An intelligent detection system based on remote operation and maintenance

Abstract

The present invention discloses an intelligent detection system based on remote operation and maintenance, which relates to the technical field of belt conveyor detection, and comprises an operation data acquisition module, a cloud module and an early warning module; the collected data is sent to a server in the cloud module for monitoring and analysis, and the data is monitored by the server in the cloud module to realize centralized management and remote access of the data, which facilitates the remote operation and maintenance work of the operation and maintenance personnel. The operation and maintenance personnel can analyze the data at the remote end, and the operation and maintenance personnel can remotely view the real-time operation status and historical data of the belt conveyor through a mobile device or a control center, quickly locate the problem and take corresponding measures, thereby reducing the maintenance cost and the risk of production interruption, timely discovering the problem and taking measures, ensuring the stable operation of the production line and reducing the maintenance cost, and improving the operation and maintenance efficiency and accuracy.

Description

Technical Field

[0001] The present invention relates to the technical field of belt conveyor detection, and in particular to an intelligent detection system based on remote operation and maintenance. Background Art

[0002] In the industrial field, the cleaning equipment products in the field of belt conveyors can realize the connection between equipment and equipment, and the connection between equipment and information systems can reduce circulation links, save management costs, and improve production efficiency. Belt conveyors are one of the important transportation equipment for underground mining and transportation of coal mines. The belts play the role of traction and load-bearing. Because belt conveyors have the characteristics of low energy consumption and easy assembly, they are widely used in ground transportation and transportation lanes in coal mines. With the increase in coal mining and the application of conveyors, their economic value is also gradually increasing.

[0003] The patent publication number CN101231251A discloses a conveyor belt tear detection device and method, which is a belt conveyor belt fault detection device and method. It includes an image acquisition device and an electronic device installed below the belt, and the image acquisition device is connected to the electronic device. Its detection method is: an image acquisition device and an electronic device are installed below the belt, the image acquisition device continuously photographs the lower surface of the running belt conveyor belt, and outputs the imaging signal to the electronic device, after the electronic device performs real-time analysis and processing on the image of the belt surface and the leaked material, it outputs a signal of whether the belt is torn, and uses an automatic camera device to take pictures, scan and scan the lower surface of the running belt, and cooperate with the electronic device. After analyzing and processing the collected images, an alarm signal can be issued at the early stage of the belt tearing, preventing accidents from occurring and expanding, reducing the equipment operation cost, and improving the operation safety performance and safety factor of the conveyor.

[0004] However, during the operation of the belt conveyor, due to the complex contact between the belt and the roller, affected by factors such as vibration and wear, traditional measurement methods are difficult to detect roller abnormalities and belt position deviation changes in a timely and accurate manner, which will cause the angle of the belt to change, thus affecting the normal use of the belt conveyor. Based on this, an intelligent detection system based on remote operation and maintenance is proposed. Summary of the invention

[0005] The purpose of the present invention is to provide an intelligent detection system based on remote operation and maintenance, which solves the technical problem that traditional measurement methods are difficult to detect roller abnormalities and belt position deviation changes in a timely and accurate manner.

[0006] The purpose of the present invention can be achieved through the following technical solutions:

[0007] An intelligent detection system based on remote operation and maintenance, comprising:

[0008] Operation data acquisition module, real-time collection of belt conveyor operation status data;

[0009] The cloud module sends the collected data to the cloud server for monitoring and analysis, detects belt conveyor anomalies, and generates anomaly mark types, including roller anomalies and belt position deviation marks;

[0010] The early warning module will immediately generate an alarm message once an abnormality is detected in the belt conveyor, and send it to the mobile device or control center of the operation and maintenance personnel via SMS, email or APP push.

[0011] As a further solution of the present invention: the specific method of real-time collection of the running status data of the belt conveyor is:

[0012] The deviation switch installed on the belt conveyor is used to detect the belt deviation signal and monitor in real time whether the belt deviates from the normal track. The tear switch is used to detect the belt tear signal and discover the belt damage in time. The pull rope switch is used for emergency shutdown. The smoke sensor is used to detect the smoke signal, and the frequency converter is used to monitor the current and voltage data of the head position motor. At the same time, these sensors are used to collect the operating status data of the belt conveyor in real time.

