Safe operation monitoring system of vertical lifting belt conveyor on coal-fired power generation unit

Abstract

The invention provides a system for monitoring safe operation of a vertical lifting belt conveyor on a coal-fired power generation unit. The system comprises a belt visual detection module, an online monitoring module, a pulverized coal accumulation spontaneous combustion monitoring module, a sound wave ash removal module, a belt deviation and tearing prevention module and a 3D simulation demonstration module. The belt visual detection module is used for processing the images of the belt, the wavy flange and the baffle to obtain detection results of flange tearing, baffle falling and belt surface damage, and uploading the detection results to the server and the 3D monitoring interface; and the 3D simulation demonstration module is used for simulating the dynamic real-time operation condition and dynamic change of the vertical lifting belt conveyor, displaying equipment parameters and states, and accurately positioning equipment alarm and fault parts through a 3D model. According to the monitoring system, the reliability and the safety of equipment are remarkably improved, the maintenance cost is reduced, the production efficiency is remarkably improved, and a powerful guarantee is provided for stable operation of the coal-fired power generation unit.

Description

Technical Field

[0001] The invention relates to the technical field of conveyor monitoring, and in particular to a safe operation monitoring system for a vertical lifting belt conveyor on a coal-fired power generation unit. Background Art

[0002] As an innovative and efficient bulk material transportation equipment, vertical lifting belt conveyor has demonstrated excellent performance in multiple industries such as mining, metallurgy, coal, etc. with its unique design concept and wide applicability. The equipment can flexibly meet the material transportation needs within the range of 0 to 90 degrees, and is particularly suitable for production environments with limited space or strict environmental protection requirements, such as the transportation of bulk or bulk materials such as raw materials and gravel. Its unique corrugated sidewall belt design not only enhances the transportation capacity, but also ensures the stability and safety of the material during the vertical lifting process.

[0003] After in-depth research and comparative analysis, the company proactively selected two vertical lifting belt conveyors to be introduced into the coal handling system to store coal in silos. These two conveyors were designed and supplied by Shanghai Zemark Company and use corrugated sidewall belts produced by CONTITECH of Germany. The belt output is designed to be up to 1,500 tons / hour and the lifting height is 78 meters.

[0004] However, with the long-term operation of vertical lifting belt conveyors, a series of potential safety hazards and operating problems have gradually emerged. Fatigue cracking and deformation of the corrugated sidewalls of the conveyor belt, deformation or detachment of the partition plate position, deformation and displacement of the concrete foundation of the drive roller, the risk of spontaneous combustion of coal and dust accumulation in the sealing cover, and wear caused by belt deviation all pose a serious threat to the stable operation of the equipment. It is particularly noteworthy that since this type of conveyor usually adopts a fully enclosed design, traditional inspection methods are difficult to effectively detect these hidden fault points. Once a serious accident such as a fire or belt breakage occurs, it will directly endanger the safe and stable operation of the unit and may cause huge economic losses.

[0005] Therefore, it is particularly urgent to conduct in-depth technical research and analysis on the above-mentioned problems that may arise during the operation of vertical lifting belt conveyors and develop an effective safety operation monitoring system. Summary of the invention

[0006] In view of the above, the present invention provides a safe operation monitoring system for a vertical lifting belt conveyor on a coal-fired power generation unit. Through an online detection system, the operating status of the equipment is monitored in real time, potential faults are discovered in time, the downtime of the equipment is reduced, and the reliability and safety of the equipment are improved; by timely detecting and predicting equipment failures, maintenance plans are reasonably arranged, unplanned repair and maintenance costs are reduced, equipment failures and downtime are reduced, the continuity and efficiency of production are improved, the stability of fuel supply is ensured, and a strong guarantee is provided for the safe and stable operation of the coal-fired power generation unit.

[0007] The technical solution of the present invention:

[0008] The present invention provides a safe operation monitoring system for a vertical lifting belt conveyor on a coal-fired power generation unit, comprising a belt visual detection module, an online monitoring module, a coal dust accumulation and spontaneous combustion monitoring module, an acoustic wave cleaning module, a belt deviation and tearing prevention module, and a 3D simulation demonstration module;

[0009] The vertical lifting belt conveyor comprises a frame, a first roller, a second roller, a third roller, a fourth roller, a fifth roller, a guide roller and a conveyor belt, wherein the first roller and the second roller are rotatably mounted at the bottom of the frame and arranged horizontally at intervals, the third roller is rotatably mounted on the frame and located above the right side of the second roller, the fourth roller, the fifth roller and a plurality of guide rollers are rotatably mounted on the top of the frame, the conveyor belt is wound around the first roller, the second roller, the third roller, the fourth roller, the fifth roller and the guide roller to form a vertical lifting belt, the conveyor belt comprises a belt, corrugated ribs connected to both sides of the belt, and a plurality of baffles connected between the two corrugated ribs;

[0010] The belt visual inspection module is used to process the images of the belt, corrugated flange and baffle to obtain the inspection results of flange tearing, baffle shedding and belt surface damage, and upload the inspection results to the server and 3D monitoring interface to provide support for subsequent predictive maintenance services;

