Mining conveyor carrier roller state detection system and method

Abstract

The invention relates to the technical field of mining conveyor carrier roller state detection, and discloses a mining conveyor carrier roller state detection system and method, and the system comprises a sound monitoring module which is used for obtaining the noise decibel of the operation of a conveyor carrier roller; the image acquisition module is provided with a moving unit and used for acquiring running images of the carrier rollers of the conveyor. And the processing module is used for judging whether abnormal noise occurs in the operation of each carrier roller according to the relationship between the real-time noise decibels of the operation of each carrier roller of the conveyor, controlling the image acquisition module to move to the carrier roller with the abnormal noise, and acquiring the image information of the operation of the carrier roller. And the scoring module is used for performing state score evaluation according to the image information of carrier roller operation. And the alarm module is used for determining the danger level of the carrier roller according to the state score and a preset state score, and sending an alarm notice. According to the invention, through integration of sound monitoring and image acquisition technologies, comprehensive and intelligent monitoring of the running state of the mining conveyor carrier roller is realized.

Description

Technical Field

[0001] The present invention relates to the technical field of idler state detection for mine conveyors, and more particularly, to a system and method for detecting the state of idlers of mine conveyors. Background Art

[0002] In the mining and material handling fields, mine conveyors play a crucial role, and the normal operation of idlers is directly related to the efficiency and reliability of the entire conveying system.

[0003] However, traditional methods for monitoring the state of idlers mainly rely on regular routine maintenance inspections. This approach has serious problems. Firstly, periodic regular maintenance inspections usually involve cumbersome manual work, requiring a large amount of manpower and time costs. This method is not only inefficient but also prone to overlooking some minor abnormal conditions that may cause problems. Secondly, since mine conveyors usually operate under harsh environmental conditions, such as high temperature, humidity, dust, etc., it is difficult for traditional methods to achieve accurate monitoring and timely fault warning under these conditions. Moreover, this inspection method is only periodic and intermittent, and cannot achieve continuous monitoring of the operating state of idlers. Therefore, when a fault occurs, irreversible damage is likely to have been caused.

[0004] In view of this, there is an urgent need to invent a method for detecting the state of idlers of mine conveyors to solve the problems in the current technology that periodic regular maintenance inspections are costly in terms of manpower and time, have low inspection efficiency, and cannot perform continuous real-time monitoring. Summary of the Invention

[0005] In view of this, the present invention proposes a system and method for detecting the state of idlers of mine conveyors, aiming to solve the problems in the current technology that periodic regular maintenance inspections are costly in terms of manpower and time, have low inspection efficiency, and cannot perform continuous real-time monitoring.

[0006] On the one hand, the present invention provides a system for detecting the state of idlers of mine conveyors, comprising:

[0007] A sound monitoring module for obtaining the noise decibels of the operation of each idler of the conveyor;

[0008] An image acquisition module provided with a moving unit, the image acquisition module being used to acquire the running images of the idlers of the conveyor;

[0009] A processing module electrically connected to the sound monitoring module and the moving unit, the processing module being used to judge whether abnormal noise occurs in the operation of each idler according to the relationship between the real-time noise decibels and the historical noise decibels of the operation of each idler of the conveyor, and being used to control the moving unit to move the image acquisition module to the idler where abnormal noise occurs to acquire the image information of the operation of the idler;

[0010] A scoring module, electrically connected to the image acquisition module, for evaluating the status score according to the image information of the idler running;

[0011] An alarm module, electrically connected to the scoring module, for determining the danger level of the idler according to the relationship between the status score and the preset status score, and sending an alarm notification.

[0012] Further, when the processing module is used to judge whether abnormal noise occurs in the running of each idler of the conveyor according to the relationship between the real-time noise decibel and the historical noise decibel of each idler running of the conveyor, it includes:

[0013] The processing module is also used to obtain the noise decibel of each idler's historical running, and determine the average noise decibel of each idler according to the noise decibel of each idler's historical running; wherein,

[0014] The processing module is also used to remove the abnormal noise decibel in the noise decibel of each idler's historical running, and obtain the average noise decibel of the sum of the noise decibel of each idler's historical running after removing the abnormal noise decibel;

[0015] The processing module is also used to judge whether abnormal noise occurs when the idler runs according to the relationship between the real-time noise decibel of the idler running and the average noise decibel corresponding to the idler;

[0016] If the real-time noise decibel of the idler running is consistent with the average noise decibel corresponding to the idler, it is judged that no abnormal noise occurs when the idler runs;

[0017] If the real-time noise decibel of the idler running is inconsistent with the average noise decibel corresponding to the idler, it is judged that abnormal noise occurs when the idler runs, and the image acquisition module is controlled to move to the position of the idler to obtain the image information of the idler running.

[0018] Further, when the scoring module is used to evaluate the status score according to the image information of the idler running, it includes:

[0019] The scoring module is also used to obtain the front weight score and the rear weight score of the idler running, and obtain the status score of the idler running according to the following formula:

[0020] A = (z1 * Q) + (z2 * H);

[0021] In the formula, A is the status score of the idler running, Q is the front weight score of the idler running, H is the rear weight score of the idler running, z1 and z2 are the weight coefficients of the status score, and the sum of z1 and z2 is 1.

