Coal conveying belt with anti-tearing function

Abstract

The invention relates to the technical field of coal transportation, and discloses a coal conveying belt with an anti-tearing function, which consists of a distributed sensing network, a tension triggering unit, an energy storage power supply unit, a signal processing unit, a wireless communication unit and an execution control unit. The tear event is detected in real time through the distributed sensing network, accident expansion is effectively prevented and equipment damage and personnel risk are reduced by combining a hierarchical response strategy, the energy storage power supply unit is only activated when the microswitch is closed and is physically isolated in a normal state, and the energy storage power supply unit is only activated when the microswitch is closed and is physically isolated in a normal state by combining the low-self-discharge-rate battery or super capacitor design. The energy consumption is obviously reduced, the long-term standby reliability is ensured, the unique ID code of the signal processing unit is bound with the pre-stored position identifier, the tearing point can be quickly identified, the maintenance response time is shortened, the production interruption is reduced, and the false triggering rate is reduced through anti-interference mechanisms such as mechanical buffering, circuit low-pass filtering and communication return verification. And the overall operation stability is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of coal transportation equipment, in particular to a coal conveying belt with an anti-tearing function. Background Art

[0002] Belts are core equipment for coal transportation. Tearing failures can lead to material leaks, equipment damage, and even accidents. Traditional detection methods suffer from delayed response, high false alarm rates, and poor environmental adaptability.

[0003] The utility model patent with authorization number CN219970954U uses a photoelectric sensor to monitor cracks on the belt surface, but cannot distinguish between scratches and penetrating tears; it lacks adaptability under dusty working conditions and has difficulty dealing with situations where coal dust adhesion causes false photoelectric alarms; it only alarms but does not locate, requiring manual inspection of the entire belt, resulting in low work efficiency; the photoelectric sensor requires continuous active power supply, which increases production costs.

[0004] The utility model patent with grant number CN217846121U uses a multi-channel laser rangefinder to detect belt tears. However, the required mechanical structure is complex and bulky, increasing the belt load and resulting in high operating and maintenance costs. The laser rangefinder is poorly adaptable to humid and dusty environments, prone to false alarms. It lacks a self-test function and can only provide a digital alarm signal. The lack of hands-free maintenance and preventive testing makes this solution less intelligent. To address these issues, a tear prevention technology with strong real-time performance, excellent anti-interference capabilities, and maintenance-free operation is urgently needed. Summary of the Invention

[0005] The object of the present invention is to provide a coal conveyor belt with an anti-tearing function to solve the problems raised in the above background technology.

[0006] To solve the above technical problems, the present invention is achieved through the following technical solutions: The present invention is a coal conveyor belt with an anti-tearing function, which is composed of a distributed sensor network, a tension trigger unit, an energy storage power supply unit, a signal processing unit, a wireless communication unit and an execution control unit. Distributed sensing network: Multiple independent closed-loop copper wire loops are embedded in the interlayer of the coal conveyor belt. Each copper wire loop is distributed in a cross-pile pattern within the belt cross section, forming a continuous topology that crosses around the piles at the left and right turning points.

[0007] Tension trigger unit: A micro switch connected to each section of copper wire, used to detect changes in the tension of the copper wire, and is normally in the disconnected state.

[0008] Energy storage power supply unit: The energy storage battery connected to the output end of the micro switch is physically isolated from the early warning circuit under normal conditions.

[0009] Signal processing unit: A controller containing a unique ID code, with the input end connected to a micro switch and the power end connected to an energy storage battery.

[0010] Wireless communication unit: 2.4GHz wireless transmitter module built into the controller.

[0011] Execution control unit: A program-controlled system that receives wireless signals and configures hierarchical response strategies.

[0012] Furthermore, the cross-pillar-circling distribution is specifically carried out in the following steps: a. A single copper wire loop forms a closed loop path within the belt cross section.

[0013] b. The copper wire turns back and crosses at the left and right ends of the cross section through the turning piles.

[0014] c. The copper wires between adjacent sections are continuously connected through extension sections.