[0011] The online monitoring module is used to monitor the drive roller of the vertical lifting belt conveyor, the displacement of the concrete foundation, and the vibration and temperature data of the motor and reducer in real time, and set the alarm threshold to realize automatic alarm;

[0012] The coal powder accumulation spontaneous combustion monitoring module is used to automatically scan the thermal distribution status of the coal powder surface in real time and generate intuitive images for all-weather monitoring;

[0013] The sonic cleaning module is used to regularly clean the accumulated coal and dust using sonic waves;

[0014] The belt anti-deviation and tearing module is used to monitor belt deviation and tearing;

[0015] The 3D simulation demonstration module is used to simulate the dynamic real-time operation and dynamic changes of the vertical lifting belt conveyor, display the equipment parameters and status, and accurately locate the equipment alarm and fault parts through the 3D model.

[0016] The vertical lifting belt conveyor safe operation monitoring system on the coal-fired power generation unit provided by the present invention realizes comprehensive and real-time monitoring and management of the vertical lifting belt conveyor by integrating multiple functional modules. Its beneficial effects are mainly reflected in the following aspects:

[0017] 1. Significantly improve equipment reliability and safety:

[0018] Through the belt visual inspection module, this system can accurately identify the damage of belts, corrugated flanges and baffles, such as flange tearing, baffle detachment and belt surface damage, and upload the inspection results to the server and 3D monitoring interface in time, providing strong support for predictive maintenance.

[0019] The online monitoring module monitors the key components of the vertical lifting belt conveyor, such as the drive roller, concrete foundation displacement, and the vibration and temperature data of the motor and reducer in real time. Once an abnormality is found, an alarm is triggered immediately, effectively preventing further deterioration of equipment failure and significantly improving the reliability and safety of the equipment.

[0020] 2. Effectively reduce maintenance costs:

[0021] Through the all-weather monitoring of the coal powder accumulation spontaneous combustion monitoring module, the system can grasp the thermal distribution status of the coal powder surface in real time, discover the hidden dangers of spontaneous combustion in time, avoid equipment damage and downtime accidents caused by coal powder spontaneous combustion, and thus reduce maintenance costs caused by failures.

[0022] The effective monitoring of the belt anti-deviation and tearing module can prevent serious faults such as belt deviation and tearing, extend the service life of the equipment, and reduce the cost of replacing parts and maintaining equipment.

[0023] The precise fault location and predictive maintenance suggestions provided by the system enable maintenance personnel to arrange maintenance plans reasonably, avoid unnecessary repairs and excessive maintenance, and further reduce maintenance costs.

[0024] 3. Significantly improve production efficiency:

[0025] The 3D simulation demonstration module simulates the dynamic real-time operation and dynamic changes of the vertical lifting belt conveyor, providing managers with an intuitive display of equipment operation status and parameters, facilitating quick decision-making and adjustments, and ensuring the continuity and stability of production.

[0026] The system's real-time monitoring and early warning functions enable potential faults to be dealt with promptly before they occur, avoiding extended downtime due to equipment failures, thereby significantly improving production efficiency and ensuring the stable operation of coal-fired power generation units and the continuity of fuel supply.

[0027] To sum up, the vertical lifting belt conveyor safe operation monitoring system on the coal-fired power generation unit provided by the present invention significantly improves the reliability and safety of the equipment, reduces maintenance costs, and significantly improves production efficiency through comprehensive and real-time monitoring and management, providing a strong guarantee for the stable operation of the coal-fired power generation unit.

[0028] The preferred embodiments of the present invention and their beneficial effects will be further described in detail in conjunction with specific implementation methods. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the following specific embodiments, they are used to explain the present invention, but should not be construed as limiting the present invention. In the accompanying drawings:

[0030] Figure 1 It is a module diagram of the safe operation monitoring system of the vertical lifting belt conveyor on the coal-fired power generation unit of the present invention;

[0031] Figure 2 This is a hardware layout diagram of the safe operation monitoring system of the vertical lifting belt conveyor on the coal-fired power generation unit of the present invention;

[0032] Figure 3 It is a structural schematic diagram of the cooperation between the conveyor belt and the deviation-correcting wheel of the vertical lifting belt conveyor of the present invention;

[0033] Figure 4 It is a front view of the deviation-correcting wheel of the vertical lifting belt conveyor of the present invention;

[0034] Figure 5 This is a diagram of the tear detection state detection interface of the conveyor belt anti-tear detection system of the present invention.

[0035] Explanation of the accompanying figures: belt visual detection module 101, online monitoring module 102, coal powder accumulation and spontaneous combustion monitoring module 103, acoustic wave cleaning module 104, belt anti-deviation and tearing module 105, 3D simulation demonstration module 106, frame 1, first roller 2, second roller 3, third roller 4, fourth roller 5, fifth roller 6, guide roller 7, conveyor belt 8, belt 81, corrugated sidewall 82, baffle 83, 3D line scan camera and line laser device 1011, three-axis temperature and vibration sensor 1021, thermal imager 1031, deviation correction wheel 1051, conveyor belt anti-tear detection system 1052, annular slide groove 10511, shaft hole 10512, extrusion hole 10513. DETAILED DESCRIPTION

[0036] The specific implementation of the present invention is described in detail below in conjunction with the accompanying drawings. It should be understood that the specific implementation described here is only used to illustrate and explain the present invention, and is not used to limit the present invention.

