Vertical lifting belt conveyor safe operation monitoring system for coal-fired power generating unit

Abstract

The application provides a vertical lifting belt conveyor safe operation monitoring system on a coal-fired power generating unit, comprising a belt visual detection module, an online monitoring module, a coal dust accumulation spontaneous combustion monitoring module, a sound wave dust removal module, a belt deviation and tearing prevention module and a 3D simulation demonstration module; the belt visual detection module is used for processing images of the belt, a wave-shaped baffle and a baffle plate to obtain detection results of baffle tearing, baffle plate falling and belt surface damage, and uploading the detection results to a server and a 3D monitoring interface; the 3D simulation demonstration module is used for simulating dynamic real-time operation conditions and dynamic changes of the vertical lifting belt conveyor, displaying equipment parameters and states, and accurately positioning equipment alarm and fault positions through a 3D model. The monitoring system significantly improves the reliability and safety of the equipment, reduces the maintenance cost, significantly improves the production efficiency, and provides a strong guarantee for stable operation of the coal-fired power generating unit.

Description

Technical Field

[0001] This invention relates to the field of conveyor monitoring technology, specifically to a monitoring system for the safe operation of a vertical lifting belt conveyor on a coal-fired power generating unit. Background Technology

[0002] Vertical lifting belt conveyors, as innovative and efficient bulk material transport equipment, have demonstrated outstanding performance in various industries such as mining, metallurgy, and coal mining, thanks to their unique design concept and wide applicability. This equipment can flexibly handle material conveying needs within a 0-90 degree range, and is particularly suitable for production environments with limited space or strict environmental requirements, such as the conveying of raw materials, crushed stone, and other block or bulk materials. Its unique corrugated sidewall belt design not only enhances conveying capacity but also ensures the stability and safety of materials during vertical lifting.

[0003] After in-depth research and comparative analysis, we proactively chose to introduce two vertical lifting belt conveyors into the coal conveying system to work with silos for coal storage operations. These two conveyors were designed and supplied by Shanghai Zemark Company, using corrugated sidewall belts manufactured by CONTITECH in Germany, with a designed belt output of up to 1500 tons / hour and a lifting height of 78 meters.

[0004] However, with the long-term operation of vertical lifting belt conveyors, a series of potential safety hazards and operational problems have gradually emerged. Fatigue cracking and deformation of the conveyor belt's corrugated sidewalls, deformation or detachment of partitions, deformation and displacement of the drive drum's concrete foundation, the risk of spontaneous combustion from coal and dust accumulation inside the sealed enclosure, and wear caused by belt misalignment all pose serious threats to the stable operation of the equipment. Of particular concern is that, because these conveyors typically employ a fully enclosed design, traditional inspection methods are insufficient to effectively detect these hidden fault points. In the event of a fire or belt breakage, or other serious accidents, the safe and stable operation of the unit will be directly jeopardized, potentially leading to significant economic losses.

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

[0006] In view of the above, the present invention provides a safety operation monitoring system for vertical lifting belt conveyors on coal-fired power generating units. Through an online detection system, the system monitors the equipment's operating status in real time, promptly detects potential faults, reduces equipment downtime, and improves equipment reliability and safety. By timely detecting and predicting equipment faults, the system can rationally arrange maintenance plans, reduce unplanned repairs and maintenance costs, minimize equipment failures and downtime, improve production continuity and efficiency, ensure stable fuel supply, and provide strong support for the safe and stable operation of coal-fired power generating units.

[0007] The technical solution of the present invention:

[0008] This invention provides a safety monitoring system for a vertical lifting belt conveyor on a coal-fired power generation unit, including a belt visual inspection module, an online monitoring module, a coal powder accumulation spontaneous combustion monitoring module, an acoustic ash removal module, a belt anti-deviation and tearing module, and a 3D simulation demonstration module.

[0009] The vertical lifting belt conveyor includes a frame, a first roller, a second roller, a third roller, a fourth roller, a fifth roller, a guide roller, and a conveyor belt. The first roller and the second roller are rotatably mounted on the bottom of the frame and arranged horizontally at intervals. The third roller is rotatably mounted on the frame and located to the upper right of the second roller. The fourth roller, the fifth roller, and multiple 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 includes a belt, corrugated sidewalls connected to both sides of the belt, and multiple baffles connected between the two corrugated sidewalls.

