Device and method applied to online fault monitoring of tubular belt conveyor

Abstract

The automatic conveying device comprises four sets of monitoring cameras and a deviation switch, the first set of monitoring cameras are installed above the head of a belt, the two sets of monitoring cameras in the middle are installed above the middle turning position of the belt, and the deviation switch is installed above the middle turning position of the belt. And the fourth group of monitoring cameras are arranged above the tail part of the belt. Two groups of the deviation switches are arranged on two sides of the unfolding section of the working surface of the machine head belt, and the other two groups of the deviation switches are arranged on two sides of the unfolding section of the non-working surface of the machine tail belt. The invention relates to the field of monitoring of tubular belt conveyors, in particular to equipment and a method applied to online fault monitoring of a tubular belt conveyor.

Description

Technical Field

[0001] The invention relates to the field of tubular belt conveyor monitoring, and in particular to a device and method for online monitoring of faults of tubular belt conveyors. Background Art

[0002] Ironmaking raw materials are generally transported by belt conveyors, which consist of several transfer stations and multiple belts. The transfer stations are artificially added to achieve the function of controlling the direction of the material flow. The significant feature of tubular belt conveyors over general belt conveyors is that they can make small radius turns, thereby reducing the profile. Tubular belt conveyors can be selected when general belt conveyors cannot be used geographically or when multiple transfer points are required.

[0003] The tubular belt conveyor is a new type of continuous conveying equipment developed on the basis of ordinary belt conveyors. Its head and tail structures are similar to those of ordinary belt conveyors. The middle belt is forcibly wrapped into a circle by hexagonally arranged drag rollers. The conveyed materials are completely enclosed in the round tube and run stably with the belt. The tubular belt conveyor technology occupies an important position in the ironmaking transportation system. It plays a vital role in the efficient transportation of raw materials and environmental protection, and is the key to ensuring the stable operation and efficient production of ironmaking.

[0004] Due to long-term operation, various faults of tubular belts are difficult to avoid. Among them, the more common faults are belt twisting, tube expansion, and tube collapse. If such faults occur in the belt and are not discovered and stopped in time, the entire belt will be damaged. The belt replacement workload is large, the maintenance time is long, the production is interrupted, and the losses are extremely huge. Summary of the invention

[0005] The technical problem to be solved by the present invention is that various faults of tubular belts are difficult to avoid during long-term operation. Among them, the more common faults are belt twisting, tube expansion and tube collapse. If such faults occur in the belt and are not discovered and stopped in time, the entire belt will be damaged, the belt replacement workload is large, the maintenance time is long, the production is interrupted, and the loss is extremely huge.

[0006] In order to solve the above problems, the technical solution adopted by the present invention is as follows: The present invention is a device used for online monitoring of faults of tubular belt conveyors, including monitoring cameras and deviation switches. The monitoring cameras are provided in four groups. The monitoring cameras in the first group are installed above the belt head, the monitoring cameras in the middle two groups are installed above the middle turning point of the belt, and the monitoring cameras in the fourth group are installed above the tail of the belt.

[0007] There are four groups of deviation switches, two groups of which are installed on both sides of the unfolded section of the working surface of the head belt, and the other two groups of which are installed on both sides of the unfolded section of the non-working surface of the tail belt.

[0008] Furthermore, it also includes a 10 Gigabit switch, to which a first video recorder is electrically connected, to which an intelligent analysis host is electrically connected, to which a display is electrically connected, and to which a PLC controller is electrically connected. The PLC controller sends out an alarm and an interlocking protection signal.

[0009] Furthermore, a rack-mounted optical fiber box is connected to the 10 Gigabit switch, and the rack-mounted optical fiber box is electrically connected to a monitoring camera, and the monitoring camera is connected via the rack-mounted optical fiber box to obtain real-time belt running image data.

[0010] Furthermore, the rack-mounted optical fiber box is electrically connected to a network relay, and the network relay is electrically connected to a lighting device. The rack-mounted optical fiber box controls the network relay contacts and then controls the attraction of the relay, thereby realizing the turning on and off of the lighting device.

[0011] Furthermore, the rack-mounted optical fiber box is electrically connected to an alarm, and the rack-mounted optical fiber box controls the serial port server and then connects to the alarm to realize the on-site alarm function.

[0012] A method for online monitoring of faults of a tubular belt conveyor, comprising the following steps:

[0013] Step 1: Install one surveillance camera at the belt head, two surveillance cameras at the belt middle bend, and one surveillance camera at the belt tail, and use the first video recorder for auxiliary monitoring;

[0014] Step 2: Set up a local video front-end box next to the surveillance camera, and set up a network relay, optical fiber box and other components in the front-end box;

[0015] Step 3: The system controls the network relay contacts through the rack-mounted fiber optic box and then controls the relay to turn on and off the lighting device. The system connects to the monitoring camera through the rack-mounted fiber optic box to obtain real-time belt running image data. The system controls the serial port server through the rack-mounted fiber optic box and then connects to the alarm to realize the on-site alarm function.