[0015] Furthermore, the micro switch is a normally open self-resetting switch, and its trigger threshold is set to 5-15N. It automatically resets and disconnects when the tension is lower than the threshold. When a metal foreign body tears the belt and causes the tension of the copper wire to exceed the threshold, the micro switch closes and connects the energy storage battery. The controller generates an early warning signal containing an ID and transmits it to the program control system via a wireless link, triggering a graded response.

[0016] Furthermore, the early warning circuit is normally in a high-impedance state, and there is a physical breakpoint between the energy storage battery and the controller, and a power supply path is formed only when the micro switch is closed.

[0017] Furthermore, the controller performs the following steps: a. Complete hardware self-test after power on.

[0018] b. Encode the unique ID and the pre-stored location identifier into a data packet.

[0019] c. Send warning signals via the 2.4GHz frequency band with a delay of ≤500ms.

[0020] Furthermore, the hierarchical response strategy includes a primary response, a secondary response, and a tertiary response, specifically the following steps: Level 1 response: The program control system will shut down immediately when it detects a pulsed on / off signal (on / off frequency ≥ 2Hz).

[0021] Secondary response: When an emergency stop signal lasting ≥10s is received, the system will shut down.

[0022] Level 3 response: When a short-term trigger signal lasting ≤5s is received, the speed is reduced to 30%-50% of the rated speed and the manual confirmation timer is started.

[0023] Furthermore, the pulse on-off signal is generated by the high-frequency on-off of the micro switch due to the breakage of multiple sections of copper wire, the emergency stop signal is triggered by the continuous tension of a single section of copper wire and the micro switch remaining closed, and the short-time trigger signal is generated by the instantaneous closure of the micro switch due to deformation of the belt surface.

[0024] Furthermore, an anti-interference mechanism is provided, which includes mechanical anti-interference, circuit anti-interference and communication anti-interference.

[0025] a. Mechanical anti-interference, the micro switch has a built-in coil spring buffer mechanism to filter mechanical vibrations with a frequency greater than 50Hz.

[0026] b. For circuit anti-interference, an RC low-pass filter network with a cut-off frequency ≤ 10 Hz is set at the controller signal input end.

[0027] c. Communication is anti-interference and adopts a feedback verification mechanism. When the controller does not receive the ACK signal from the program control system, it will resend with a delay of 2ⁿ increments (n=1,2,3...).

[0028] Furthermore, the energy storage battery is a lithium thionyl chloride battery with a self-discharge rate of ≤1% / year, or a supercapacitor with an equivalent capacitance value of ≥100F.

[0029] Furthermore, the position identifier is bound to the physical coordinates of the belt, and the mapping relationship between the ID code and the position identifier is pre-stored in the program control system database.

[0030] The present invention has the following beneficial effects: (1) The present invention uses a distributed sensor network to detect tearing events in real time, combined with a hierarchical response strategy (such as immediate shutdown or speed reduction), to effectively prevent accidents from escalating, reduce equipment damage and personnel risks. The energy storage power supply unit is only activated when the microswitch is closed, and is physically isolated under normal conditions. Combined with a low self-discharge rate battery or supercapacitor design, it significantly reduces energy consumption and ensures long-term backup reliability. The unique ID code of the signal processing unit is bound to the pre-stored location identifier, facilitating rapid identification of the tear point, shortening maintenance response time and reducing production interruptions. Through anti-interference mechanisms such as mechanical buffering, circuit low-pass filtering, and communication return verification, it effectively filters external interference (such as vibration or noise), reduces false triggering rate, and improves overall operational stability.

[0031] (2) The present invention arranges parallel copper wires at equal intervals in the direction of the belt cross section, and each copper wire is connected to a micro switch. Compared with long-distance coal conveyor belts, the micro switches are arranged in a distributed acquisition and centralized processing manner. The output signals of all micro switches are connected to a single controller in parallel. Any normally open micro switch can send an early warning signal after being triggered. The maintenance cost of the short-distance coal conveyor belt is low, and it is not difficult to locate the position of the belt tear. It can realize system tasks such as regular sending of status signals and timely replacement of batteries. The embedded copper wires in the short-distance coal conveyor belt are distributed in a cross-sectional manner to reduce the total length of the copper wires to achieve a low-cost coal conveyor belt.