[0022] Further, when the scoring module is further configured to obtain the previous weighted score of the idler running, it includes:

[0023] The scoring module is further configured to obtain the rotational speed difference and vibration frequency difference of the idler running, and based on the rotational speed difference and vibration frequency difference of the idler running, obtain the previous weighted score of the idler running according to the following formula:

[0024] Q = (k1 * T) + (k2 * Y);

[0025] Where Q is the previous weighted score of the idler running, T is the rotational speed difference of the idler running, Y is the vibration frequency difference of the idler running, k1 and k2 are the weight coefficients of the previous weighted score, and the sum of k1 and k2 is 1.

[0026] Further, when the scoring module is further configured to obtain the rotational speed difference and vibration frequency difference of the idler running, it includes:

[0027] The scoring module is further configured to obtain the real-time rotational speed of the idler running, and based on the relationship between the real-time rotational speed and the preset running rotational speed, determine whether to obtain the rotational speed difference of the idler running, where:

[0028] When the real-time rotational speed is consistent with the preset running rotational speed, the scoring module determines that the rotational speed of the idler is in a normal state, and at this time, the rotational speed difference of the idler running is not obtained;

[0029] When the real-time rotational speed is lower than the preset running rotational speed, the scoring module determines that the rotational speed of the idler is in an abnormal state, and obtains the rotational speed difference T of the idler running, and sets T = M0 - M, where M is the real-time rotational speed of the idler running and M0 is the preset running rotational speed.

[0030] Further, when the scoring module is further configured to obtain the rotational speed difference and vibration frequency difference of the idler running, it further includes:

[0031] The scoring module is further configured to obtain the real-time vibration frequency of the idler running, and based on the relationship between the real-time vibration frequency and the preset running vibration frequency, determine whether to obtain the vibration frequency difference of the idler running, where;

[0032] When the real-time vibration frequency is consistent with the preset running vibration frequency, the scoring module determines that the vibration of the idler is in a normal state, and does not obtain the vibration frequency difference of the idler running;

[0033] When the real-time vibration frequency is slower than the preset operating vibration frequency, the scoring module determines that the vibration of the idler is in an abnormal state, and obtains the vibration frequency difference Y of the idler operation, and sets Y = N0 - N, where N0 is the preset operating vibration frequency and N is the real-time vibration frequency.

[0034] Further, when the scoring module is further configured to obtain the post-weight score of the idler operation, it includes:

[0035] The scoring module is further configured to obtain the surface temperature difference during the operation of the idler and the lateral displacement distance of the conveyor belt on the surface of the idler during operation, and obtain the post-weight score of the idler operation based on the following formula:

[0036] H = (c1 * J) + (c2 * F);

[0037] In the formula, H is the post-weight score of the idler operation, J is the surface temperature difference during the operation of the idler, F is the lateral displacement distance of the conveyor belt on the surface of the idler during operation, c1 and c2 are weight coefficients, and the sum of c1 and c2 is 1.

[0038] Further, when the scoring module is further configured to obtain the surface temperature difference during the operation of the idler, it includes:

[0039] The scoring module is further configured to obtain the real-time temperature on the surface of the idler during operation, and determine whether to obtain the surface temperature difference during the operation of the idler according to the relationship between the real-time temperature and the preset operating temperature, where:

[0040] When the real-time temperature is lower than or equal to the preset operating temperature, the scoring module determines that the surface temperature of the idler is in a normal state, and at this time, the surface temperature difference during the operation of the idler is not obtained;

[0041] When the real-time temperature is higher than the preset operating temperature, the scoring module determines that the surface temperature of the idler is in an abnormal state, and obtains the surface temperature difference J during the operation of the idler, and sets J = B0 - B, where B is the real-time temperature on the surface of the idler during operation and B0 is the preset operating temperature.

[0042] Further, when the alarm module is configured to determine the danger level of the idler according to the state score and the preset state score and send an alarm notification, it includes:

[0043] The alarm module is further configured to preset a first preset state score P1 and a second preset state score P2;

[0044] The alarm module is further configured to determine the danger level of the idler according to the relationship between the state score A of the idler operation and each preset state score, and send an alarm notification;

[0045] When A < P1, the warning module determines that the risk level of the idler is the first level and sends a warning notice.

[0046] When P1 ≤ A < P2, the warning module determines that the risk level of the idler is the second level and sends a warning notice.

[0047] When A ≥ P2, the warning module determines that the risk level of the idler is the third level and sends a warning notice.

[0048] Among them, in terms of the degree of danger: the first level < the second level < the third level.

[0049] On the other hand, the present invention provides a method for detecting the state of a mine conveyor idler, which is applicable to the mine conveyor idler state detection system of the present invention described above, and includes:

[0050] Obtain the noise decibels of each idler of the conveyor, and judge whether there is abnormal noise in the operation of each idler according to the relationship between the real-time noise decibels and the historical noise decibels of the operation of each idler of the conveyor.

[0051] Obtain the image information of the idler with abnormal noise, and evaluate the state score according to the image information of the idler operation.

[0052] Determine the risk level of the idler according to the relationship between the state score and the preset state score, and send a warning notice.