[0010] The belt vision inspection module is used to process images of belts, corrugated sidewalls and baffles to obtain detection results of sidewall tearing, baffle detachment and belt surface damage, and upload the detection results to the server and 3D monitoring interface to support subsequent predictive maintenance services.

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

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

[0013] The acoustic cleaning module is used to clean accumulated coal and dust using acoustic waves at regular intervals.

[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 equipment parameters and status, and accurately locate equipment alarms and fault locations through the 3D model.

[0016] The safety operation monitoring system for vertical lifting belt conveyors on coal-fired power generating units provided by this invention integrates multiple functional modules to achieve comprehensive and real-time monitoring and management of vertical lifting belt conveyors. Its beneficial effects are mainly reflected in the following aspects:

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

[0018] This system uses a belt vision inspection module to accurately identify damage to belts, corrugated sidewalls, and baffles, such as sidewall tears, baffle detachment, and belt surface damage. The inspection results are uploaded to the server and 3D monitoring interface in a timely manner, providing strong support for predictive maintenance.

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

[0020] II. Effectively reduce maintenance costs:

[0021] Through the 24 / 7 monitoring of the coal dust accumulation spontaneous combustion monitoring module, the system can grasp the heat distribution status of the coal dust surface in real time, detect potential spontaneous combustion hazards in a timely manner, avoid equipment damage and downtime accidents caused by coal dust spontaneous combustion, and thus reduce maintenance costs caused by failure.

[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 the equipment.

[0023] The system's accurate fault location and predictive maintenance suggestions enable maintenance personnel to rationally plan maintenance schedules, avoid unnecessary repairs and over-maintenance, and further reduce maintenance costs.

[0024] III. Significantly improve production efficiency:

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

[0026] The system's real-time monitoring and early warning functions enable potential faults to be addressed in a timely manner before they occur, avoiding prolonged downtime caused by equipment failures, thereby significantly improving production efficiency and ensuring the stable operation of coal-fired power generating units and the continuity of fuel supply.

[0027] In summary, the vertical lifting belt conveyor safety operation monitoring system for coal-fired power generating units provided by this 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 coal-fired power generating units.

[0028] The preferred embodiments of the present invention and their beneficial effects will be further described in detail with reference to specific implementation methods. Attached Figure Description

[0029] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the following detailed description to explain the invention, but should not be construed as limiting the invention. In the drawings:

[0030] Figure 1 This is a block diagram of the safety operation monitoring system for the vertical lifting belt conveyor on a coal-fired power generating unit according to the present invention;

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

[0032] Figure 3 This is a schematic diagram of the structure of the vertical lifting belt conveyor of the present invention, showing the cooperation between the conveyor belt and the straightening wheel;

[0033] Figure 4 This is a front view of the alignment wheel of the vertical lifting belt conveyor of the present invention;

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

[0035] The reference numerals in the attached diagrams are as follows: Belt Vision Inspection Module 101, Online Monitoring Module 102, Coal Powder Accumulation Spontaneous Combustion Monitoring Module 103, Acoustic Ash Removal Module 104, Belt Anti-Deviation and Tear 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, Triaxial Temperature and Vibration Sensor 1021, Thermal Imager 1031, Correction Wheel 1051, Conveyor Belt Tear Prevention Detection System 1052, Annular Slide Groove 10511, Shaft Hole 10512, Extrusion Hole 10513. Detailed Implementation

[0036] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0037] Please see Figure 1 and Figure 2 This invention provides a safety monitoring system for a vertical lifting belt conveyor on a coal-fired power generation unit, including a belt visual inspection module 101, an online monitoring module 102, a coal powder accumulation spontaneous combustion monitoring module 103, an acoustic ash removal module 104, a belt anti-deviation and tearing module 105, and a 3D simulation demonstration module 106. The vertical lifting belt conveyor includes 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, located to the upper right of the second roller 3. The fourth roller 5, the fifth roller 6, and multiple 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 rollers 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 vision inspection module 101 is used to process images of the belt 81, the corrugated sidewall 82, and the baffle 83 to obtain detection results of sidewall tearing, baffle detachment, and belt surface damage. The detection results are then uploaded to the server and the 3D monitoring interface to provide necessary support for subsequent predictive maintenance services.