[0037] See also Figure 1 and Figure 2 The present invention provides a safe operation monitoring system for a vertical lifting belt conveyor on a coal-fired power generation unit, comprising a belt visual detection module 101, an online monitoring module 102, a coal dust accumulation and spontaneous combustion monitoring module 103, an acoustic wave cleaning module 104, a belt anti-deviation and tearing module 105, and a 3D simulation demonstration module 106. The vertical lifting belt conveyor comprises a frame 1, a first roller 2, a second roller 3, a third roller 4, a fourth roller 5, a fifth roller 6, a guide roller 7, and a conveyor belt 8. The first roller 2 and the second roller 3 are rotatably mounted at the bottom of the frame 1 and arranged horizontally at intervals. The third roller 4 is rotatably mounted on the frame 1 and is located above the right side of the second roller 3. The fourth roller 5, the fifth roller 6, and a plurality of guide rollers 7 are rotatably mounted on the top of the frame 1. The conveyor belt 8 is wound around the first roller 2, the second roller 3, the third roller 4, the fourth roller 5, the fifth roller 6, and the guide roller 7 to form a vertical lifting belt. The conveyor belt 8 includes a belt 81 , corrugated sidewalls 82 connected to both sides of the belt 81 , and a plurality of baffles 83 connected between the two corrugated sidewalls 82 .

[0038] The belt visual inspection module 101 is used to process the images of the belt 81, the corrugated rib 82 and the baffle 83 to obtain the inspection results of the rib tearing, the baffle detachment and the belt surface damage, and upload the inspection results to the server and the 3D monitoring interface to provide necessary support for the subsequent predictive maintenance service.

[0039] The online monitoring module 102 is used to monitor the driving roller of the vertical lifting belt conveyor, the displacement of the concrete foundation, and the vibration and temperature data of the motor and the reducer in real time, and set the alarm threshold to realize automatic alarm.

[0040] The pulverized coal accumulation spontaneous combustion monitoring module 103 is used to automatically scan the thermal distribution state of the pulverized coal surface in real time and generate intuitive images for all-weather monitoring.

[0041] The acoustic wave cleaning module 104 is used to regularly clean the accumulated coal and dust using acoustic waves.

[0042] The belt anti-deviation and tearing module 105 is used for monitoring the deviation and tearing of the belt 81 .

[0043] The 3D simulation demonstration module 106 is used to simulate the dynamic real-time operation and dynamic changes of the vertical lifting belt conveyor, display equipment parameters and status, and accurately locate equipment alarms and fault parts through the 3D model.

[0044] The vertical lifting belt conveyor safe operation monitoring system on the coal-fired power generation unit provided by the present invention realizes comprehensive and real-time monitoring and management of the vertical lifting belt conveyor by integrating multiple functional modules. Its beneficial effects are mainly reflected in the following aspects:

[0045] 1. Significantly improve equipment reliability and safety:

[0046] Through the belt visual inspection module 101, the system can accurately identify the damage of the belt, corrugated flange and baffle, such as flange tearing, baffle detachment and belt surface damage, and upload the inspection results to the server and 3D monitoring interface in time, providing strong support for predictive maintenance.

[0047] The online monitoring module 102 monitors the key components of the vertical lifting belt conveyor, such as the drive roller, concrete foundation displacement, and the vibration and temperature data of the motor and reducer in real time. Once an abnormality is found, an alarm is immediately triggered, which effectively prevents further deterioration of equipment failure and significantly improves the reliability and safety of the equipment.

[0048] 2. Effectively reduce maintenance costs:

[0049] Through the all-weather monitoring of the coal powder accumulation spontaneous combustion monitoring module 103, the system can grasp the thermal distribution state of the coal powder surface in real time, discover the hidden dangers of spontaneous combustion in time, avoid equipment damage and shutdown accidents caused by coal powder spontaneous combustion, and thus reduce the maintenance costs caused by failures.

[0050] The effective monitoring of the belt anti-deviation and tearing module 105 can prevent the occurrence of serious faults such as belt deviation and tearing, extend the service life of the equipment, and reduce the cost of replacing parts and maintaining the equipment.

[0051] The precise fault location and predictive maintenance suggestions provided by the system enable maintenance personnel to arrange maintenance plans reasonably, avoid unnecessary repairs and excessive maintenance, and further reduce maintenance costs.

[0052] 3. Significantly improve production efficiency:

[0053] The 3D simulation demonstration module 106 provides managers with intuitive equipment operation status and parameter display by simulating the dynamic real-time operation and dynamic changes of the vertical lifting belt conveyor, facilitating quick decision-making and adjustments, and ensuring the continuity and stability of production.