[0053] Compared with the prior art, the beneficial effects of the present invention are as follows: By obtaining the noise decibels during the operation of the conveyor idler through the sound monitoring module, it can sensitively sense whether there is abnormal noise in the idler, so as to discover potential problems in time. Secondly, through the image acquisition module equipped with a mobile unit, according to the feedback of the sound monitoring module, it automatically adjusts its position to obtain the image information of the idler where abnormal noise occurs, realizing the intelligent association of sound and image. The processing module can accurately judge whether there is abnormal noise in the operation of each idler by analyzing the relationship between the real-time noise decibels. Once abnormal noise is detected, the image acquisition module quickly moves to the source of the abnormal noise to obtain the image information of the idler, providing reliable data support for subsequent state evaluation. In addition, through the scoring module to evaluate the state score according to the image information of the idler operation, a direct and comprehensive quantitative evaluation of the idler operation state is realized. Finally, the warning module determines the risk level of the idler according to the difference between the state score and the preset state score, and sends a warning notice in time, enabling the operation and maintenance personnel to respond quickly and take necessary maintenance measures.

[0054] On the other hand, the present application also provides a method for detecting the state of a roller of a mine conveyor, which is applicable to a system for detecting the state of a roller of a mine conveyor according to the above-mentioned invention, and includes:

[0055] Obtain the noise decibels of the operation of the conveyor rollers, and determine whether there is abnormal noise in the operation of each of the rollers according to the relationship between the real-time noise decibels of the operation of each roller of the conveyor;

[0056] Obtain the image information of the operation of the roller with abnormal noise, and evaluate the state score according to the image information of the operation of the roller;

[0057] Determine the danger level of the roller according to the state score and the preset state score, and send an alarm notification.

[0058] It can be understood that the above-mentioned system and method for detecting the state of a roller of a mine conveyor in the invention have the same beneficial effects and will not be repeated here. Description of the Drawings

[0059] By reading the following detailed description of the preferred embodiments, various other advantages and benefits will become clear to those of ordinary skill in the art. The drawings are only for the purpose of showing the preferred embodiments and are not considered to be a limitation of the present invention. Moreover, throughout the drawings, the same reference numerals are used to represent the same components. In the drawings:

[0060] Figure 1 is a structural block diagram of a system for detecting the state of a roller of a mine conveyor provided by an embodiment of the present invention;

[0061] Figure 2 is a flow block diagram of a method for detecting the state of a roller of a mine conveyor provided by an embodiment of the present invention. Detailed Embodiments

[0062] The exemplary embodiments of the present disclosure will be described in more detail below with reference to the drawings. Although the exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided so that the present disclosure can be more thoroughly understood and the scope of the present disclosure can be fully conveyed to those skilled in the art. It should be noted that, without conflict, the embodiments in the present invention and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the drawings and in combination with the embodiments.

[0063] As Figure 1As shown, in some embodiments of the present application, this embodiment provides a belt conveyor idler status detection system, including: a sound monitoring module, an image acquisition module, a processing module, a scoring module, and an alarm module. The sound monitoring module is used to obtain the noise decibels of each idler during the operation of the conveyor. The image acquisition module is provided with a moving unit, and the image acquisition module is used to obtain the running images of the conveyor idlers. The processing module is electrically connected to the sound monitoring module and the moving unit. The processing module is used to determine whether abnormal noise occurs in the operation of each idler according to the relationship between the real-time noise decibels and the historical noise decibels of each idler during the operation of the conveyor, and is used to control the moving unit to move the image acquisition module to the idler where abnormal noise occurs to obtain the image information of the operation of the idler. The scoring module is electrically connected to the image acquisition module, and the scoring module is used to evaluate the status score according to the image information of the idler operation. The alarm module is electrically connected to the scoring module, and the alarm module is used to determine the danger level of the idler according to the difference between the status score and the preset status score, and send an alarm notification.

[0064] It can be understood that, firstly, the sound monitoring module accurately reflects the operating conditions of each idler by obtaining the noise decibels, providing real-time sound signal input for the system. Secondly, the image acquisition module is equipped with a moving unit, and by intelligently adjusting the position, it can capture the image information of the idler with abnormal noise in real time, making the monitoring range more comprehensive and providing intuitive image data for subsequent analysis. In addition, after receiving the data from the sound monitoring module, the processing module quickly determines whether abnormal noise occurs in the idler by analyzing the relationship between the real-time noise decibels and the historical noise decibels of each idler during the operation of the conveyor, realizing the real-time monitoring and intelligent determination of the idler status. Once abnormal noise is identified, the processing module immediately controls the image acquisition module to move to the source of the abnormal noise to obtain the image information of the operation of the idler, providing a reliable multi-dimensional data basis for subsequent status evaluation. The scoring module comprehensively evaluates the idler status in combination with the image information, enabling the operation and maintenance personnel to intuitively understand the health status of the idler and improving the accuracy and comprehensiveness of the monitoring. Finally, the alarm module determines the danger level of the idler according to the difference between the status score and the preset status score, realizing the timely alarm of the idler health status. This automated alarm mechanism effectively improves the fault response speed, enables the operation and maintenance personnel to quickly take measures to prevent potential risks, thereby reducing the maintenance cost and improving the safety and reliability of the belt conveyor in mines.