[0032] (3) This invention proposes a coal conveyor belt status monitoring scheme. The core is to capture the mechanical vibration of the belt during operation and convert it into electrical energy through an optimized cantilever beam piezoelectric generator (piezoelectric ceramic plate and stainless steel substrate). After rectification, the energy is used to trickle charge the capacitor in the form of pulsating DC. In addition, the system adopts intelligent power management: when the capacitor voltage reaches the threshold, the controller is triggered to start, and then a rapid self-test is performed (detecting the copper wire loop impedance, micro switch contact resistance, and wireless module status). Health information such as device ID and capacitor voltage is collected and transmitted wirelessly.

[0033] Of course, any product implementing the present invention does not necessarily need to achieve all of the advantages described above at the same time. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0035] Figure 1 This is the overall architecture diagram of the present invention; Figure 2 This is a schematic block diagram of the circuit principle of the present invention; Figure 3 This is a schematic cross-sectional view of the copper wire winding pile distribution of the present invention; Figure 4 This is a schematic block diagram of the system flow of the present invention; Figure 5 This is a schematic block diagram of the program control system process of the present invention. DETAILED DESCRIPTION

[0036] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0037] Example 1 See also Figure 1-Figure 5 As shown, the present invention is a coal conveyor belt with anti-tearing function, which is composed of a distributed sensor network, a tension trigger unit, an energy storage power supply unit, a signal processing unit, a wireless communication unit and an execution control unit. Distributed sensing network: Multiple independent closed-loop copper wire loops are embedded in the interlayer of the coal conveyor belt. Each copper wire loop is distributed in a cross-pile pattern within the belt cross section, forming a continuous topology that crosses around the piles at the left and right turning points.

[0038] The cross-pile-circling distribution is specifically as follows: a. A single copper wire loop forms a closed loop path within the belt cross section.

[0039] b. The copper wire turns back and crosses at the left and right ends of the cross section through the turning piles.

[0040] c. The copper wires between adjacent sections are continuously connected through extension sections.

[0041] Tension trigger unit: A micro switch connected to each section of copper wire, used to detect changes in the tension of the copper wire, and is normally in the disconnected state.

[0042] In this embodiment, the micro switch is a normally open self-resetting switch, and its triggering threshold is set to 5-15N. When the tension is lower than the threshold, it automatically resets and disconnects. When a metal foreign body tears the belt and causes the tension of the copper wire to exceed the threshold, the micro switch closes and connects the energy storage battery. The controller generates an early warning signal containing an ID and transmits it to the program control system via a wireless link, triggering a graded response. The energy storage battery uses a lithium thionyl chloride battery with a self-discharge rate of ≤1% / year, or a supercapacitor with an equivalent capacitance value of ≥100F.

[0043] Energy storage power supply unit: The energy storage battery connected to the output end of the micro switch is physically isolated from the early warning circuit under normal conditions. The early warning circuit is normally in a high-impedance state. There is a physical breakpoint between the energy storage battery and the controller, and a power supply path is formed only when the micro switch is closed.

[0044] Signal processing unit: A controller containing a unique ID code, with the input connected to a micro switch and the power supply connected to a storage battery. The controller performs the following steps: a. Complete hardware self-test after power on.

[0045] b. Encode the unique ID and the pre-stored position identifier into a data packet, bind the position identifier to the physical coordinates of the belt, and pre-store the mapping relationship between the ID code and the position identifier in the program control system database.

[0046] c. Send warning signals via the 2.4GHz frequency band with a delay of ≤500ms.

[0047] Wireless communication unit: 2.4GHz wireless transmitter module built into the controller.