[0054] The system's real-time monitoring and early warning functions enable potential faults to be dealt with promptly before they occur, avoiding extended downtime due to equipment failures, thereby significantly improving production efficiency and ensuring the stable operation of coal-fired power generation units and the continuity of fuel supply.

[0055] To sum up, the vertical lifting belt conveyor safe operation monitoring system on the coal-fired power generation unit provided by the present invention significantly improves the reliability and safety of the equipment, reduces maintenance costs, and significantly improves production efficiency through comprehensive and real-time monitoring and management, providing a strong guarantee for the stable operation of the coal-fired power generation unit.

[0056] The belt visual inspection module 101 includes:

[0057] 3D line scan camera and line laser device 1011, used for real-time imaging and obtaining images of belt 81, corrugated rib 82 and baffle 83 respectively;

[0058] A preprocessing unit, used for performing image denoising, image enhancement and image segmentation preprocessing on the acquired image to improve the accuracy of subsequent detection and recognition;

[0059] The belt detection model unit is used to detect and record the positions of sidewall tearing, baffle detachment and belt surface damage. It adopts deep learning technology and trains a large amount of sample data to achieve effective detection and identification of sidewall tearing, baffle detachment and belt surface damage faults.

[0060] A model compression and lightweight processing unit, used to compress and lightweight the detection model so as to be deployed on the edge terminal;

[0061] The data uploading unit is used to upload the detection result image including the fault type, location and fault area to the server and the 3D monitoring interface.

[0062] The application of the belt visual inspection module 101 brings significant beneficial effects, which are specifically reflected in the following aspects:

[0063] 1. Improve detection accuracy and efficiency:

[0064] The belt visual inspection module 101 can accurately acquire images of belts, corrugated sidewalls and baffles in real time through the cooperation of 3D line scan cameras and line laser devices. The preprocessing unit performs preprocessing operations such as denoising, enhancement and segmentation on the image, further improving the image quality and providing a solid foundation for subsequent detection and recognition. The belt detection model unit adopts deep learning technology and is trained with a large amount of sample data. It can effectively detect and identify faults such as sidewall tearing, baffle shedding and belt surface damage, greatly improving the accuracy and efficiency of detection.

[0065] 2. Realize lightweight deployment of models:

[0066] The model compression and lightweight processing unit compresses and optimizes the detection model, significantly reducing the model's computational workload and storage requirements, allowing the model to be efficiently deployed on edge terminals. This improvement not only improves the system's response speed, but also reduces the requirements for hardware resources, making the system more flexible and portable.

[0067] 3. Facilitate fault location and subsequent maintenance:

[0068] The data upload unit uploads the detection result images including fault type, location, and fault area to the server and 3D monitoring interface in real time, providing managers with intuitive and clear fault information. This not only facilitates managers to quickly locate the fault location, but also provides strong support for subsequent predictive maintenance and troubleshooting, effectively reducing equipment downtime and maintenance costs.

[0069] In summary, the belt vision inspection module 101 in the present invention provides a strong guarantee for the safe operation of the vertical lifting belt conveyor by improving the inspection accuracy and efficiency, realizing lightweight deployment of the model, and facilitating fault location and subsequent maintenance.

[0070] In the online monitoring module 102, the displacement of the roller bearings, motor and concrete foundation of the vertical lifting belt conveyor is monitored by a combination of electromagnetic and acoustic print. The temperature and vibration of the motor and reducer of the vertical lifting belt conveyor are monitored by a three-axis temperature and vibration sensor. The first roller 2, the second roller 3, the third roller 4, the fourth roller 5, the fifth roller 6 and the guide roller 7 are equipped with a three-axis temperature and vibration sensor 1021 at both ends of the shaft. The roller bearing bolts and the anchor bolts of the reducer of the vertical lifting belt conveyor are equipped with loose sensors. The cables between the loose sensors are connected in series by hand-in-hand method, and the output power and communication cables enter the control box.

[0071] In the present invention, the application of the online monitoring module 102 provides an important guarantee for the safe operation of the vertical lifting belt conveyor, and its beneficial effects are mainly reflected in the following aspects:

[0072] 1. Improve monitoring accuracy and reliability:

[0073] The online monitoring module 102 innovatively uses electromagnetic and soundprint combined monitoring technology to monitor the displacement of the roller bearings, motors and concrete foundations of the vertical lifting belt conveyor. This combined monitoring method can fully utilize the advantages of electromagnetic sensors and soundprint sensors to achieve accurate perception and real-time monitoring of displacement changes, effectively improving the accuracy and reliability of monitoring.

[0074] 2. Comprehensively monitor the status of the motor and reducer:

[0075] For the motor and reducer of the vertical lifting belt conveyor, the online monitoring module 102 uses a three-axis temperature and vibration sensor to monitor temperature and vibration. This comprehensive monitoring method can reflect the operating status of the motor and reducer in real time, discover potential fault hazards in time, and provide strong support for equipment maintenance and management.