[0016] Step 4: The system collects on-site image data in real time and uses the model to judge the image data. When the current state abnormality exceeds the warning threshold, the system triggers the alarm program and archives the data. At the same time, the switch signal is output to the PLC controller through the network relay, and the PLC controller realizes the control alarm and interlock shutdown;

[0017] Step 5: Install deviation switches at the head and tail of the tubular belt conveyor where the deviation characteristics are most obvious. When the belt is distorted, the belt will touch the deviation switch at the characteristic position. The deviation switch signal is connected to the PLC controller, and the PLC controller sends out an alarm and interlocking signal.

[0018] Step 6: When the belt shows signs of buckling, expansion or collapse, a voice alarm will be issued in the operation room to alert the operator, and a voice and sound and light alarm will be issued on site to alert the inspection personnel;

[0019] Step seven: To avoid false tripping of the equipment due to inaccurate detection, the belt will be interlocked and stopped only when the video and deviation switch trip signals appear at the same time.

[0020] The beneficial effects achieved by the present invention using the above structure are as follows:

[0021] 1. The system uses optical fiber to connect the remote server in the operation room to the camera and network relay in the belt corridor, and connects the monitoring camera through the optical fiber network to obtain real-time belt operation image data, controls the serial port server and then connects the sound and light alarm to realize the on-site alarm function. The system collects on-site image data in real time, judges the image data through the model, and triggers the alarm when the current state is abnormal, starts the alarm program and archives the data. At the same time, the switch signal is output to the PLC through the network relay, and the PLC realizes the control alarm and interlock shutdown.

[0022] 2. Install two deviation switches on the working surface of the belt expansion section at the head of the belt conveyor, and install two deviation switches on the non-working surface of the belt expansion section at the tail of the belt conveyor. The deviation switch signals are connected to the PLC. When the belt deviates and is about to reach the belt correction deviation, the belt touches the deviation switch. After the PLC receives the deviation signal, the PLC program implements alarm and interlock shutdown. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic diagram of the overall structure proposed by the present invention;

[0024] Figure 2 This is a schematic diagram of the installation positions of the monitoring camera, money-running switch and belt proposed in the present invention. DETAILED DESCRIPTION

[0025] Cameras, monitoring cameras, deviation switches, etc. are installed at relevant parts of the tubular belt, and image comparison, machine learning, position detection and other technologies are used to realize multi-dimensional data hybrid monitoring and intelligent analysis. The belt forming (tube expansion, tube collapse, torsion) and other working conditions can be monitored, video tracking, linked alarm system and interlocked PLC shutdown can be carried out to solve the pain points of long, time-consuming and untimely manual inspection paths, which is convenient for early warning of equipment failures, prevent the expansion of losses, and thus shorten the downtime.

[0026] A monitoring camera and deviation switch are installed at the belt head to monitor material blockage, deviation and twisting;

[0027] Two monitoring cameras are installed at the middle bend of the belt to monitor twisting, tube expansion and tube collapse;

[0028] A monitoring camera and deviation switch are installed at the tail of the belt to monitor the twisting and expansion of the tube;

[0029] By comparing the above monitoring signals with the benchmark, the alarm threshold can be modified. When the alarm threshold is reached, an alarm is triggered, prompting the operator to make timely adjustments and interventions.

[0030] As the instruction manual Figure 1-2 As shown, the present invention is a device and method for online monitoring of faults of a tubular belt conveyor. The present invention is a device for online monitoring of faults of a tubular belt conveyor, including monitoring cameras and deviation switches. The monitoring cameras are provided in four groups. The monitoring cameras in the first group are installed above the belt head, the monitoring cameras in the middle two groups are installed above the middle turning point of the belt, and the monitoring cameras in the fourth group are installed above the tail of the belt. The four groups of monitoring cameras comprehensively monitor the belt condition.

[0031] There are four groups of deviation switches, two groups of which are installed on both sides of the unfolded section of the working surface of the head belt, and the other two groups of which are installed on both sides of the unfolded section of the non-working surface of the tail belt, with externally controlled deviation switches.

[0032] It also includes a 10 Gigabit switch, which is electrically connected to a first video recorder, which is electrically connected to an intelligent analysis host, which is electrically connected to a display, and which is electrically connected to a PLC controller. The PLC controller sends out an alarm and interlocking protection signal.

[0033] The 10G switch is connected to a rack-mounted optical fiber box, which is electrically connected to a monitoring camera. The rack-mounted optical fiber box is connected to the monitoring camera to obtain real-time belt running image data and detect problems in time.

[0034] The rack-mounted optical fiber box is electrically connected to a network relay, and the network relay is electrically connected to a lighting device. The rack-mounted optical fiber box controls the network relay contacts and then controls the relay to be attracted, thereby realizing the opening and closing of the lighting device and providing a light source.

[0035] The rack-mounted optical fiber box is electrically connected to an alarm, and the rack-mounted optical fiber box controls the serial port server and then connects to the alarm to realize the on-site alarm function and sound and light alarm prompts.