[0013] As a further solution of the present invention: the specific method of generating roller abnormality and tape position deviation mark is:

[0014] An image acquisition module is used to capture image data of the belt conveyor when it is working;

[0015] The elevation difference interval acquisition module analyzes the distance between the contact point and the center point between the tape and the roller to obtain the first and second elevation difference intervals;

[0016] The deviation angle interval acquisition module obtains the angle deviation interval between the tape and the horizontal line by establishing a right triangle and angle calculation;

[0017] The abnormal marking module analyzes the contact point position between the tape and the roller in real time, obtains the real-time distance between contact point one, contact point two and center point one, center point two and the real-time angle of the tape, and compares it with the corresponding first and second elevation difference intervals and angle deviation intervals, and generates the first abnormal mark, the second abnormal mark or the deviation abnormal mark according to the comparative analysis results.

[0018] As a further solution of the present invention: the specific method of obtaining the first and second elevation difference intervals is:

[0019] Mark the two rollers as roller one and roller two respectively, determine their center points one and two, set contact point one and contact point two between the belt and roller one and roller two, randomly obtain the position coordinates of the contact points and center points n times during the operation of the belt conveyor, calculate the distance L1n between contact point one and center point one each time by using the distance calculation formula, and calculate the discrete value F1 of L1n, determine the reference value E1 between contact point one and center point one according to the comparison between the discrete value and the preset value Y1, determine the reference value E2 between contact point two and center point two by the same method, and establish the first elevation difference interval G1[E1-F1, E1+F1] and the second elevation difference interval G2[E2-F2, E2+F2] between the belt and the rollers of the belt conveyor according to the reference values ​​E1, E2 and the discrete values ​​F1, F2, respectively, where n is a positive integer, n≥1.

[0020] As a further solution of the present invention: the specific method of determining the reference value E1 between the contact point 1 and the center point 1 is:

[0021] When the discrete value F1 is less than the preset value Y1, the mean value L1p of L1a is used as the reference value E1; when the discrete value F1 is greater than or equal to the preset value Y1, the mean value of the maximum and minimum values ​​in L1a is used as the reference value E1.

[0022] As a further solution of the present invention: the specific method of obtaining the angle deviation interval between the tape and the horizontal line is:

[0023] While randomly obtaining the coordinates of the contact point positions n times, a horizontal line P is set with contact point one as the origin each time, and a perpendicular line C is made with contact point two as the origin and perpendicular to the horizontal line P, and the foot of the perpendicular D is marked. At the same time, a closed right triangle is constructed, and the length of the connecting line RAn between contact point one and contact point two, the length of the connecting line RBn between contact point one and the foot of the perpendicular D, and the length of the connecting line RCn between contact point two and the foot of the perpendicular D in the right triangle constructed each time are calculated respectively by the distance calculation formula. The cosine value of the angle between the line segments RAn and RBn is calculated according to the cosine theorem, and then the angle value θn of the angle between the line segments RAn and RBn in the right triangle constructed each time is calculated by the inverse cosine function, and the discrete value W of θn is obtained. The reference deviation angle J is determined according to the preset screening condition Q, and finally the deviation angle interval K[JW, J+W] is obtained.

[0024] As a further solution of the present invention: the specific method for calculating the angle value θn between the line segments RAn and RBn in the right triangle constructed each time is:

[0025] According to the cosine theorem, through the formula: Calculate the cosine value cos(θn) of the angle between the line segments RAn and RBn in each constructed right triangle;

[0026] Then, based on the arccosine function, the angle value θn corresponding to the angle between the line segments RAn and RBn in the right triangle constructed each time is calculated using the formula θn=arccos[cos(θn)]×(180 / π).

[0027] As a further solution of the present invention: the specific method of determining the reference deviation angle according to the preset screening conditions is:

[0028] Get the value θc in θn that meets the preset condition |θn-θp|≥Y3, where c is the number of values ​​in θn that meet the preset condition Q, n≥c≥1, and compare the number c with the preset threshold value Y2. When the number c is greater than the preset threshold value Y2, the mean θp of θj is defined as the reference deviation angle J corresponding to the tape. When the number c is less than the preset threshold value Y2, the mean of the maximum and minimum values ​​in θn is defined as the reference deviation angle J corresponding to the tape, where Y3 is the preset value.