[0065] It can be seen that in this application, through the real-time monitoring of sound, the sound monitoring module can efficiently obtain the noise decibel data during the operation of the conveyor idlers. These noise data contain the sound signals generated during the operation of the idlers, and their changes can reflect the different working states of the idlers. The real-time monitoring of noise decibels provides an intuitive means to sense the operation of the idlers. Especially for potential abnormal noises, possible problems can be quickly identified. Secondly, the noise decibel data obtained by the sound monitoring module is used as the input of the processing module. The processing module can judge in real time whether there is abnormal noise in the idlers by analyzing the relationship between the real-time noise decibels of the operation of each idler. This real-time judgment mechanism ensures the timely response of the system to the idler state, enabling abnormal noises to be detected at an early stage and providing a larger window period for subsequent maintenance and repair. At the same time, when the processing module determines that there is abnormal noise in the operation of a certain idler, it controls the image acquisition module to move to the source of the abnormal noise. This intelligent collaborative operation combines sound monitoring and image acquisition, realizing the real-time positioning of the idler with abnormal noise and the acquisition of image information. Through this collaborative mechanism, not only can abnormal noises be detected, but also visual image support can be provided, providing more comprehensive data support for subsequent condition assessment. At the same time, it also greatly reduces the operating cost during real-time monitoring.

[0066] Preferably, the mobile unit is a wheeled mobile unit or a tracked mobile unit.

[0067] In some embodiments of this application, when the processing module is used to judge whether there is abnormal noise in the operation of each idler according to the relationship between the real-time noise decibel and the historical noise decibel of the operation of each idler of the conveyor, it includes: The processing module is also used to obtain the noise decibels of the historical operation of each idler and determine the noise decibel mean value of each idler according to the noise decibels of the historical operation of each idler, where: The processing module is also used to remove the abnormal noise decibels in the noise decibels of the historical operation of each idler and obtain the noise decibel mean value of the sum of the noise decibels of the historical operation of each idler after removing the abnormal noise decibels. The processing module is also used to judge whether there is abnormal noise during the operation of the idler according to the relationship between the real-time noise decibel of the idler operation and the corresponding noise decibel mean value of the idler: If the real-time noise decibel of the idler operation is consistent with the corresponding noise decibel mean value of the idler, it is judged that there is no abnormal noise during the operation of the idler. If the real-time noise decibel of the idler operation is inconsistent with the corresponding noise decibel mean value of the idler, it is judged that there is abnormal noise during the operation of the idler, and the image acquisition module is controlled to move to the position of the idler to obtain the image information of the operation of the idler.

[0068] It can be seen that by introducing the analysis of historical noise decibel data, the accurate judgment ability of abnormal noise is improved. Specifically, the processing module first obtains the noise decibels of each idler roller during historical operation, calculates the average noise decibel of each idler roller, so as to form a benchmark for the normal operation noise level of the idler roller. At the same time, the processing module obtains more reliable historical noise decibel data by removing the abnormal values in the historical operation noise decibels of each idler roller, further improving the robustness of the system. Subsequently, the processing module can judge whether there is abnormal noise during the operation of the idler roller by comparing the relationship between the real-time noise decibel of the idler roller operation and the average noise decibel corresponding to the idler roller. This judgment method fully considers the average value of the historical noise decibels of each idler roller, enabling the system to more intelligently judge whether the current noise level is within the normal range. When the real-time noise decibel of the idler roller operation is consistent with its average value, it is determined that the idler roller is operating normally; otherwise, if it is inconsistent, it is judged that there is abnormal noise in the idler roller operation. In addition, when the processing module judges that there is abnormal noise, it not only simply discriminates the abnormal noise, but further cooperates with the image acquisition module to move to the idler roller with abnormal noise to obtain the image information of the idler roller operation. This intelligent cooperation mechanism realizes the positioning and visual display of abnormal noise, provides more comprehensive data support for maintenance personnel, and accelerates the process of fault diagnosis.

[0069] It can be understood that through the analysis of historical noise decibels and the intelligent comparison of real-time noise decibels, this technical solution not only improves the accuracy of abnormal noise detection, but also realizes the intelligent positioning and image display of abnormal noise, providing a more comprehensive and intelligent solution for the real-time monitoring and fault diagnosis of the system.

[0070] In some embodiments of the present application, when the scoring module is used to evaluate the status score according to the image information of the idler roller operation, it includes: the scoring module is also used to obtain the front weight score and the back weight score of the idler roller operation, and obtain the status score of the idler roller operation according to Formula I, where Formula I is as follows:

[0071] A = (z1 * Q) + (z2 * H).

[0072] In the formula, A is the status score of the idler roller operation, Q is the front weight score of the idler roller operation, H is the back weight score of the idler roller operation, z1 and z2 are the weight coefficients of the status score, and the sum of z1 and z2 is 1.

[0073] It can be understood that the scoring module of the belt conveyor idler state detection system designs a comprehensive state score evaluation method. By obtaining the image information of the idler operation and the front weight score and the rear weight score, a multi-dimensional comprehensive evaluation of the idler state is achieved. Specifically, the scoring module first obtains the front weight score and the rear weight score of the idler operation. These two weight scores respectively represent the importance of the front and rear parts of the idler in the state evaluation, providing a weight reference for the subsequent calculation of the state score. Subsequently, the scoring module uses Formula Ⅰ to calculate the state score. The design of this weight coefficient enables users to adjust the weight ratio of the front and rear parts in the overall state evaluation according to actual needs, so as to meet the different degrees of emphasis on the front and rear parts under different working conditions. Furthermore, it allows users to flexibly configure the weight coefficient according to the specific operating environment, improving the applicability and customization for various application scenarios when detecting the state of the conveyor idler.