[0076] 3. Realize early warning of bolt loosening:

[0077] The online monitoring module 102 also installs loose sensors on the roller bearing bolts of the vertical lifting belt conveyor and the anchor bolts of the reducer. These sensors can monitor the looseness of the bolts in real time, and output power and communication cables to the control box after being connected in series in a hand-in-hand manner. Once the bolts are loose, the sensors will immediately send out a warning signal to remind the management personnel to take timely measures to deal with it, thereby avoiding equipment failures and safety accidents caused by loose bolts.

[0078] To sum up, the online monitoring module 102 in the present invention provides comprehensive and real-time monitoring and early warning functions for the safe operation of the vertical lifting belt conveyor by improving monitoring accuracy and reliability, comprehensively monitoring the status of the motor and reducer, and realizing bolt loosening early warning and other beneficial effects, thereby effectively reducing equipment failure rate and maintenance costs and improving production efficiency.

[0079] The coal dust accumulated on the sealing cover and steel structure of the vertical lifting belt conveyor is prone to spontaneous combustion. On the one hand, spontaneous combustion releases toxic and harmful gases, endangering the personal safety of workers; on the other hand, the temperature of spontaneously combusted coal dust exceeds 350℃, which is very easy to ignite the belt or burn equipment, resulting in the paralysis of the entire coal transportation system and unplanned shutdown of the unit, causing great economic losses and posing a serious threat to the safe operation of the entire unit.

[0080] In order to effectively solve this problem, a new infrared video imaging fire alarm system is used, which can greatly improve the efficiency of fire detection. The system has fast response and accurate temperature measurement. It can monitor the areas prone to coal dust accumulation around the clock, and alarm when the dangerous temperature value is reached, so as to guide the staff to handle it correctly, eliminate the hidden dangers of fire, and truly prevent it before it burns. At least 2 sets of infrared thermal imagers are installed on each vertical lifting belt.

[0081] The pulverized coal accumulation spontaneous combustion monitoring module 103 includes thermal imagers 1031 installed at both ends of the second roller 3 and the third roller 4, and is used to monitor the pulverized coal nature and accumulation.

[0082] The sonic wave cleaning module 104 adopts a low-frequency sonic wave vibration cleaner and is installed on the working surface of the sealing cover lifting section and the other three vertical surfaces of the tail frame except the working surface.

[0083] See also Figure 3 and Figure 4 The belt anti-deviation and tearing module 105 includes a deviation correction wheel 1051 and a conveyor belt anti-tear detection system 1052. A plurality of rotatable deviation correction wheels 1051 are respectively installed on both sides of the belt 81. Two deviation correction wheels 1051 arranged relatively on both sides of the belt 81 form a group. An annular slide groove 10511 adapted to the edge of one side of the belt 81 is formed on the outer periphery of each deviation correction wheel 1051. A guide space adapted to the width of the belt 81 is formed between each group of deviation correction wheels 1051. An axial hole 10512 is provided at the center of each deviation correction wheel 1051 for installing a rotating shaft. A plurality of extrusion holes 10513 arranged in an annular manner are provided on the deviation correction wheel 1051 around the outer periphery of the axial hole 10512, so that the belt 81 has an elastic extrusion space when passing through the guide space of each group of deviation correction wheels 1051, thereby protecting the edge of the belt 81, improving the service life of the belt, and reducing the failure rate of the belt. The deviation correction wheel 1051 is preferably a rubber wheel.

[0084] The beneficial effects of the deviation correction wheel 1051 with the above structural design are mainly reflected in the following aspects:

[0085] 1. Effectively prevent the belt from running off track: by installing a plurality of rotatable correcting wheels 1051 on both sides of the belt 81 and arranging them relatively on both sides of the belt to form a guide space, the annular groove 10511 of the correcting wheel 1051 slides with the edge of each side of the belt 81, so that the belt can pass through each set of correcting wheels smoothly, ensuring that the belt can always maintain the correct position during the transmission process, and effectively avoiding the occurrence of belt deviation.

[0086] 2. Improve the tear resistance of the belt: Multiple extrusion holes 10513 are opened around the outer periphery of the shaft hole 10512 on the deviation correction wheel 1051, providing elastic extrusion space for the belt to pass through the guide space of each set of deviation correction wheels. This design can absorb and disperse the impact force through elastic extrusion when the belt is subjected to unexpected impact or tension changes, thereby effectively preventing the belt from tearing due to uneven force.

[0087] The present invention optimizes the structure of the belt transmission system, thereby not only improving the running stability and service life of the belt, but also significantly reducing the failure rate of the belt, thus providing a strong guarantee for the continuous and stable operation of the equipment.

[0088] The conveyor belt tear detection system 1052 is used to select appropriate monitoring points in the running path of the conveyor belt 8 to complete real-time monitoring of the entire journey under working conditions, and to send out alarm signals in time when dangerous conditions occur during the operation of the conveyor belt. The dry contact alarm signal of the substation is transmitted to the central control room through cables and connected to the existing PLC control system; the visual monitoring platform is arranged in the user's central control room, which can display the status of the conveyor belt in real time and realize emergency handling methods such as manual operation to select shutdown or automatic shutdown.