[0029] As a further solution of the present invention: the specific method of generating the first abnormal mark, the second abnormal mark or the deviation abnormal mark is:

[0030] During the operation of the belt conveyor, the real-time position coordinates of the belt and the roller at contact point one and contact point two are obtained in real time, and the real-time distances R1 and R2 between contact point one, contact point two and center point one and center point two, as well as the real-time angle Z of the belt are calculated. When the real-time distance R1 does not belong to the first elevation difference interval, a first abnormal mark is generated; when the real-time distance R2 does not belong to the second elevation difference interval, a second abnormal mark is generated; when the real-time angle Z does not belong to the deviation angle interval, a deviation abnormal mark is generated, otherwise no processing is performed.

[0031] As a further solution of the present invention: it also includes a shutdown control module;

[0032] The shutdown control module generates a shutdown signal when the first abnormal mark, the second abnormal mark and the deviation abnormal mark are generated at the same time, and performs shutdown control on the belt conveyor through the control center.

[0033] Beneficial effects of the present invention:

[0034] (1) The present invention sends the collected data to the server in the cloud module for monitoring and analysis. The server in the cloud module monitors the data to realize centralized management and remote access of the data, which facilitates the remote operation and maintenance work of the operation and maintenance personnel. The operation and maintenance personnel can analyze the data at the remote end. The operation and maintenance personnel can remotely view the real-time operating status and historical data of the belt conveyor through a mobile device or a control center, quickly locate the problem and take corresponding measures, thereby reducing maintenance costs and production interruption risks, timely discovering problems and taking measures, ensuring the stable operation of the production line and reducing maintenance costs, and improving operation and maintenance efficiency and accuracy.

[0035] (2) The present invention obtains the position coordinates of the belt and the roller and the angle between the belt and the horizontal line in real time, and compares and analyzes them with the preset elevation difference interval and deviation angle interval. Once an abnormality is found, a corresponding abnormal mark such as a first abnormal mark, a second abnormal mark, and a deviation abnormal mark is immediately generated to help operation and maintenance personnel quickly locate the specific problem part such as roller one, roller two or the belt as a whole, thereby improving the operation and maintenance efficiency and accuracy, being able to more accurately monitor the operating status of the belt conveyor, promptly discover and deal with potential problems, ensure the stable operation of the production line and reduce maintenance costs.

[0036] (3) In the present invention, when the first abnormal mark, the second abnormal mark and the deviation abnormal mark are generated at the same time, a shutdown signal is generated and sent to the control module, which controls the belt conveyor to shut down. When multiple abnormal situations occur at the same time, it indicates that the belt conveyor may be in a serious fault state. Timely shutdown can prevent the equipment from continuing to run and causing more serious damage, reduce maintenance costs and recovery time. The shutdown control module plays an important role in safety protection. It can shut down the equipment in time when a serious abnormality occurs, prevent further damage to the equipment and ensure production safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The present invention will be further described below in conjunction with the accompanying drawings.

[0038] Figure 1 It is a schematic diagram of the system framework structure of the present invention;

[0039] Figure 2 It is a schematic diagram of the framework structure for generating roller abnormality and tape position deviation marks according to the present invention;

[0040] Figure 3 It is a schematic structural diagram of a right triangle of the present invention. DETAILED DESCRIPTION

[0041] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0042] Embodiment 1

[0043] See also Figure 1 As shown, the present invention is an intelligent detection system based on remote operation and maintenance, comprising:

[0044] Operation data acquisition module, install deviation switch, tear switch, pull rope switch, smoke sensor and frequency converter and other sensors on the belt conveyor to collect the operation status data of the belt conveyor in real time;

[0045] Install a deviation switch to detect belt deviation signals and monitor in real time whether the belt deviates from the normal track;

[0046] Tear switch, used to detect belt tearing signals and find belt damage in time;

[0047] Pull rope switch, used for emergency shutdown. When an abnormal situation occurs, the operator can pull the rope to trigger the shutdown signal;

[0048] Smoke sensor, used to detect smoke signals and prevent potential safety hazards such as fire;