[0074] It can be seen that through the comprehensive application of image information and weight allocation, a more accurate and comprehensive evaluation of the idler operation state is achieved. This comprehensive evaluation method helps to improve the accuracy of the idler health condition evaluation, provides more comprehensive state information for the operation and maintenance personnel, enabling them to formulate maintenance strategies more pertinently and reduce maintenance costs. Overall, the design of this scoring module provides a more scientific and flexible state evaluation method for the belt conveyor state monitoring system.

[0075] In some embodiments of the present application, when the scoring module is also used to obtain the front weight score of the idler operation, it includes: the scoring module is also used to obtain the rotational speed difference and the vibration frequency difference of the idler operation, and based on the rotational speed difference and the vibration frequency difference of the idler operation, obtain the front weight score of the idler operation according to Formula Ⅱ. Formula Ⅱ is shown as follows:

[0076] Q = (k1 * T) + (k2 * Y).

[0077] Wherein, Q is the front weight score of the idler operation, T is the rotational speed difference of the idler operation, Y is the vibration frequency difference of the idler operation, k1 and k2 are the weight coefficients of the front weight score, and the sum of k1 and k2 is 1.

[0078] In some embodiments of the present application, when the scoring module is further configured to obtain the rotational speed difference and vibration frequency difference of the idler running, it includes: The scoring module is further configured to obtain the real-time rotational speed of the idler running, and determine whether to obtain the rotational speed difference of the idler running according to the relationship between the real-time rotational speed and the preset running rotational speed, where: When the real-time rotational speed is consistent with the preset running rotational speed, the scoring module determines that the rotational speed of the idler is in a normal state and does not obtain the rotational speed difference of the idler running. When the real-time rotational speed is lower than the preset running rotational speed, the scoring module determines that the rotational speed of the idler is in an abnormal state, and obtains the rotational speed difference T of the idler running, and sets T = M0 - M, where M is the real-time rotational speed of the idler running, and M0 is the preset running rotational speed.

[0079] In some embodiments of the present application, when the scoring module is further configured to obtain the rotational speed difference and vibration frequency difference of the idler running, it further includes: The scoring module is further configured to obtain the real-time vibration frequency of the idler running, and determine whether to obtain the vibration frequency difference of the idler running according to the relationship between the real-time vibration frequency and the preset running vibration frequency, where: When the real-time vibration frequency is consistent with the preset running vibration frequency, the scoring module determines that the vibration of the idler is in a normal state and does not obtain the vibration frequency difference of the idler running. When the real-time vibration frequency is slower than the preset running vibration frequency, the scoring module determines that the vibration of the idler is in an abnormal state, and obtains the vibration frequency difference Y of the idler running, and sets Y = N0 - N, where N0 is the preset running vibration frequency and N is the real-time vibration frequency.

[0080] It can be understood that when obtaining the previous weighted score of the idler running, the influence of the rotational speed difference and the vibration frequency difference is comprehensively considered. Specifically, the scoring module uses Formula II for calculation, enabling the scoring module to more comprehensively consider the two important parameters of rotational speed and vibration, thereby improving the multi-dimensional evaluation ability of the idler state. In this design, the parameter Q in Formula II represents the previous weighted score of the idler running. This comprehensive consideration method provides a more comprehensive and scientific basis for the state evaluation of the scoring module, helping to more accurately judge the running condition of the idler. At the same time, when obtaining the rotational speed difference and the vibration frequency difference of the idler running, the scoring module realizes the dynamic perception of the idler running state through the monitoring of the real-time rotational speed and the real-time vibration frequency. When the real-time rotational speed is consistent with the preset running rotational speed, the scoring module determines that the rotational speed of the idler is in a normal state and does not obtain the rotational speed difference; while when the real-time rotational speed is lower than the preset running rotational speed, the scoring module determines that the rotational speed of the idler is abnormal and obtains the corresponding rotational speed difference. For the monitoring of the vibration frequency, the scoring module dynamically obtains the vibration frequency difference by judging the relationship between the real-time vibration frequency and the preset running vibration frequency, further improving the accuracy of the scoring module's evaluation of the idler state. This design of dynamic perception enables the scoring module to respond in real time to the changes in the idler running state, timely identify abnormal situations, and helps to improve the real-time monitoring performance of the scoring module.

[0081] It can be understood that by introducing more detailed state evaluation parameters, the comprehensiveness and accuracy of the idler running state are improved. This comprehensive evaluation method can not only more accurately reflect the health status of the idler, but also adjust the evaluation parameters in real time during the dynamic operation process, making the scoring module more adaptable and intelligent.

[0082] In some embodiments of the present application, the scoring module is further used to obtain the subsequent weighted score of the idler running, including: the scoring module is further used to obtain the surface temperature difference during the idler running and the lateral displacement distance of the conveyor belt on the surface of the idler during running, and obtain the subsequent weighted score of the idler running based on Formula III. Formula III is as follows:

[0083] H = (c1 * J) + (c2 * F).

[0084] In the formula, H is the subsequent weighted score of the idler running, J is the surface temperature difference during the idler running, F is the lateral displacement distance of the conveyor belt on the surface of the idler during running, c1 and c2 are weighting coefficients, and the sum of c1 and c2 is 1.

