt, for a total of 4.

[0039] According to the present invention, a method for monitoring belt conveyor misalignment is characterized in that,

[0040] Regular inspections of belt conveyors should be conducted based on the size or type of material being fed.

[0041] For example, belt conveyors primarily used for transporting small particles such as auxiliary materials and alloys have a lower usage frequency.

[0042] The check-up can be performed every 10-15 days;

[0043] For conveyor belts transporting large particles, such as lime, the belt conveyor is used frequently.

[0044] A check-up should be performed every 3-4 days.

[0045] To prevent abnormal wear of the belt from causing material blockage, the counting modules of the four belt misalignment switches should be recorded during inspection. After recording, the values ​​should be reset.

[0046] The present invention provides a belt conveyor misalignment monitoring device, characterized in that the device comprises:

[0047] The system comprises a detection switch (1), a counting module (2), a display module (3), a power supply, and a reset button (5), characterized in that...

[0048] The detection switch includes: a vertical roller (11), a linkage mechanism (12), a first micro switch (13) and a second micro switch (14); when the belt deviates, it presses against the vertical roller (11), and is driven by the linkage mechanism (12) to trigger the first micro switch and the second micro switch to issue an alarm signal.

[0049] Among them, the first micro switch (13) is used to detect the first-level belt misalignment alarm, including a normally closed contact and a normally open contact. The normally closed contact is connected in series with the normally closed contacts of other detection switches and sent to the alarm relay of the belt conveyor control system for alarming minor misalignment. The normally open contact is connected to the counting module (2) for triggering the counting of minor misalignment signals.

[0050] The second micro switch (14) is used to detect the secondary belt misalignment alarm. It includes a normally closed contact and a normally open contact. The normally closed contact is connected in series with the normally closed contacts of other detection switches and sent to the emergency stop relay of the belt conveyor control system for alarm and shutdown of severe misalignment. The normally open contact is connected to the counting module (2) for triggering the counting of severe misalignment signals.

[0051] According to the present invention, a belt conveyor misalignment monitoring device is characterized in that the counting module (2) includes a first counter and a second counter, which are respectively connected to a first micro switch (13) and a second micro switch (14) for accumulating and counting mild misalignment signals and severe misalignment signals and recording the number of mild and severe misalignment faults.

[0052] According to the present invention, a belt conveyor misalignment monitoring device is characterized in that a display module (3) connected to the counting module (2) is provided to display the accumulated value of the two counters on the display module (3) for maintenance personnel to quickly diagnose the location and frequency of the fault.

[0053] According to the present invention, a belt conveyor misalignment monitoring device is characterized in that the reset button (5) is connected to the counting module (2) and is used to initialize and reset the accumulated values ​​of the two counters of the counting module.

[0054] Therefore, maintenance personnel can quickly determine the location and frequency of the deviation fault by observing the number of deviation signals and their changes displayed on the display module, thereby enabling them to quickly locate and eliminate the fault.

[0055] Beneficial effects of this invention:

[0056] Using this detection switch can effectively improve the ability to diagnose belt conveyor misalignment. It not only has low modification cost and is easy and quick to install, but also helps to quickly locate the fault point, reduce the time for troubleshooting misalignment, and improve maintenance efficiency. It can be widely used for misalignment monitoring of various belt conveyor equipment. Attached Figure Description

[0057] Figure 1 A structural diagram of a detection switch for a belt conveyor.

[0058] Figure 2 Circuit connection diagram for detecting slight deviation of the switch.

[0059] Figure 3 Connection diagram of circuit for detecting severe deviation of switch.

[0060] Figure 4 Schematic diagram of the detection switch application.

[0061] In the diagram, 1-detection switch, 2-counting module, 3-display module, 4-power supply, 5-reset button, 6-alarm relay, 7-emergency stop relay, 8-conveyor, 11-vertical roller, 12-linkage mechanism; 13-first micro switch, 14-second micro switch. Detailed Implementation

[0062] Example

[0063] This embodiment provides a belt conveyor misalignment monitoring device, such as... Figure 1 As shown, it includes: a detection switch 1, a counting module 2, a display module 3, a power supply 4, and a reset button 5.

[0064] The detection switch 1 includes: a vertical roller 11, a linkage mechanism 12, a first micro switch 13, and a second micro switch 14. In this example, the first micro switch 13 and the second micro switch 14 are ball-bearing rocker type micro switches, which are installed inside the detection switch 1. When the belt deviates, it presses against the vertical roller 11, which is driven by the linkage mechanism 12 to trigger the first micro switch 13 and the second micro switch 14 to issue an alarm signal.