[0049] The frequency converter is used to monitor the current and voltage data of the motor at the machine head position and determine the motor operating status;

[0050] It should be noted that in order to more accurately monitor the operating status of the belt conveyor, the operating data acquisition module sets a reasonable data acquisition frequency. For switch sensors such as deviation switches and tear switches, the acquisition frequency can be dynamically adjusted according to the operating speed of the belt conveyor and actual needs. For example, when the belt conveyor is running at high speed, the acquisition frequency should be appropriately increased to ensure that the moment of abnormal situations such as belt deviation or tearing can be captured in time. For devices that can continuously monitor data, such as smoke sensors and frequency converters, it can ensure that extremely low concentrations of smoke can be accurately detected to warn of fire hazards in advance. The frequency converter provides reliable data support for accurately judging the operating status of the motor.

[0051] Deviation switches are installed on both sides of the belt conveyor and evenly distributed along the running direction of the belt to ensure that the deviation of the belt in the lateral direction can be fully monitored. A deviation switch is installed at a certain interval and adjusted reasonably according to the length of the belt conveyor and the actual operating environment. The tear switch is installed at the position where the belt is prone to tearing, such as the joints of the belt, the area near sharp objects, etc. The pull rope switch is installed in a position that is easy for the operator to reach, usually set along the periphery of the belt conveyor, so that the operator can quickly pull the pull rope in an emergency. The smoke sensor is installed at the key parts of the belt conveyor, such as near the motor, the area where the belt is prone to generate friction heat, and the poorly ventilated area, to ensure that the possible smoke can be detected in time. The inverter is directly connected to the head position motor to collect the current and voltage data of the motor.

[0052] The cloud module sends the collected data to the cloud server for monitoring and analysis. Monitoring the data through the cloud realizes centralized management and remote access of the data, which facilitates the remote operation and maintenance work of the operation and maintenance personnel. The operation and maintenance personnel can analyze the data remotely. The operation and maintenance personnel can remotely view the real-time operation status and historical data of the belt conveyor through mobile devices or control centers, quickly locate problems and take corresponding measures, reduce maintenance costs and production interruption risks, and timely discover problems and take measures;

[0053] For example, when an abnormal mark appears, the cloud system will promptly notify the operation and maintenance personnel, who can quickly locate the specific problem area based on the specific type of abnormal mark, such as roller abnormality or tape position deviation, and then make corresponding adjustments or repairs to the equipment through remote control, thereby improving the efficiency and accuracy of operation and maintenance, ensuring the stable operation of the production line, reducing maintenance costs, and improving the efficiency and accuracy of operation and maintenance.

[0054] The early warning module immediately generates an alarm message once an abnormality is detected, and sends it to the operation and maintenance personnel's mobile device or control center via SMS, email or APP push. It can monitor the operating status of the belt conveyor in real time and send the data to the cloud for monitoring and analysis, realizing remote operation and maintenance and fault early warning functions, improving operation and maintenance efficiency and accuracy, and reducing maintenance costs and production interruption risks.

[0055] Embodiment 2

[0056] As a second embodiment of the present invention, please refer to Figure 2-Figure 3 As shown, in the specific implementation of the present application, compared with the first embodiment, the technical solution of the present embodiment is different from the first embodiment only in that the present embodiment also includes a marking determination method for roller abnormality or tape position deviation, and the specific method is:

[0057] An image acquisition module is used to acquire image data of the belt conveyor when it is working;

[0058] It should be noted that in order to ensure the acquisition of high-quality image data of the belt conveyor when it is working, you can choose industrial cameras, network cameras and other equipment to shoot. At the same time, you can clearly observe the position of the contact area between the belt and the roller according to the selection, avoid being blocked by other objects, and also consider the lighting conditions and the safety of the equipment. Avoid installing it in a position that is susceptible to vibration, dust, etc. If necessary, equip it with appropriate lighting equipment such as LED lights to supplement the ambient light and reduce the impact of shadows and reflections on the image data quality;