[0089] Principle of linear array image analysis: When imaging a normal conveyor belt, since the surface of the conveyor belt is smooth and unpolluted, the grayscale changes in the horizontal and vertical areas of the image are similar to linear changes. When a crack appears, there will be an obvious grayscale difference between the crack area and the flat area. The system finds the contour of the crack based on the grayscale difference and determines whether it is indeed a crack feature based on the contour characteristics. If so, an alarm will be issued or the conveyor belt will be stopped. If it is ordinary interference, it will be ignored.

[0090] The conveyor belt anti-tear detection system 1052 specifically includes:

[0091] Feature extraction unit: extract the features of longitudinal tear on the conveyor belt surface. Longitudinal tear is mostly manifested as two main features: tear length > 1500mm and width < 20mm. Therefore, thresholds are established from the two dimensions of length and width, and the features of longitudinal tear in the image are extracted based on the thresholds. There are no special features of conveyor belt surface damage, and the program processes it according to general image features.

[0092] Damage point merging unit: After feature extraction and recognition, there may be many damage points marked in an image. Damage within a certain number of pixels needs to be merged and merged into a feature area by setting the surrounding pixel threshold. At the same time, when the tear damage length exceeds the length of a picture, a one-to-many relationship will be established between the tear damage and the picture, and the characteristic damage points of multiple pictures need to be merged.

[0093] Result processing unit: After the tear damage is determined, follow-up processing is required. The tear damage is marked on the picture and displayed on the interface, and the damage location information and other results are saved in the database to establish a tear damage sample database. If the tear damage exceeds the set threshold, an alarm instruction is sent to the sound and light alarm device to drive the sound and light alarm and establish an alarm database.

[0094] The tear detection state detection interface diagram of the conveyor belt tear prevention detection system provided by the present invention is as follows: Figure 5 shown.

[0095] The conveyor belt tear prevention detection system 1052 provided by the present invention realizes real-time monitoring of the entire conveyor belt travel and accurate identification of longitudinal tearing by integrating a feature extraction unit, a damage point merging unit and a result processing unit. Its beneficial effects are mainly reflected in the following aspects:

[0096] 1. Real-time monitoring and early warning capability: The device can select appropriate monitoring points in the running path of the conveyor belt to complete real-time monitoring of the entire journey under working conditions. Once a dangerous situation occurs during the operation of the conveyor belt, such as longitudinal tearing, the device can immediately send out an alarm signal, and transmit the dry contact alarm signal to the central control room through a cable, and connect to the existing PLC control system, thereby realizing real-time monitoring and early warning of the running status of the conveyor belt.

[0097] 2. Accurate identification and damage point merging: The feature extraction unit can accurately extract the features of longitudinal tearing on the conveyor belt surface. By setting the length and width thresholds, it can effectively identify the longitudinal tearing features with a tear length greater than 1500mm and a width less than 20mm. The damage point merging unit can further effectively merge the characteristic damage points of the same tearing damage in multiple images, avoiding the problem of tearing damage information loss or repeated counting caused by image segmentation, and improving the accuracy and reliability of identification.

[0098] 3. Efficient processing and emergency response: The result processing unit can not only mark the tear damage on the picture and display it on the interface, but also save the damage location information and other results in the database, providing strong data support for subsequent tear damage analysis and management. At the same time, when the tear damage exceeds the set threshold, the unit can automatically send an alarm command to the sound and light alarm device, issue an alarm in time, and trigger emergency processing methods such as automatic shutdown or manual shutdown, effectively avoiding equipment damage and production accidents caused by tear damage.

[0099] 4. System integration and compatibility: The device can be seamlessly integrated with the existing PLC control system, and transmit alarm signals to the visual monitoring platform in the central control room through cables. The platform can display the status of the conveyor belt in real time, and realize emergency handling methods such as manual operation to select shutdown or automatic shutdown, thereby improving the overall performance and compatibility of the system.

[0100] To sum up, the conveyor belt anti-tear detection system 1052 provided by the present invention has many advantages such as real-time monitoring and early warning capabilities, accurate identification and damage point merging, efficient processing and emergency response, system integration and compatibility, etc. It can significantly improve the safety and stability of conveyor belt operation, reduce the risk of production accidents, and provide a strong guarantee for the safe production of enterprises.

[0101] In the 3D simulation demonstration module 106, the BKC 3D engine development component is used. It is a WebGL graphical interface 3D engine based on the HTML5 standard. It includes a model component library, UI library, and interactive action library for the process industry. The script configuration is implemented for the measurement point marking, digital-analog linkage, and disassembly sequence of the 3D equipment, which efficiently completes the project customization and is conducive to later maintenance. At the same time, the component library has built-in special effects such as flame, steam, and water flow, which can easily realize the operation of equipment mechanisms, medium flow, and solid particle transportation. For common scenes in the process industry, data is lightweight, loading is realized in seconds, and the integrated graphics terminal can run smoothly. It can easily build cross-platform enterprise-level applications, and the 3D graphics display is highly encapsulated based on HTML5 technology to quickly build a 3D visualization scene.