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

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

[0041] The acoustic cleaning module 104 is used to clean accumulated coal and dust using acoustic waves at regular intervals.

[0042] The belt misalignment and tear prevention module 105 is used to monitor belt misalignment and tearing of 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 locations through the 3D model.

[0044] The safety operation monitoring system for vertical lifting belt conveyors on coal-fired power generating units provided by this invention integrates multiple functional modules to achieve comprehensive and real-time monitoring and management of vertical lifting belt conveyors. Its beneficial effects are mainly reflected in the following aspects:

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

[0046] This system, through the belt vision inspection module 101, can accurately identify damage to belts, corrugated sidewalls, and baffles, such as sidewall tears, baffle detachment, and belt surface damage, and promptly upload the inspection results to the server and 3D monitoring interface, providing strong support for predictive maintenance.

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

[0048] II. 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 heat distribution status of the coal powder surface in real time, detect spontaneous combustion hazards in a timely manner, avoid equipment damage and downtime accidents caused by coal powder spontaneous combustion, and thus reduce maintenance costs caused by failure.

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

[0051] The system's accurate fault location and predictive maintenance suggestions enable maintenance personnel to rationally plan maintenance schedules, avoid unnecessary repairs and over-maintenance, and further reduce maintenance costs.

[0052] III. Significantly improve production efficiency:

[0053] The 3D simulation demonstration module 106 simulates the dynamic real-time operation and changes of the vertical lifting belt conveyor, providing managers with an intuitive display of equipment operating status and parameters, 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 addressed in a timely manner before they occur, avoiding prolonged downtime caused by equipment failures, thereby significantly improving production efficiency and ensuring the stable operation of coal-fired power generating units and the continuity of fuel supply.

[0055] In summary, the vertical lifting belt conveyor safety operation monitoring system for coal-fired power generating units provided by this 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 coal-fired power generating units.

[0056] The belt vision inspection module 101 includes:

[0057] The 3D line scan camera and line laser device 1011 are used for real-time imaging and to acquire images of the belt 81, the corrugated edge 82 and the baffle 83 respectively.

[0058] The preprocessing unit is used to perform 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 location of edge 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 edge tearing, baffle detachment, and belt surface damage faults.

[0060] The model compression and lightweighting processing unit is used to compress and lightweight the detection model for deployment on edge terminals.

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

[0062] The application of the belt vision inspection module 101 has brought significant benefits, specifically in the following aspects:

[0063] I. Improve detection accuracy and efficiency:

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

[0065] II. Achieving lightweight model deployment:

[0066] The model compression and lightweight processing unit compresses and optimizes the detection model, significantly reducing its computational and storage requirements, enabling efficient deployment on edge devices. This improvement not only increases system response speed but also reduces hardware resource requirements, making the system more flexible and portable.

[0067] Third, it facilitates fault location and subsequent maintenance:

[0068] The data upload unit uploads 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 quick fault location for managers 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 this invention provides a strong guarantee for the safe operation of vertical lifting belt conveyors by improving inspection accuracy and efficiency, enabling lightweight model deployment, and facilitating fault location and subsequent maintenance.

[0070] In the online monitoring module 102, a combination of electromagnetic and acoustic sensors is used to monitor the displacement of the roller bearings, motor, and concrete foundation of the vertical lifting belt conveyor. Triaxial temperature and vibration sensors are used to monitor the temperature and vibration of the motor and reducer of the vertical lifting belt conveyor. Triaxial temperature and vibration sensors 1021 are installed at both ends of the shafts of the first roller 2, second roller 3, third roller 4, fourth roller 5, fifth roller 6, and guide roller 7. Loosening sensors are installed on the roller bearing bolts and the anchor bolts of the reducer of the vertical lifting belt conveyor. The cables between the loosening sensors are connected in series using a daisy-chain method, and the output power and communication cables enter the control box.