[0059] The elevation difference interval acquisition module analyzes the image data of the belt conveyor when it is working, sets contact point 1 and contact point 2 between the belt and the roller of the belt conveyor, analyzes the distance between contact point 1 and contact point 2 and center point 1 and center point 2, and obtains the first elevation difference and the second elevation difference interval between the belt and the roller of the belt conveyor according to the analysis results. The specific method of obtaining the first elevation difference and the second elevation difference interval between the belt and the roller of the belt conveyor is:

[0060] Mark the two rollers as roller one and roller two, define the center points of roller one and roller two as center point one and center point two, respectively, and set contact point one and contact point two between the belt of the belt conveyor and roller one and roller two, respectively;

[0061] During the operation of the belt conveyor, the position coordinates of the belt and the roller at the contact point 1 and the contact point 2 are obtained randomly n times, and marked as A1n (A1xn, A1yn) and A2n (A2xn, A2yn), and the coordinates of the center point 1 and the center point 2 are marked as O1 (O1x, O1y) and O2 (O2x, O2y) respectively;

[0062] The distance calculation formula is: Calculate the distance L1 n between n contact points A1 n (A1 xn, A1 yn) and the center point O1 (O1 x, O1 y);

[0063] By formula Calculate the discrete value F1 of L1a, where L1p is the mean of L1a, n≥a≥1. When the discrete value F1 is less than the preset value Y1, the mean L1p of L1a is used as the reference value E1. When the discrete value F1 is greater than or equal to the preset value Y1, the mean of the maximum and minimum values ​​in L1a is used as the reference value E1. According to the reference value E1 and the discrete value F1, the first elevation difference interval G1[E1-F1, E1+F1] between the belt and the roller of the belt conveyor is established.

[0064] The same method is used to analyze the distance L2n between the n contact points A2n (A2xn, A2yn) and the center point O2 (O2x, O2y), and the second elevation difference interval G2 [E2-F2, E2+F2] between the belt and the roller of the belt conveyor is obtained according to the analysis results;

[0065] By randomly obtaining the position coordinates of the tape and the roller at the contact point n times, and using discrete value calculation to determine the first elevation difference interval and the second elevation difference interval, the influence of single data fluctuation on the result is effectively reduced, and the accuracy and stability of elevation difference detection are improved;

[0066] The deviation angle interval acquisition module is used to analyze the angle between the belt and the horizontal line, and obtain the deviation angle interval corresponding to the belt of the belt conveyor according to the analysis results. The specific method is as follows:

[0067] During the operation of the belt conveyor, the position coordinates of the belt and the roller at the contact point 1 and the contact point 2 are obtained randomly n times, and each time the contact point 1 is used as the origin. A horizontal line P is first set, and then a vertical line C perpendicular to the horizontal line P is made with the contact point 2 as the origin. At the same time, the intersection between the vertical line C and the horizontal line P is marked as the foot of the vertical line D, and the coordinates of each foot of the vertical line D are marked as Dn (Dxn, Dyn). At the same time, the contact point 1, the contact point 2 and the foot of the vertical line D are connected each time to construct a closed right triangle, where n is the preset number of times, n is a positive integer, and the specific value is formulated by relevant personnel according to actual needs, n≥1;

[0068] Connect contact 1 and contact 2, mark them as line segment RAn, and calculate the length of the connecting line RAn between contact 1 and contact 2, the length of the connecting line RBn between contact 1 and the foot of the perpendicular D, and the length of the connecting line RCn between contact 2 and the foot of the perpendicular D by using the distance formula. The specific calculation method is:

[0069] The distance calculation formula is: Calculate and obtain the length of the connecting line RAn between contact 1 and contact 2 each time;

[0070] The distance calculation formula is: Calculate and obtain the length of the connecting line RBn between the contact point 1 and the foot of the perpendicular D each time;

[0071] The distance calculation formula is: Calculate the length of the connecting line RCn between the second contact and the foot of the perpendicular D each time;

[0072] After each right triangle is constructed, according to the cosine theorem, the formula is: Calculate the cosine value cos(θn) of the angle between the line segments RAn and RBn in the right triangle constructed each time, and then calculate the angle value θn corresponding to the angle between the line segments RAn and RBn in the right triangle constructed each time according to the inverse cosine function through the formula θn=arccos[cos(θn)]×(180 / π);