[0102] Through three-dimensional modeling of the vertical lifting belt conveyor, 360-degree panoramic visualization combined with data scene linkage, a three-dimensional visualization system for real-time monitoring of intelligent equipment with comprehensive control intelligence is established to achieve real-time monitoring of the dynamic real-time operation and dynamic changes of the vertical lifting belt conveyor, equipment parameters and status, etc.

[0103] The overall design style of the 3D modeling of the vertical lifting belt conveyor is realistic. When displaying the key internal components, it is necessary to switch to wireframe mode. During the display process, the 2D data panel is used in the information board in 3D, which needs to be harmonious with the 3D style and the data information can be clearly viewed. The picture is in vector format and there will be no distortion when enlarged.

[0104] The three-dimensional modeling of the vertical lifting belt conveyor is carried out in a standard facade modeling. A schematic modeling is carried out based on the conveyor CAD drawings, real photos and other materials. It includes key components such as rollers, belts, corrugated sidewalls, baffles, etc. The style is realistic, and the appearance of the building is restored in a certain proportion. The method of simple model plus texture is used to achieve the purpose of efficient WEB loading and rendering.

[0105] In the description of the present invention, it should be noted that the orientation or positional relationship indicated by the terms "upper" and "lower" is based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying importance; the words "bottom surface" and "top surface", "inside" and "outside" refer to the geometric direction toward or away from a specific component, respectively.

[0106] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installation", "connection" and "connection" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be a connection between the inside of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances. In addition, in the description of the present invention, unless otherwise specified, "plurality" means two or more.

[0107] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A vertical lifting belt conveyor safe operation monitoring system on a coal-fired power generation unit, characterized in that: It comprises a belt visual detection module (101), an online monitoring module (102), a coal powder accumulation spontaneous combustion monitoring module (103), an acoustic wave ash cleaning module (104), a belt deviation and tearing prevention module (105) and a 3D simulation demonstration module (106); The vertical lifting belt conveyor comprises a frame (1), a first roller (2), a second roller (3), a third roller (4), a fourth roller (5), a fifth roller (6), a guide roller (7) and a conveyor belt (8); the first roller (2) and the second roller (3) are rotatably mounted on the bottom of the frame (1) and arranged horizontally at intervals; the third roller (4) is rotatably mounted on the frame (1) and located above the right side of the second roller (3); the fourth roller (5), the fifth roller (6) and a plurality of guide rollers (7) are rotatably mounted on the top of the frame (1); the conveyor belt (8) is wound around the first roller (2), the second roller (3), the third roller (4), the fourth roller (5), the fifth roller (6) and the guide roller (7) to form a vertical lifting belt; the conveyor belt (8) comprises a belt (81), a corrugated rib (82) connected to both sides of the belt (81), and a plurality of baffles (83) connected between the two corrugated ribs (82); The belt visual inspection module (101) is used to process images of the belt (81), the corrugated sidewall (82) and the baffle (83) to obtain inspection results of sidewall tearing, baffle detachment and belt surface damage, and upload the inspection results to the server and the 3D monitoring interface to provide support for subsequent predictive maintenance services; The online monitoring module (102) is used to monitor the driving roller of the vertical lifting belt conveyor, the displacement of the concrete foundation, and the vibration and temperature data of the motor and the reducer in real time, and set the alarm threshold to realize automatic alarm; The coal powder accumulation spontaneous combustion monitoring module (103) is used to automatically scan the thermal distribution state of the coal powder surface in real time and generate intuitive images for all-weather monitoring; The acoustic wave cleaning module (104) is used to regularly clean the accumulated coal and dust using acoustic waves; The belt anti-deviation and tearing module (105) is used for monitoring the deviation and tearing of the belt (81); The 3D simulation demonstration module (106) is used to simulate the dynamic real-time operation and dynamic changes of the vertical lifting belt conveyor, display equipment parameters and status, and accurately locate equipment alarms and fault locations through the 3D model.

2. The vertical lifting belt conveyor safe operation monitoring system on a coal-fired power generation unit according to claim 1 is characterized in that: The belt visual inspection module (101) comprises: A 3D line scan camera and a line laser device (1011) are used for real-time imaging and respectively acquiring images of the belt (81), the corrugated rib (82) and the baffle (83); A preprocessing unit, used for performing image denoising, image enhancement and image segmentation preprocessing on the acquired image to improve the accuracy of subsequent detection and recognition; The belt detection model unit is used to detect and record the positions of sidewall tearing, fender detachment, and belt surface damage. It uses deep learning technology and trains a large amount of sample data to effectively detect and identify sidewall tearing, fender detachment, and belt surface damage faults. A model compression and lightweight processing unit, used to compress and lightweight the detection model so as to be deployed on the edge terminal; The data uploading unit is used to upload the detection result image including the fault type, location and fault area to the server and the 3D monitoring interface.