[0071] In this 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] I. Improve monitoring accuracy and reliability:

[0073] The online monitoring module 102 innovatively employs a combination of electromagnetic and acoustic fingerprint monitoring technologies to monitor the displacement of the roller bearings, motor, and concrete foundation of a vertical lifting belt conveyor. This combined monitoring method fully utilizes the advantages of both electromagnetic and acoustic fingerprint sensors to achieve accurate perception and real-time monitoring of displacement changes, effectively improving the accuracy and reliability of the monitoring.

[0074] II. Comprehensive monitoring of motor and reducer status:

[0075] For the motors and reducers of the vertical lifting belt conveyor, the online monitoring module 102 uses triaxial temperature and vibration sensors for temperature and vibration monitoring. This comprehensive monitoring method can reflect the operating status of the motors and reducers in real time, promptly detect potential faults, and provide strong support for equipment maintenance and management.

[0076] III. Implementing a bolt loosening early warning system:

[0077] The online monitoring module 102 also installs loosening sensors on the roller bearing bolts of the vertical lifting belt conveyor and the anchor bolts of the reducer. These sensors can monitor the loosening of the bolts in real time and are connected in series to output power and communication cables to the control box. Once a bolt becomes loose, the sensor will immediately issue an early warning signal, reminding management personnel to take timely measures to deal with it, thereby avoiding equipment failures and safety accidents caused by loose bolts.

[0078] In summary, the online monitoring module 102 of this invention provides comprehensive and real-time monitoring and early warning functions for the safe operation of vertical lifting belt conveyors by improving monitoring accuracy and reliability, comprehensively monitoring the status of motors and reducers, and providing early warning of bolt loosening. This effectively reduces equipment failure rate and maintenance costs, and improves production efficiency.

[0079] Coal dust accumulating on the sealing covers and steel structures of vertical lifting belt conveyors is prone to spontaneous combustion. Spontaneous combustion releases toxic and harmful gases, endangering the personal safety of workers; moreover, the temperature of spontaneously combusting coal dust exceeds 350°C, which can easily ignite the belt or burn equipment, causing the entire coal conveying system to shut down and resulting in unplanned unit shutdowns, leading to significant economic losses and posing a serious threat to the safe operation of the entire unit.

[0080] To effectively address this issue, a new infrared video imaging fire alarm system is adopted. This system significantly improves the efficiency of fire detection, offering rapid response and accurate temperature measurement. It can monitor areas prone to coal dust accumulation around the clock, triggering an alarm when dangerous temperatures are reached. This guides staff in proper handling, eliminating fire hazards and truly preventing fires before they start. At least two infrared thermal imager devices are installed on each vertical conveyor belt.

[0081] The coal dust accumulation spontaneous combustion monitoring module 103 includes a thermal imager 1031 installed at both ends of the second drum 3 and the third drum 4 for monitoring coal dust spontaneous combustion and accumulation.

[0082] The acoustic cleaning module 104 uses a low-frequency acoustic 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, excluding the working surface.

[0083] Please see Figure 3 and Figure 4 The belt anti-deviation and tearing module 105 includes a guide wheel 1051 and a conveyor belt anti-tear detection system 1052. Multiple rotatable guide wheels 1051 are installed on both sides of the belt 81. Two guide wheels 1051 arranged opposite each other on both sides of the belt 81 form a group. Each guide wheel 1051 has an annular groove 10511 on its outer periphery that matches one edge of the belt 81. A guide space matching the width of the belt 81 is formed between each group of guide wheels 1051. A shaft hole 10512 is provided at the center of each guide wheel 1051 for mounting a rotating shaft. Multiple compression holes 10513 arranged in a ring around the shaft hole 10512 are provided on the guide wheel 1051 to provide elastic compression space when the belt 81 passes through the guide space of each group of guide wheels 1051, thereby protecting the edge of the belt 81, improving the belt's service life, and reducing the belt failure rate. The guide wheels 1051 are preferably made of rubber.

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

[0085] 1. Effectively prevent belt misalignment: By installing multiple rotatable correction wheels 1051 on both sides of the belt 81 and arranging them opposite each other to form a guide space, the annular groove 10511 of the correction wheel 1051 slides and engages with the edge of each side of the belt 81, so that the belt can pass smoothly through each set of correction wheels, ensuring that the belt can always maintain the correct position during transmission and effectively preventing belt misalignment.