[0073] pass Calculate the discrete value W of θj, where θp is the mean of θj, n≥j≥1, obtain the value θc in θj that meets the preset condition Q, where c is the number of values ​​in θj that meet the preset condition Q, n≥c≥1, compare the number c with the preset threshold value Y2, when the number c is greater than the preset threshold value Y2, it means that the number of values ​​in θj that meet the preset condition Q is large, and the mean of θj is representative, and then define the mean θp of θj as the reference deviation angle J corresponding to the tape, when the number c is less than the preset threshold value Y2, it means that the number of values ​​in θj that meet the preset condition Q is small, and the mean of θj is not representative, and then define the mean of the maximum and minimum values ​​in θj as the reference deviation angle J corresponding to the tape, that is, J=(θ min +θ ax ) / 2, where θ max and θ min are the maximum and minimum values ​​in θj respectively;

[0074] Here, the preset condition Q is specifically: |θj-θp|≥Y3, where Y3 is a preset value, and the specific values ​​of Y2 and Y3 are formulated by relevant personnel according to actual needs;

[0075] According to the discrete value W and the reference deviation angle J, the deviation angle interval K[JW, J+W] corresponding to the belt of the belt conveyor is established;

[0076] By setting the preset condition Q and calculating the discrete value W, it is possible to intelligently screen out representative data points and determine the reference deviation angle J, thus improving the robustness and accuracy of deviation angle monitoring.

[0077] The abnormal marking module obtains the real-time position coordinates of the belt and the roller at the contact point 1 and the contact point 2 in real time during the operation of the belt conveyor, and calculates the real-time distances R1 and R2 between the real-time position coordinates of the contact point 1 and the contact point 2 and the center point 1 and the center point 2, respectively. At the same time, the real-time angle between the belt and the horizontal line is obtained, and the real-time distances R1 and R2 and the real-time angle are compared and analyzed with the corresponding first elevation difference interval, second elevation difference interval and deviation angle interval, and an abnormal mark is generated according to the analysis results. The specific method is as follows:

[0078] The specific method for obtaining the real-time angle between the tape and the horizontal line is:

[0079] During the operation of the belt conveyor, the real-time position coordinates of the belt and the roller at the contact point 1 and the contact point 2 are obtained in real time. The real-time right triangle is established in the same way as the right triangle is constructed in the deviation angle interval acquisition module. The real-time right triangle is analyzed by the cosine theorem, and the real-time angle Z between the belt and the horizontal line is obtained according to the analysis results.

[0080] The specific way to generate an exception marker is:

[0081] The real-time distances R1 and R2 are compared and analyzed with the first elevation difference interval and the second elevation difference interval respectively. When the real-time distance R1 does not belong to the first elevation difference interval, a first abnormal mark is generated. When the real-time distance R2 does not belong to the second elevation difference interval, a second abnormal mark is generated. Otherwise, no processing is performed.

[0082] The real-time angle Z between the tape and the horizontal line is compared with the deviation angle interval. When the real-time angle Z does not belong to the deviation angle interval, an abnormal deviation mark is generated, otherwise no processing is performed. The distance change between the tape and the roller can be monitored in real time, and abnormal roller position or tape wear can be discovered in time, thereby improving the stability and reliability of the equipment.

[0083] Generating the first abnormal mark indicates that roller one has an abnormality, generating the second abnormal mark indicates that roller two has an abnormality, and generating the deviation abnormal mark indicates that there is an abnormal deviation between the position of the tape and the horizontal line. The deviation of the tape can be discovered in time, avoiding equipment failure and production interruption caused by tape deviation, thereby improving production efficiency.

[0084] The distance between the contact point and the center point is calculated in real time and compared with the preset elevation difference interval. Once an abnormality is found, a mark is generated immediately to ensure that the operation and maintenance personnel can respond quickly. The position coordinates of the belt and the roller and the angle between the belt and the horizontal line are obtained in real time, and compared and analyzed with the preset elevation difference interval and deviation angle interval. Once an abnormality is found, the corresponding abnormal mark is generated immediately, such as the first abnormal mark, the second abnormal mark, and the deviation abnormal mark, to ensure that the operation and maintenance personnel can quickly locate the problem and take measures. The generated abnormal mark not only indicates the specific type of problem such as roller abnormality and belt position deviation, but also helps the operation and maintenance personnel to quickly locate the specific problem part such as roller one, roller two or the entire belt, which improves the operation and maintenance efficiency and accuracy, and can more accurately monitor the operating status of the belt conveyor, timely discover and deal with potential problems, ensure the stable operation of the production line and reduce maintenance costs.