[0085] It can be understood that the scoring module not only considers the front weight score of the idler operation, but also comprehensively considers the back weight score to more comprehensively evaluate the idler state. Specifically, when obtaining the back weight score of the idler operation, the scoring module uses Formula III for calculation. This design enables the scoring module to more comprehensively consider factors such as the temperature and lateral displacement of the idler in the state evaluation, improving the multi-dimensional evaluation accuracy of the idler state. Specifically, the parameters J and F in Formula III represent the surface temperature difference of the idler and the lateral displacement distance of the conveyor belt respectively, while c1 and c2 are the weight coefficients of the corresponding parameters. This design enables the scoring module to more flexibly adjust the weights of temperature and displacement in the back weight score to adapt to different degrees of attention to these two parameters under different working conditions. By dynamically adjusting the weight coefficients, the scoring module can more intelligently adapt to complex working conditions, improving the flexibility and adaptability to the idler operation state.

[0086] It can be seen that by introducing the back weight score and comprehensively considering factors such as the surface temperature difference and the lateral displacement distance of the conveyor belt, the multi-dimensional evaluation ability of the idler state is improved. This comprehensive design further provides a more scientific and accurate state evaluation method for the system, helping the operation and maintenance personnel to more comprehensively understand the operation status of the idler, prevent potential problems in advance, thereby reducing the maintenance cost and improving the safety and reliability of the conveyor.

[0087] In some embodiments of the present application, when the scoring module is also used to obtain the surface temperature difference during the operation of the idler, it includes: the scoring module is also used to obtain the real-time temperature on the surface of the idler during operation, and judge whether to obtain the surface temperature difference during the operation of the idler according to the relationship between the real-time temperature and the preset operating temperature, where: when the real-time temperature is lower than or equal to the preset operating temperature, the scoring module judges that the surface temperature of the idler is in a normal state and does not obtain the surface temperature difference during the operation of the idler. When the real-time temperature is higher than the preset operating temperature, the scoring module judges that the surface temperature of the idler is in an abnormal state and obtains the surface temperature difference J during the operation of the idler, and sets J = B0 - B, where B is the real-time temperature on the surface of the idler during operation and B0 is the preset operating temperature.

[0088] It can be understood that by judging whether the surface temperature exceeds the set preset value, the scoring module can timely identify and feedback the abnormal situation of the idler surface temperature, providing a timely warning of potential problems. Since the surface temperature has an important indicating effect on the idler state, this temperature monitoring design helps to prevent potential failures of the idler caused by overheating and other problems, reducing the operation risk of the mine conveyor.

[0089] It can be seen that by real-time monitoring the surface temperature and judging the temperature difference, a more detailed and sensitive means of state evaluation is provided for the scoring module. This dynamic temperature monitoring not only improves the timeliness of perceiving abnormal temperature states of the idlers, but also further provides more accurate state information for maintenance and operation personnel, which helps to formulate timely maintenance measures and improve the safety and reliability of the conveyor.

[0090] In some embodiments of the present application, when the alarm module is used to determine the risk level of the idler according to the relationship between the state score and the preset state score and send an alarm notification, it includes: The alarm module is also used to preset a first preset state score P1 and a second preset state score P2 in advance. The alarm module is also used to determine the risk level of the idler according to the relationship between the state score A of the idler during operation and each preset state score, and send an alarm notification: when A < P1, the alarm module determines that the risk level of the idler is the first level and sends an alarm notification. When P1 ≤ A < P2, the alarm module determines that the risk level of the idler is the second level and sends an alarm notification. When A ≥ P2, the alarm module determines that the risk level of the idler is the third level and sends an alarm notification. Among them, the first level < the second level < the third level.

[0091] It can be seen that the alarm module realizes the flexible classification of the risk level of the idler and the alarm notification through the relationship between the preset state score and the actual state score of the idler during operation. In this design, the alarm module preset a first preset state score P1 and a second preset state score P2 in advance, and determines the risk level of the idler by comparing with the actual state score, and sends the corresponding alarm notification accordingly. Specifically, when the state score A of the idler is less than P1, the system determines that the state of the idler is at a low risk level, determines it as the first level, and sends the corresponding alarm notification; when A is between P1 and P2, the system determines that the state of the idler is at a medium risk level, determines it as the second level, and sends the corresponding alarm notification; when A is greater than or equal to P2, the system determines that the state of the idler is at a high risk level, determines it as the third level, and sends the corresponding alarm notification. This classification mechanism provides a more flexible and intelligent alarm notification method by setting the preset state score and adjusting the risk level according to the actual situation.

[0092] It is understandable that the alarm module can dynamically adjust the danger level according to the change of the actual state, accurately reflect the health status of the idler, and improve the accuracy and timeliness of the alarm. At the same time, setting different danger levels helps the operation and maintenance personnel to more quickly and clearly understand the urgency of the idler state, so that more appropriate maintenance measures can be taken. Generally speaking, this hierarchical alarm mechanism provides a more flexible and intelligent warning means for the maintenance and operation personnel, reduces the risk of potential problems, and improves the safety and reliability of the system. At the same time, by setting the preset state score and flexibly dividing the danger level, a more accurate evaluation and alarm notification of the idler state are realized. This design provides more decision-making information for the system, enables the operation and maintenance personnel to better respond to the idler state under different danger levels, and improves the health monitoring and safety management level of the system.