[0036] A method for online monitoring of faults of a tubular belt conveyor, comprising the following steps:

[0037] Step 1: Install one surveillance camera at the belt head, two surveillance cameras at the belt middle bend, and one surveillance camera at the belt tail, and use the first video recorder for auxiliary monitoring;

[0038] Step 2: Set up a local video front-end box next to the surveillance camera, and set up a network relay, optical fiber box and other components in the front-end box;

[0039] Step 3: The system controls the network relay contacts through the rack-mounted fiber optic box and then controls the relay to turn on and off the lighting device. The system connects to the monitoring camera through the rack-mounted fiber optic box to obtain real-time belt running image data. The system controls the serial port server through the rack-mounted fiber optic box and then connects to the alarm to realize the on-site alarm function.

[0040] Step 4: The system collects on-site image data in real time and uses the model to judge the image data. When the current state abnormality exceeds the warning threshold, the system triggers the alarm program and archives the data. At the same time, the switch signal is output to the PLC controller through the network relay, and the PLC controller realizes the control alarm and interlock shutdown;

[0041] Step 5: Install deviation switches at the head and tail of the tubular belt conveyor where the deviation characteristics are most obvious. When the belt is distorted, the belt will touch the deviation switch at the characteristic position. The deviation switch signal is connected to the PLC controller, and the PLC controller sends out an alarm and interlocking signal.

[0042] Step 6: When the belt shows signs of buckling, expansion or collapse, a voice alarm will be issued in the operation room to alert the operator, and a voice and sound and light alarm will be issued on site to alert the inspection personnel;

[0043] Step seven: To avoid false tripping of the equipment due to inaccurate detection, the belt will be interlocked and stopped only when the video and deviation switch trip signals appear at the same time.

[0044] It should be understood that although this specification is described according to implementation methods, not every implementation method contains only one independent technical solution. This narrative method of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.

Claims

1. A device for online fault monitoring of a tubular belt conveyor, characterized in that: It includes monitoring cameras and deviation switches. The monitoring cameras are arranged in four groups. The monitoring cameras in the first group are installed above the belt head, the monitoring cameras in the middle two groups are installed above the middle bend of the belt, and the monitoring cameras in the fourth group are installed above the belt tail. There are four groups of deviation switches, two groups of which are installed on both sides of the unfolded section of the working surface of the head belt, and the other two groups of which are installed on both sides of the unfolded section of the non-working surface of the tail belt.

2. The device for online fault monitoring of a tubular belt conveyor according to claim 1 is characterized in that: It also includes a 10 Gigabit switch, to which a first video recorder is electrically connected, to which an intelligent analysis host is electrically connected, to which a display is electrically connected, and to which a PLC controller is electrically connected. The PLC controller sends out an alarm and an interlocking protection signal.

3. The device for online fault monitoring of a tubular belt conveyor according to claim 2 is characterized in that: The 10G switch is connected to a rack-mounted optical fiber box, which is electrically connected to a monitoring camera. The monitoring camera is connected via the rack-mounted optical fiber box to obtain real-time belt running image data.

4. The device and method for online fault monitoring of a tubular belt conveyor according to claim 3 is characterized in that: The rack-mounted optical fiber box is electrically connected to a network relay, and the network relay is electrically connected to a lighting device. The rack-mounted optical fiber box controls the network relay contacts and then controls the relay to be attracted, thereby realizing the turning on and off of the lighting device.

5. The device and method for online fault monitoring of a tubular belt conveyor according to claim 4 is characterized in that: The rack-mounted optical fiber box is electrically connected to an alarm device, and the rack-mounted optical fiber box controls the serial port server and then connects to the alarm device to realize the on-site alarm function.

6. A method for online fault monitoring of a tubular belt conveyor, characterized in that: The steps include: Step 1: Install one surveillance camera at the belt head, two surveillance cameras at the belt middle bend, and one surveillance camera at the belt tail, and use the first video recorder for auxiliary monitoring; Step 2: Set up a local video front-end box next to the surveillance camera, and set up a network relay, optical fiber box and other components in the front-end box; Step 3: The system controls the network relay contacts through the rack-mounted fiber optic box and then controls the relay to turn on and off the lighting device. The system connects to the monitoring camera through the rack-mounted fiber optic box to obtain real-time belt running image data. The system controls the serial port server through the rack-mounted fiber optic box and then connects to the alarm to realize the on-site alarm function. Step 4: The system collects on-site image data in real time and uses the model to judge the image data. When the current state abnormality exceeds the warning threshold, the system triggers the alarm program and archives the data. At the same time, the switch signal is output to the PLC controller through the network relay, and the PLC controller realizes the control alarm and interlock shutdown; Step 5: Install deviation switches at the head and tail of the tubular belt conveyor where the deviation characteristics are most obvious. When the belt is distorted, the belt will touch the deviation switch at the characteristic position. The deviation switch signal is connected to the PLC controller, and the PLC controller sends out an alarm and interlocking signal. Step 6: When the belt shows signs of buckling, expansion or collapse, a voice alarm will be issued in the operation room to alert the operator, and a voice and sound and light alarm will be issued on site to alert the inspection personnel; Step seven: To avoid false tripping of the equipment due to inaccurate detection, the belt will be interlocked and stopped only when the video and deviation switch trip signals appear at the same time.

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