[0085] Embodiment 3

[0086] As the third embodiment of the present invention, when the present application is implemented, compared with the first and second embodiments, the technical solution of this embodiment is different from the first and second embodiments only in that this embodiment further includes a shutdown control module;

[0087] A shutdown control module generates a shutdown signal when the first abnormality mark, the second abnormality mark and the deviation abnormality mark are generated at the same time, sends the shutdown signal to the control module, and performs shutdown control on the belt conveyor through the control center;

[0088] When the first abnormal mark, the second abnormal mark and the deviation abnormal mark are generated at the same time, a shutdown signal will be generated and sent to the control module. The control module will control the belt conveyor to shut down. When multiple abnormal conditions occur at the same time, it indicates that the belt conveyor may be in a serious fault state. Timely shutdown can avoid more serious damage caused by continued operation of the equipment, reduce maintenance costs and recovery time. The shutdown control module plays an important role in safety protection. It can shut down the equipment in time when a serious abnormality occurs, prevent further damage to the equipment and ensure production safety.

[0089] Embodiment 4

[0090] As the fourth embodiment of the present invention, when the present application is specifically implemented, compared with the first, second and third embodiments, the technical solution of this embodiment is to combine and implement the solutions of the first, second and third embodiments.

[0091] The above formulas are all dimensionless and numerical calculations. The formula is a formula for the most recent real situation obtained by collecting a large amount of data and performing software simulation. The preset parameters and thresholds in the formula are set by technicians in this field according to actual conditions.

[0092] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art who is familiar with the present technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. An intelligent detection system based on remote operation and maintenance, characterized in that: include: Operation data acquisition module, real-time collection of belt conveyor operation status data; The cloud module sends the collected data to the cloud server for monitoring and analysis, detects belt conveyor anomalies, and generates anomaly mark types, including roller anomalies and belt position deviation marks; Early warning module: when the belt conveyor generates abnormal mark type, it will generate alarm information and send it to the mobile device or control center of the operation and maintenance personnel through SMS, email or APP push; The specific method for generating roller anomaly and tape position deviation marks is: An image acquisition module is used to capture image data of the belt conveyor when it is working; The elevation difference interval acquisition module analyzes the distance between the contact point and the center point between the tape and the roller to obtain the first and second elevation difference intervals; The deviation angle interval acquisition module obtains the angle deviation interval between the tape and the horizontal line by establishing a right triangle and angle calculation; The abnormal marking module analyzes the contact point position between the tape and the roller in real time, obtains the real-time distance between contact point one, contact point two and center point one, center point two and the real-time angle of the tape, and compares it with the corresponding first and second elevation difference intervals and angle deviation intervals, and generates the first abnormal mark, the second abnormal mark or the deviation abnormal mark according to the comparative analysis results.

2. According to claim 1, an intelligent detection system based on remote operation and maintenance is characterized in that: The specific method of real-time collection of the operating status data of the belt conveyor is: The deviation switch installed on the belt conveyor is used to detect the belt deviation signal and monitor in real time whether the belt deviates from the normal track. The tear switch is used to detect the belt tear signal and discover the belt damage in time. The pull rope switch is used for emergency shutdown. The smoke sensor is used to detect the smoke signal, and the frequency converter is used to monitor the current and voltage data of the head position motor. At the same time, these sensors are used to collect the operating status data of the belt conveyor in real time.

3. According to claim 1, the intelligent detection system based on remote operation and maintenance is characterized in that: The specific method of obtaining the first and second elevation difference intervals is: Mark the two rollers as roller one and roller two respectively, determine their center points one and two, set contact point one and contact point two between the belt and roller one and roller two, randomly obtain the position coordinates of the contact points and center points n times during the operation of the belt conveyor, calculate the distance L1n between contact point one and center point one each time by using the distance calculation formula, and calculate the discrete value F1 of L1n, determine the reference value E1 between contact point one and center point one according to the comparison between the discrete value and the preset value Y1, determine the reference value E2 between contact point two and center point two by the same method, and establish the first elevation difference interval G1[E1-F1, E1+F1] and the second elevation difference interval G2[E2-F2, E2+F2] between the belt and the rollers of the belt conveyor according to the reference values ​​E1, E2 and the discrete values ​​F1, F2, respectively, where n is a positive integer, n≥1.