[0065] In this embodiment, as Figure 2As shown, the first micro switch 13 is used to detect the first-level belt misalignment alarm. One of its normally closed contacts is connected in series with the normally closed contacts of other detection switches to send a signal to the alarm relay 6 of the belt conveyor control system for alarming minor misalignment. The first micro switch 13 also includes a normally open contact, which is connected to the counting module 2 to trigger the counting of minor misalignment signals.

[0066] The second micro switch 14 is used to detect the secondary belt misalignment alarm. One of its normally closed contacts is connected in series with the normally closed contacts of other detection switches, sending a signal to the emergency stop relay 7 of the belt conveyor control system for alarming and stopping the machine in case of severe misalignment. The second micro switch 14 also includes a normally open contact connected to the counting module 2, used to trigger the counting of severe misalignment signals. The counting module 2 includes a first counter and a second counter, connected to the first micro switch 13 and the second micro switch 14 respectively, used to accumulate and count the minor and severe misalignment signals, recording the number of times minor and severe misalignment faults occur.

[0067] The display module 3 is connected to the counting module 2 and is used to display the accumulated values ​​of the two counters of the counting module 2 on the display module 3. This is used by maintenance personnel to quickly diagnose the location and frequency of the fault. The display module 3 adopts a dual-channel digital LED display screen, which can display the number of minor and major deviation faults. The display module 3 is protruding above the detection switch 1.

[0068] The power module 4 is connected to the counting module 2 and the display module 3, and is used to supply power to the counting module 2 and the display module 3. In this example, the power module 4 uses a 5V button battery. The reset button 5 is connected to the counting module 2 and is used to initialize and reset the accumulated values ​​of the two counters in the counting module. The reset button 5 used in this example also has a self-locking function to prevent accidental triggering.

[0069] According to the detection switch provided by the present invention, when the belt conveyor experiences slight deviation, the vertical roller 11 of the detection switch 1 deflects, triggering the first micro switch 13 to operate. Its normally closed contact sends a first-level deviation alarm signal to the control system to remind the operator to pay attention; its normally open contact sends a first-level deviation alarm signal to the counting module 2, and the number of signal occurrences is accumulated by the first counter and displayed on the display module 3.

[0070] When the belt conveyor experiences severe misalignment, the vertical roller 11 of the detection switch 1 deflects further, triggering the second micro switch 14 to operate. Its normally closed contact sends a secondary misalignment alarm signal to the control system, triggering the belt conveyor to stop. Its normally open contact sends a secondary misalignment alarm signal to the counting module 2. The number of severe misalignment signals is accumulated by the second counter and displayed on the display module 3.

[0071] Maintenance personnel can quickly determine the location and frequency of the deviation fault by observing the number of deviation signals and their changes displayed on the display module 3, thereby enabling rapid identification and elimination of the fault.

[0072] In this embodiment, the conveyor belt is installed in pairs, typically with one pair installed at each end. For example... Figure 3 As shown, the detection switch should be installed so that the vertical roller 11 is perpendicular to the edge plane of the conveyor belt 8, the height of the vertical roller 11 is preferably at 1 / 2 position of the conveyor belt 8, and the distance is preferably such that the vertical roller 11 is 100mm away from the conveyor belt 10.

[0073] According to the present invention, the ability to diagnose belt misalignment faults can be effectively improved by using this detection switch. It not only has low modification cost and is easy and quick to install, but also helps to quickly locate the fault point, reduce the time for troubleshooting misalignment faults, and improve maintenance efficiency. It can be widely used in the monitoring of misalignment of various belt conveyor equipment.