[0093] In the above embodiment, the noise decibel of the conveyor idler during operation is obtained through the sound monitoring module, which can sensitively sense whether the idler has abnormal noise, so as to timely discover potential problems. Secondly, through the image acquisition module equipped with a mobile unit, according to the feedback of the sound monitoring module, the position is automatically adjusted to obtain the image information of the idler where the abnormal noise occurs, realizing the intelligent association of sound and image. The processing module can accurately judge whether each idler has abnormal noise by analyzing the relationship between the real-time noise decibels. Once abnormal noise is detected, the image acquisition module quickly moves to the source of the abnormal noise to obtain the image information of the idler, providing reliable data support for subsequent state evaluation. In addition, through the scoring module, the state score is evaluated according to the image information of the idler operation, realizing an intuitive and comprehensive quantitative evaluation of the idler operation state. Finally, the alarm module determines the danger level of the idler according to the difference between the state score and the preset state score, and sends an alarm notification in time, enabling the operation and maintenance personnel to quickly respond and take necessary maintenance measures.

[0094] In another preferred way based on the above embodiment, as Figure 2 shown, this embodiment provides a method for detecting the state of a mine conveyor idler, including:

[0095] Step S100: Obtain the noise decibel of each idler of the conveyor, and judge whether each idler has abnormal noise according to the relationship between the real-time noise decibel and the historical noise decibel of each idler of the conveyor.

[0096] Step S200: Obtain the image information of the idler with abnormal noise during operation, and evaluate the state score according to the image information of the idler operation.

[0097] Step S300: Determine the danger level of the idler according to the relationship between the state score and the preset state score, and send an alarm notification.

[0098] It is understandable that a belt conveyor idler state detection system and method in the above invention have the same beneficial effects and will not be elaborated here.

[0099] Those skilled in the art should understand that the embodiments of the present application can be provided as methods, systems, or computer program products. Therefore, the present application can adopt the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware aspects. Moreover, the present application can adopt the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk memories, CD-ROMs, optical memories, etc.) containing computer-usable program codes.

[0100] The present application is described with reference to the flowcharts and / or block diagrams of methods, devices (systems), and computer program products according to the embodiments of the present application. It should be understood that each process and / or block in the flowchart and / or block diagram can be implemented by computer program instructions, and the combination of processes and / or blocks in the flowchart and / or block diagram can also be implemented. These computer program instructions can be provided to the processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing devices to generate a machine, so that the instructions executed by the processor of the computer or other programmable data processing devices generate a device for realizing the functions specified in Figure 1 one process or multiple processes and / or blocks Figure 1 one block or multiple blocks.

[0101] These computer program instructions can also be stored in a computer-readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer-readable memory generate a manufactured article including an instruction device, and the instruction device realizes the functions specified in Figure 1 one process or multiple processes and / or blocks Figure 1 one block or multiple blocks.

[0102] These computer program instructions can also be loaded onto a computer or other programmable data processing device, so that a series of operation steps are executed on the computer or other programmable device to generate a computer-implemented process, and thus the instructions executed on the computer or other programmable device provide steps for realizing the functions specified in Figure 1 one process or multiple processes and / or blocks Figure 1 one block or multiple blocks.

[0103] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit them. Although the present invention has been described in detail with reference to the above embodiments, those of ordinary skill in the art should understand that: modifications or equivalent substitutions can still be made to the specific implementation manners of the present invention, and any modification or equivalent substitution that does not depart from the spirit and scope of the present invention should be covered within the protection scope of the claims of the present invention.

Claims

1. A mining conveyor roller status detection system, characterized in that: include: Sound monitoring module, used to obtain the noise decibels of each conveyor roller operation; An image acquisition module is provided with a moving unit, and the image acquisition module is used to acquire the running image of the conveyor roller; a processing module, electrically connected to the sound monitoring module and the mobile unit, the processing module being used to determine whether abnormal noise occurs in the operation of each roller according to the relationship between the real-time noise decibel and the historical noise decibel of each roller of the conveyor, and being used to control the mobile unit to move the image acquisition module to the roller where the abnormal noise occurs, so as to acquire image information of the operation of the roller; A scoring module, electrically connected to the image acquisition module, and configured to evaluate the status score according to the image information of the roller operation; The alarm module is electrically connected to the scoring module, and is used to determine the danger level of the roller according to the relationship between the status score and the preset status score, and send an alarm notification.

2. The mining conveyor roller status detection system according to claim 1, characterized in that: The processing module is used to determine whether abnormal noise occurs in the operation of each roller according to the relationship between the real-time noise decibel and the historical noise decibel of each roller of the conveyor, including: The processing module is also used to obtain the noise decibels of each roller during its historical operation, and determine the average noise decibel of each roller according to the noise decibels of each roller during its historical operation; wherein, The processing module is also used to remove abnormal noise decibels from the noise decibels of the historical operation of each roller, and obtain the noise decibel mean of the sum of the noise decibels of the historical operation of each roller after removing the abnormal noise decibels; The processing module is also used to determine whether abnormal noise occurs when the roller is running according to the relationship between the real-time noise decibel of the roller and the average noise decibel corresponding to the roller; If the real-time noise decibel of the roller running is consistent with the noise decibel mean value corresponding to the roller, it is judged that no abnormal noise occurs during the operation of the roller; If the real-time noise decibel of the roller operation is inconsistent with the noise decibel average corresponding to the roller, it is determined that abnormal noise occurs during the operation of the roller, and the image acquisition module is controlled to move to the roller to acquire image information of the roller operation.