[0086] II. Improved belt tear resistance: Multiple compression holes 10513 on the outer periphery of the shaft hole 10512 on the straightening pulley 1051 provide elastic compression space for the belt as it passes through the guide space of each set of straightening pulleys. This design can absorb and disperse the impact force through elastic compression when the belt is subjected to accidental impact or tension change, thereby effectively preventing the belt from tearing due to uneven force.

[0087] This invention optimizes the structure of the belt conveyor system, which not only improves the operational stability and service life of the belt, but also significantly reduces the failure rate of the belt, 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 along the running path of the conveyor belt 8 to complete real-time monitoring of the entire journey under working conditions. It promptly issues alarm signals when dangerous conditions occur during conveyor belt operation. The dry contact alarm signals from the substations are transmitted to the central control room via cable and connected to the existing PLC control system. A visual monitoring platform is located in the user's central control room, which can display the real-time status of the conveyor belt and enable manual selection of emergency handling methods such as automatic shutdown.

[0089] Linear array image analysis principle: When imaging a normal conveyor belt, since the surface of the conveyor belt is smooth and uncontaminated, the grayscale changes in the horizontal and vertical regions of the image are similar to linear changes. When a crack appears, a significant grayscale difference will be formed between the crack area and the smooth area. The system finds the contour of the crack based on the grayscale difference and judges whether it is indeed a crack feature based on the contour characteristics. If it is, an alarm is triggered or the conveyor belt is stopped. If it is ordinary interference, it is ignored.

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

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

[0092] Damage point merging unit: After feature extraction and identification, many damage points may be identified in an image. Damage within a certain number of pixels needs to be merged by setting a threshold for surrounding pixels to merge them into a single feature region. Simultaneously, when the tear damage length exceeds the length of an image, a one-to-many relationship is established between the tear damage and the images, requiring the merging of feature damage points from multiple images.

[0093] Result Processing Unit: After tear damage is determined, further processing is required. The tear damage is marked on the image 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 command is sent to the audible and visual alarm device to activate the alarm, and an alarm database is established.

[0094] The tear detection status detection interface of the conveyor belt tear detection system provided by this invention is shown in the figure below. Figure 5 As shown.

[0095] The conveyor belt tear detection system 1052 provided by this invention, through the integration of a feature extraction unit, a tear point merging unit, and a result processing unit, achieves real-time monitoring of the entire conveyor belt stroke and accurate identification of longitudinal tears. Its beneficial effects are mainly reflected in the following aspects:

[0096] I. Real-time Monitoring and Early Warning Capabilities: This device can select appropriate monitoring points along the conveyor belt's running path to achieve real-time monitoring of the entire journey under operating conditions. If a dangerous situation occurs during conveyor belt operation, such as longitudinal tearing, the device can immediately issue an alarm signal and transmit the alarm signal via cable to the central control room, connecting it to the existing PLC control system. This enables real-time monitoring and early warning of the conveyor belt's operating status.

[0097] II. Precise Identification and Damage Point Merging: The feature extraction unit can accurately extract the features of longitudinal tears on the conveyor belt surface. By setting thresholds for length and width, it can effectively identify longitudinal tears with a length greater than 1500mm and a width less than 20mm. The damage point merging unit can further effectively merge feature damage points of the same tear in multiple images, avoiding the loss of tear damage information or duplicate counting caused by image segmentation, thus improving the accuracy and reliability of identification.

[0098] III. Efficient Processing and Emergency Response: The results processing unit not only annotates and displays tear damage on images, but also saves damage location information and other results in a database, providing strong data support for subsequent tear damage analysis and management. Simultaneously, when tear damage exceeds a set threshold, the unit automatically sends an alarm command to the audible and visual alarm device, promptly issuing an alert and triggering emergency handling methods such as automatic shutdown or manual shutdown, effectively preventing equipment damage and production accidents caused by tear damage.

[0099] IV. System Integration and Compatibility: This device can be seamlessly integrated with existing PLC control systems, transmitting alarm signals to the central control room's visual monitoring platform via cable. The platform can display the conveyor belt's status in real time, enabling manual selection of shutdown or automatic shutdown as emergency handling methods, thereby improving the overall system performance and compatibility.