4. According to claim 3, the intelligent detection system based on remote operation and maintenance is characterized in that: The specific method for determining the reference value E1 between the contact point 1 and the center point 1 is: When the discrete value F1 is less than the preset value Y1, the mean value L1p of L1a is used as the reference value E1; when the discrete value F1 is greater than or equal to the preset value Y1, the mean value of the maximum and minimum values ​​in L1a is used as the reference value E1.

5. The intelligent detection system based on remote operation and maintenance according to claim 4 is characterized in that: The specific method of obtaining the angle deviation interval between the tape and the horizontal line is: While randomly obtaining the coordinates of the contact point positions n times, a horizontal line P is set with contact point one as the origin each time, and a perpendicular line C is made with contact point two as the origin and perpendicular to the horizontal line P, and the foot of the perpendicular D is marked. At the same time, a closed right triangle is constructed, and the length of the connecting line RAn between contact point one and contact point two, the length of the connecting line RBn between contact point one and the foot of the perpendicular D, and the length of the connecting line RCn between contact point two and the foot of the perpendicular D in the right triangle constructed each time are calculated respectively by the distance calculation formula. The cosine value of the angle between the line segments RAn and RBn is calculated according to the cosine theorem, and then the angle value θn of the angle between the line segments RAn and RBn in the right triangle constructed each time is calculated by the inverse cosine function, and the discrete value W of θn is obtained. The reference deviation angle J is determined according to the preset screening condition Q, and finally the deviation angle interval K[JW, J+W] is obtained.

6. The intelligent detection system based on remote operation and maintenance according to claim 5, characterized in that: The specific method for calculating the angle value θn between the line segments RAn and RBn in the right triangle constructed each time is: According to the cosine theorem, through the formula: Calculate the cosine value cos(θn) of the angle between the line segments RAn and RBn in each constructed right triangle; Then, based on the arccosine function, the angle value θn corresponding to the angle between the line segments RAn and RBn in the right triangle constructed each time is calculated using the formula θn=arccos[cos(θn)]×(180 / π).

7. The intelligent detection system based on remote operation and maintenance according to claim 6 is characterized in that: The specific method of determining the reference deviation angle according to the preset screening conditions is as follows: Get the value θc in θn that meets the preset condition |θn-θp|≥Y3, where c is the number of values ​​in θn that meet the preset condition Q, n≥c≥1, and compare the number c with the preset threshold value Y2. When the number c is greater than the preset threshold value Y2, the mean θp of θj is defined as the reference deviation angle J corresponding to the tape. When the number c is less than the preset threshold value Y2, the mean of the maximum and minimum values ​​in θn is defined as the reference deviation angle J corresponding to the tape, where Y3 is the preset value.

8. The intelligent detection system based on remote operation and maintenance according to claim 7, characterized in that: The specific method of generating the first abnormality mark, the second abnormality mark or the deviation abnormality mark is: During the operation of the belt conveyor, the real-time position coordinates of the belt and the roller at contact point one and contact point two are obtained in real time, and the real-time distances R1 and R2 between contact point one, contact point two and center point one and center point two, as well as the real-time angle Z of the belt are calculated. When the real-time distance R1 does not belong to the first elevation difference interval, a first abnormal mark is generated; when the real-time distance R2 does not belong to the second elevation difference interval, a second abnormal mark is generated; when the real-time angle Z does not belong to the deviation angle interval, a deviation abnormal mark is generated, otherwise no processing is performed.

9. The intelligent detection system based on remote operation and maintenance according to claim 8, characterized in that: Also includes a shutdown control module; The shutdown control module generates a shutdown signal when the first abnormal mark, the second abnormal mark and the deviation abnormal mark are generated at the same time, and performs shutdown control on the belt conveyor through the control center.

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