Claims

1. A method for monitoring belt conveyor misalignment, characterized in that, The method includes: 1) Detection switches are configured on both sides of the belt conveyor. The detection switch (1) includes: a vertical roller (11), a linkage mechanism (12), a first micro switch (13), and a second micro switch (14). When the belt deviates, it presses against the vertical roller (11), which is driven by the linkage mechanism (12) to trigger the first micro switch or the second micro switch. The first micro switch and the second micro switch each include a normally open contact and a normally closed contact. 2) When the belt conveyor runs slightly off track, the vertical roller (11) of the detection switch deflects, triggering the first micro switch to act. Its normally closed contact sends a first-level deviation alarm signal to the control system. The normally closed contact is connected in series with the normally closed contacts of other detection switches and sent to the alarm relay of the belt conveyor control system. 3) The normally open contact of the first micro switch (13) is connected to the counting module (2) to trigger the counting of slight deviation signals; 4) When the belt conveyor runs off track severely, the vertical roller (11) of the detection switch continues to deflect, triggering the second micro switch (14) to operate. One normally closed contact of the second micro switch (14) is connected in series with the normally closed contacts of other detection switches and sent to the emergency stop relay (7) of the belt conveyor control system for alarm and shutdown of severe deviation. 5) The normally open contact of the second micro switch (14) is connected to the counting module (2) and is used to trigger the counting of severe deviation signals; 6) Regularly test the detection switch to quickly diagnose the location of minor and severe deviation faults, accumulate and count the minor and severe deviation signals, and record the number of minor and severe deviation faults. The counting module (2) includes a first counter and a second counter, which are connected to the first micro switch (13) and the second micro switch (14) respectively, for accumulating and counting the slight deviation signal and the severe deviation signal, and recording the number of times the slight and severe deviation faults occur; The display module is connected to the counting module (2) and is used to display the accumulated value of the two counters on the display module, so that maintenance personnel can quickly diagnose the location and number of faults. 7) Based on the diagnosis in 6) above, For minor belt misalignment issues, the first step is to observe the belt's operation to maintain production, and then make adjustments during a temporary shutdown. 8) Based on the diagnosis in 6) above, For severe deviation faults, immediate action should be taken: First, to ensure belt operation, any blockages must be cleared or damaged bearings replaced before attempting to start the belt. If the belt still runs off-track, install a guide wheel to force it to correct the misalignment. If the deviation is caused by the off-center feeding position, weld a plate inside the feed tube and adjust the feeding angle; 9) After addressing the location of the minor or severe misalignment fault, activate the reset button (5) connected to the counting module (2) to initialize and reset the accumulated value of the counter in the counting module (2) for subsequent misalignment monitoring. The detection switches are installed in pairs on both the beginning and end sides of a conveyor belt, for a total of 4.

2. The belt conveyor misalignment monitoring method as described in claim 1, characterized in that, 7) For minor deviation faults, the following procedures should be followed: For unidirectional belts, adjust the tension on both sides of the belt to adjust the amount of belt misalignment. For reversible belts, due to the existence of forward and reverse rotation, there will be a situation where the belt runs to one side when rotating forward and to the other side when rotating in reverse. It is necessary to install a guide wheel to force the belt to deviate. This should be done after the machine has a downtime.

3. The belt conveyor misalignment monitoring method as described in claim 1, characterized in that, Regular inspections of belt conveyors should be conducted based on the size or type of material being transported. For belt conveyors primarily transporting small particles such as auxiliary materials and alloys, which are used less frequently, inspections can be performed every 10-15 days. For conveyor belts transporting large particles, such as lime, inspections should be conducted every 3-4 days due to the high frequency of use of the conveyor belts.

4. A belt conveyor misalignment monitoring device for use in the belt conveyor misalignment monitoring method of claim 1, characterized in that, The device includes: The system comprises a detection switch (1), a counting module (2), a display module (3), a power supply, and a reset button (5). Its features include: The detection switch includes: a vertical roller (11), a linkage mechanism (12), a first micro switch (13) and a second micro switch (14); when the belt deviates, it presses against the vertical roller (11), and is driven by the linkage mechanism (12) to trigger the first micro switch and the second micro switch to issue an alarm signal; Among them, the first micro switch (13) is used to detect the first-level belt misalignment alarm, including a normally closed contact and a normally open contact. The normally closed contact is connected in series with the normally closed contacts of other detection switches and sent to the alarm relay of the belt conveyor control system for alarming minor misalignment. The normally open contact is connected to the counting module (2) for triggering the counting of minor misalignment signals. The second micro switch (14) is used to detect the secondary belt misalignment alarm. It includes a normally closed contact and a normally open contact. The normally closed contact is connected in series with the normally closed contacts of other detection switches and sent to the emergency stop relay of the belt conveyor control system for alarm and shutdown of severe misalignment. The normally open contact is connected to the counting module (2) for triggering the counting of severe misalignment signals.

5. The belt conveyor misalignment monitoring device as described in claim 4, characterized in that, The counting module (2) includes a first counter and a second counter, which are connected to the first micro switch (13) and the second micro switch (14) respectively, and are used to accumulate and count the mild deviation signal and the severe deviation signal and record the number of mild and severe deviation faults.

6. The belt conveyor misalignment monitoring device as described in claim 4, characterized in that, A display module (3) is set up and connected to the counting module (2) to display the accumulated values ​​of the two counters, namely the minor deviation fault counter and the severe deviation fault counter, on the display module (3) for maintenance personnel to quickly diagnose the location and frequency of the fault.

7. The belt conveyor misalignment monitoring device as described in claim 4, characterized in that, The reset button (5) is connected to the counting module (2) and is used to initialize and reset the accumulated values ​​of the two counters of the counting module, namely the mild deviation fault counter and the severe deviation fault counter.

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