[0100] In summary, the conveyor belt tear detection system 1052 provided by this invention has advantages in many aspects, including real-time monitoring and early warning capabilities, accurate identification and damage point merging, efficient processing and emergency response, and system integration and compatibility. It can significantly improve the safety and stability of conveyor belt operation, reduce the risk of production accidents, and provide strong protection for the safe production of enterprises.

[0101] In the 3D simulation demonstration module 106, the BKC 3D engine is used to develop components. This is a WebGL-based 3D graphical interface engine based on the HTML5 standard, including model component libraries, UI libraries, and interactive action libraries specifically for the process industry. It allows for script-based configuration of 3D equipment measurement point annotation, digital-model linkage, and disassembly sequence, efficiently completing project customization and facilitating later maintenance. Simultaneously, the component library includes built-in effects such as flames, steam, and water flow, easily realizing effects such as equipment mechanism operation, media flow, and solid particulate matter transportation. Data is lightweighted for common process industry scenarios, achieving instant loading and smooth operation on integrated graphics terminals. It can easily build cross-platform enterprise-level applications, and its highly encapsulated 3D graphics display based on HTML5 technology allows for the rapid construction of 3D visualization scenes.

[0102] By creating a 3D model of the vertical lifting belt conveyor and combining 360-degree panoramic visualization with data scene linkage, a comprehensive intelligent equipment real-time monitoring 3D visualization system is established to realize real-time monitoring of the dynamic operation and changes of the vertical lifting belt conveyor, equipment parameters and status, etc.

[0103] The overall design style of the 3D model of the vertical lifting belt conveyor is realistic, but it needs to be switched to wireframe mode when displaying key internal components. During the display, the 2D data panel is used as an information board in the 3D model, and it needs to blend harmoniously with the 3D style while ensuring that the data information is clearly visible. The images are in vector format, so there will be no distortion when enlarged.

[0104] The 3D modeling of the vertical lifting belt conveyor is carried out using standard elevation modeling. Based on the conveyor's CAD drawings, real-world photos, and other materials, a schematic model is created, including key components such as rollers, belts, corrugated sidewalls, and baffles. The style is realistic, and the building's exterior is reproduced according to a certain scale. A simplified model with textures is used to achieve efficient web loading and rendering.

[0105] In the description of this invention, it should be noted that the terms "upper," "lower," etc., indicating orientation or positional relationships are based on the orientation or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying importance; the terms "bottom surface" and "top surface," "inner" and "outer" respectively refer to the geometric direction toward or away from a specific component.

[0106] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linkage" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. Furthermore, in the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0107] The above are merely 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 within the protection scope of the present invention.

Claims

1. A monitoring system for the safe operation of a vertical lifting belt conveyor on a coal-fired power generating unit, characterized in that, It includes a belt visual inspection module (101), an online monitoring module (102), a coal powder accumulation spontaneous combustion monitoring module (103), an acoustic ash removal module (104), a belt anti-deviation and tearing module (105), and a 3D simulation demonstration module (106); The vertical lifting belt conveyor includes 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 to the upper right of the second roller (3). The fourth roller (5), the fifth roller (6), and multiple 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 rollers (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 multiple baffles (83) connected between the two corrugated sidewalls (82). The belt vision inspection module (101) is used to process images of the belt (81), corrugated sidewall (82) and baffle (83) to obtain detection results of sidewall tearing, baffle detachment and belt surface damage, and upload the detection results to the server and 3D monitoring interface to support subsequent predictive maintenance services. The online monitoring module (102) is used to monitor the displacement of the drive drum and concrete foundation of the vertical lifting belt conveyor, as well as the vibration and temperature data of the motor and reducer in real time, and to set alarm thresholds to realize automatic alarm. The coal powder accumulation spontaneous combustion monitoring module (103) is used to automatically scan the heat distribution state of the coal powder surface in real time and generate intuitive images for all-weather monitoring; The acoustic cleaning module (104) is used to clean accumulated coal and dust using acoustic waves at regular intervals. The belt anti-misalignment and tearing module (105) is used to monitor belt (81) misalignment and tearing; 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 faults through the 3D model; The belt anti-deviation and tearing module (105) includes a belt guide wheel (1051). Multiple rotatable belt guide wheels (1051) are installed on both sides of the belt (81). Two belt guide wheels (1051) arranged opposite to each other on both sides of the belt (81) form a group. Each belt guide wheel (1051) has an annular groove (10511) on its outer periphery that is adapted to one side edge of the belt (81). A guide space adapted to the width of the belt (81) is formed between each group of belt guide wheels (1051). A shaft hole (10512) is opened at the center of each belt guide wheel (1051) for installing a rotating shaft. Multiple extrusion holes (10513) are arranged in annular around the outer periphery of the shaft hole (10512) on the belt guide wheel (1051) so that the belt (81) has an elastic extrusion space when passing through the guide space of each group of belt guide wheels (1051). 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 journey under working conditions. When a dangerous situation occurs during the operation of the conveyor belt, an alarm signal is issued in time. 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 and realize manual operation to select shutdown or automatic shutdown processing.