3. The vertical lifting belt conveyor safe operation monitoring system on a coal-fired power generation unit according to claim 1 is characterized in that: In the online monitoring module (102), the displacement of the roller bearings, motor and concrete foundation of the vertical lifting belt conveyor is monitored by a combination of electromagnetic and acoustic wave. The temperature and vibration of the motor and reducer of the vertical lifting belt conveyor are monitored by a three-axis temperature and vibration sensor. The three-axis temperature and vibration sensors (1021) are installed at the two end shafts of the first roller (2), the second roller (3), the third roller (4), the fourth roller (5), the fifth roller (6) and the guide roller (7).

4. The vertical lifting belt conveyor safe operation monitoring system on the coal-fired power generation unit according to claim 3 is characterized in that: Loose sensors are installed on the roller bearing bolts of the vertical lifting belt conveyor and the anchor bolts of the reducer. The cables between the loose sensors are connected in series by hand-in-hand method, and then the output power and communication cables enter the control box.

5. The vertical lifting belt conveyor safe operation monitoring system on a coal-fired power generation unit according to claim 1 is characterized in that: The coal powder accumulation spontaneous combustion monitoring module (103) comprises thermal imagers (1031) installed at both ends of the second roller (3) and the third roller (4) and is used to monitor the spontaneous combustion of coal powder and accumulation.

6. The vertical lifting belt conveyor safe operation monitoring system on a coal-fired power generation unit according to claim 1 is characterized in that: The sonic wave cleaning module (104) adopts a low-frequency sonic wave vibration cleaner and is installed on the working surface of the sealing cover lifting section and on the other three vertical surfaces of the tail frame except the working surface.

7. The vertical lifting belt conveyor safe operation monitoring system on a coal-fired power generation unit according to claim 1 is characterized in that: The belt deviation and tearing prevention module (105) comprises a deviation correction wheel (1051), and a plurality of rotatable deviation correction wheels (1051) are respectively installed on both sides of the belt (81), and two deviation correction wheels (1051) arranged relatively on both sides of the belt (81) form a group, and an annular sliding groove (10511) adapted to the edge of one side of the belt (81) is formed on the outer periphery of each deviation correction wheel (1051), and a guide space adapted to the width of the belt (81) is formed between each group of deviation correction wheels (1051), and an axial hole (10512) is opened at the center position of each deviation correction wheel (1051) for installing a rotating shaft, and a plurality of extrusion holes (10513) arranged in an annular manner are opened on the deviation correction wheel (1051) around the outer periphery of the axial hole (10512), so that the belt (81) has an elastic extrusion space when passing through the guide space of each group of deviation correction wheels (1051).

8. The vertical lifting belt conveyor safe operation monitoring system on the coal-fired power generation unit according to claim 7 is characterized in that: The belt anti-deviation and tearing module (105) includes a conveyor belt anti-tear detection system (1052), which is used to select appropriate monitoring points in the running path of the conveyor belt (8) to complete real-time monitoring of the entire stroke under working conditions, and to promptly send out an alarm signal when a dangerous situation occurs during the operation of the conveyor belt. The dry contact alarm signal of the substation is transmitted to the central control room through a cable and connected to the existing PLC control system; the visual monitoring platform is arranged in the user's central control room to display the status of the conveyor belt in real time, so as to realize manual operation to select shutdown or automatic shutdown processing.

9. The vertical lifting belt conveyor safe operation monitoring system on a coal-fired power generation unit according to claim 8 is characterized in that: The conveyor belt tear prevention detection system (1052) specifically includes: Feature extraction unit: extract the features of longitudinal tear on the conveyor belt surface. Longitudinal tear is mostly manifested as two main features: tear length > 1500mm and width < 20mm. Therefore, thresholds are established from the two dimensions of length and width, and the features of longitudinal tear in the image are extracted based on the thresholds. There are no special features of conveyor belt surface damage, and the program processes it according to general image features. Damage point merging unit: After feature extraction and recognition, many damage points may be marked in an image. Damage within several pixels needs to be merged into a feature area by setting the surrounding pixel threshold. At the same time, when the tear damage length exceeds the length of an image, a one-to-many relationship will be established between the tear damage and the image, and the feature damage points of multiple images need to be merged. Result processing unit: After the tear damage is determined, subsequent processing is required. The tear damage is marked on the picture and displayed on the interface, and the damage location information is saved in the database to establish a tear damage sample database; if the tear damage exceeds the set threshold, an alarm instruction is sent to the sound and light alarm device to drive the sound and light alarm, and an alarm database is established.

10. The vertical lifting belt conveyor safe operation monitoring system on a coal-fired power generation unit according to claim 7, characterized in that: In the 3D simulation demonstration module (106), a BKC 3D engine development component is used, which is a WebGL graphical interface 3D engine based on the HTML5 standard, including a model component library, a UI library, and an interactive action library for the process industry, and a script configuration for the measurement point marking, digital-analog linkage, and disassembly sequence of the 3D equipment; at the same time, the component library has built-in flame, steam, and water flow special effects to achieve the equipment mechanism operation, medium flow, and solid particle transportation effects.

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