3. The mining conveyor roller status detection system according to claim 1, characterized in that: The scoring module is used to evaluate the status score according to the image information of the roller operation, including: The scoring module is also used to obtain the pre-weighted score and post-weighted score of the roller operation, and obtain the state score of the roller operation according to the following formula: A=(z1*Q)+(z2*H); In the formula, A is the state score of the roller operation, Q is the front weight score of the roller operation, H is the rear weight score of the roller operation, z1 and z2 are weight coefficients of the state score, and the sum of z1 and z2 is 1.

4. The mining conveyor roller status detection system according to claim 3, characterized in that: The scoring module is also used to obtain the forward weighted time of the roller operation, including: The scoring module is also used to obtain the speed difference and vibration frequency difference of the roller operation, and obtain the forward weight score of the roller operation based on the following formula according to the speed difference and vibration frequency difference of the roller operation: Q = (k1*T) + (k2*Y); Among them, Q is the front weight of the roller operation, T is the speed difference of the roller operation, Y is the vibration frequency difference of the roller operation, k1 and k2 are weight coefficients of the front weight, and the sum of k1 and k2 is 1.

5. The mining conveyor roller status detection system according to claim 4, characterized in that: The scoring module is also used to obtain the speed difference and vibration frequency difference of the roller, including: The scoring module is also used to obtain the real-time rotation speed of the roller, and determine whether to obtain the rotation speed difference of the roller according to the relationship between the real-time rotation speed and the preset operation rotation speed, wherein: When the real-time rotation speed is consistent with the preset operating rotation speed, the scoring module determines that the rotation speed of the roller is in a normal state, and the rotation speed difference of the roller operation is not obtained at this time; When the real-time rotation speed is lower than the preset operating rotation speed, the scoring module determines that the rotation speed of the roller is in an abnormal state, and obtains the rotation speed difference T of the roller, and sets T=M0-M, where M is the real-time rotation speed of the roller, and M0 is the preset operating rotation speed.

6. The mining conveyor roller status detection system according to claim 5, characterized in that: When the scoring module is further used to obtain the rotation speed difference and vibration frequency difference of the roller, it also includes: The scoring module is also used to obtain the real-time vibration frequency of the roller operation, and determine whether to obtain the vibration frequency difference of the roller operation according to the relationship between the real-time vibration frequency and the preset operation vibration frequency, wherein; When the real-time vibration frequency is consistent with the preset operating vibration frequency, the scoring module determines that the vibration of the roller is in a normal state, and does not obtain the vibration frequency difference of the roller operation; When the real-time vibration frequency is slower than the preset operating vibration frequency, the scoring module determines that the vibration of the roller is in an abnormal state, and obtains the vibration frequency difference Y of the roller operation, and sets Y=N0-N, wherein N0 is the preset operating vibration frequency and N is the real-time vibration frequency.

7. The mining conveyor roller status detection system according to claim 3, characterized in that: The scoring module is also used to obtain the post-weighted time of the roller operation, including: The scoring module is also used to obtain the surface temperature difference of the roller when it is running and the lateral displacement distance of the conveyor belt on the surface of the roller when it is running, and obtain the post-weight score of the roller operation based on the following formula: H=(c1*J)+(c2*F); Wherein, H is the rear weight of the roller operation, J is the surface temperature difference of the roller operation, F is the lateral displacement distance of the conveyor belt on the surface when the roller is running, c1 and c2 are weight coefficients, and the sum of c1 and c2 is 1.

8. The mining conveyor roller status detection system according to claim 7, characterized in that: The scoring module is also used to obtain the surface temperature difference of the roller when it is running, including: The scoring module is also used to obtain the real-time surface temperature of the roller during operation, and determine whether to obtain the surface temperature difference of the roller during operation based on the relationship between the real-time temperature and the preset operating temperature, wherein: When the real-time temperature is lower than or equal to the preset operating temperature, the scoring module determines that the surface temperature of the roller is in a normal state, and does not obtain the surface temperature difference of the roller during operation; When the real-time temperature is higher than the preset operating temperature, the scoring module determines that the surface temperature of the roller is in an abnormal state, and obtains the surface temperature difference J when the roller is running, and sets J=B0-B, where B is the real-time surface temperature of the roller when it is running, and B0 is the preset operating temperature.

9. The mining conveyor roller status detection system according to claim 3, characterized in that: The alarm module is used to determine the danger level of the roller according to the difference between the status score and the preset status score, and send an alarm notification, including: The alarm module is also used to preset a first preset state score P1 and a second preset state score P2; The alarm module is also used to determine the danger level of the roller according to the relationship between the state score A of the roller operation and each of the preset state scores, and send an alarm notification; When A<P1, the alarm module determines that the danger level of the roller is the first level and sends an alarm notification; When P1≤A<P2, the alarm module determines that the danger level of the roller is the second level and sends an alarm notification; When A≥P2, the alarm module determines that the danger level of the roller is the third level and sends an alarm notification; Among them, in terms of the degree of danger: the first level < the second level < the third level.

10. A method for detecting the state of a roller of a mining conveyor, applicable to a system for detecting the state of a roller of a mining conveyor as claimed in any one of claims 1 to 9, characterized in that: include: Obtain the noise decibel of each roller of the conveyor, and determine whether abnormal noise occurs in the operation of each roller according to the relationship between the real-time noise decibel and the historical noise decibel of each roller of the conveyor; Acquire image information of the roller running with abnormal noise, and perform status score evaluation based on the image information of the roller running; According to the relationship between the status score and the preset status score, the danger level of the roller is determined, and an alarm notification is sent.

Images