2. The safety operation monitoring system for a vertical lifting belt conveyor on a coal-fired power generating unit according to claim 1, characterized in that, The belt visual inspection module (101) includes: A 3D line scan camera and a line laser device (1011) are used for real-time imaging and to acquire images of the belt (81), the corrugated sidewall (82) and the baffle (83) respectively; The preprocessing unit is used to perform 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 location of edge 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 edge tearing, baffle detachment and belt surface damage faults. The model compression and lightweighting processing unit is used to compress and lightweight the detection model for deployment on edge terminals. The data upload unit is used to upload detection result images, including fault type, location, and fault area, to the server and 3D monitoring interface.

3. The safety operation monitoring system for a vertical lifting belt conveyor on a coal-fired power generating unit according to claim 1, characterized in that, In the online monitoring module (102), the monitoring of the displacement of the roller bearings and motor of the vertical lifting belt conveyor and the concrete foundation is carried out by a combination of electromagnetic and acoustic fingerprint monitoring. The temperature and vibration of the motor and reducer of the vertical lifting belt conveyor are monitored by a triaxial temperature and vibration sensor. Triaxial temperature and vibration sensors (1021) are installed at both ends of the 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 safety operation monitoring system for a vertical lifting belt conveyor on a coal-fired power generating unit according to claim 3, characterized in that, Loosening 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 loosening sensors are connected in series using a daisy-chain method, and the output power and communication cables enter the control box.

5. The safety operation monitoring system for a vertical lifting belt conveyor on a coal-fired power generating unit according to claim 1, characterized in that, The coal dust accumulation spontaneous combustion monitoring module (103) includes a thermal imager (1031) installed at both ends of the second drum (3) and the third drum (4) for monitoring coal dust spontaneous combustion and accumulation.

6. The safety operation monitoring system for a vertical lifting belt conveyor on a coal-fired power generating unit according to claim 1, characterized in that, The acoustic cleaning module (104) adopts a low-frequency acoustic 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, excluding the working surface.

7. The safety operation monitoring system for a vertical lifting belt conveyor on a coal-fired power generating unit according to claim 1, characterized in that, The conveyor belt tear detection system (1052) specifically includes: Feature extraction unit: Extracts features of longitudinal tears on the conveyor belt surface. Longitudinal tears are characterized by two features: tear length > 1500 mm and width < 20 mm. Therefore, thresholds are established from the two dimensions of length and width, and the longitudinal tear features in the image are extracted based on the thresholds. There are no special features of surface damage on the conveyor belt, so the program processes them as general image features. Damage point merging unit: After feature extraction and recognition, damage points in an image are identified. Damage within a certain number of pixels needs to be merged. This is done by setting a threshold for surrounding pixels to merge them into a single feature region. At the same time, when the tear damage length exceeds the length of an image, a one-to-many relationship is established between the tear damage and the image, requiring the merging of feature damage points from multiple images. Result Processing Unit: After tear damage is determined, further processing is required. The tear damage is marked on the image 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 command is sent to the audible and visual alarm device to drive the audible and visual alarm, and an alarm database is established.

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