[0048] In this embodiment, the execution control unit: a program-controlled system that receives wireless signals, configures a hierarchical response strategy. In addition, the hierarchical response strategy includes a first-level response, a second-level response, and a third-level response, specifically the following steps: Level 1 response: The program control system will shut down immediately when it detects a pulsed on / off signal (on / off frequency ≥ 2Hz).

[0049] Secondary response: When an emergency stop signal lasting ≥10s is received, the system will shut down.

[0050] Level 3 response: When a short-term trigger signal lasting ≤5s is received, the speed is reduced to 30%-50% of the rated speed and the manual confirmation timer is started.

[0051] Among them, in the above scheme, the pulse on-off signal is generated by the high-frequency on-off of the micro switch due to the breakage of multiple sections of copper wire, the emergency stop signal is triggered by the continuous tension of a single section of copper wire and the micro switch remains closed, and the short-time trigger signal is generated by the instantaneous closure of the micro switch due to the deformation of the belt surface.

[0052] Anti-interference mechanism, the anti-interference mechanism includes mechanical anti-interference, circuit anti-interference and communication anti-interference.

[0053] a. Mechanical anti-interference, the micro switch has a built-in coil spring buffer mechanism to filter mechanical vibrations with a frequency greater than 50Hz.

[0054] b. For circuit anti-interference, an RC low-pass filter network with a cut-off frequency ≤ 10 Hz is set at the controller signal input end.

[0055] c. Communication is anti-interference and adopts a feedback verification mechanism. When the controller does not receive the ACK signal from the program control system, it will resend with a delay of 2ⁿ increments (n=1,2,3...).

[0056] In this solution, real-time detection of tear events through a distributed sensor network, combined with a hierarchical response strategy (such as immediate shutdown or speed reduction), effectively prevents accidents from escalating, reduces equipment damage and personnel risks. The energy storage power supply unit is activated only when the microswitch is closed. Physical isolation under normal conditions, combined with a low-self-discharge battery or supercapacitor design, significantly reduces energy consumption and ensures long-term backup reliability. The signal processing unit's unique ID code is bound to a pre-stored location identifier, facilitating rapid identification of the tear point, shortening repair response time and minimizing production interruptions. Anti-interference mechanisms such as mechanical buffering, circuit low-pass filtering, and communication return verification effectively filter out external interference (such as vibration or noise), reducing false trigger rates and improving overall operational stability.

[0057] Example 2 like Figure 1-5 As shown, based on Example 1, the present invention provides a technical solution: the distribution mode of the copper wire, controller and micro switch of the coal conveyor belt, In this embodiment, parallel copper wires are arranged at equal intervals along the cross-sectional direction of the coal conveyor belt, and each copper wire is connected to a micro switch. Compared to long-distance coal conveyor belts, the micro switches are arranged in a distributed acquisition and centralized processing manner. The output signals of all micro switches are connected in parallel to a single controller. Any normally open micro switch can send an early warning signal after being triggered. Short-distance coal conveyor belts require low maintenance costs, and locating the location of belt tears is relatively easy. System tasks such as regularly sending status signals and timely replacing batteries can be achieved. The embedded copper wires in short-distance coal conveyor belts are distributed in a transverse manner, reducing the total length of the copper wires to achieve a low-cost coal conveyor belt.

[0058] Example 3 like Figure 1-5 As shown, based on Example 1 and Example 2, the present invention provides a technical solution. This embodiment designs a polyurethane coating solution for the protection needs of copper wires under special working conditions of coal conveyor belts. The long-term operation of the coal conveyor belt includes longitudinal rotation cycles and the sinking and recovery of the transverse working surface, which causes the copper wires in the interlayer to be bent repeatedly. The friction between the coal conveyor belt and the copper wire generates static electricity or heat, which can cause safety risks. Therefore, the copper wire is laid in a polyurethane coating with good wear resistance, insulation and flexibility, or the copper wire is coated with a polyurethane material, and then the copper wire is embedded in the coal conveyor belt. This can increase the lifespan under repeated bending and friction conditions, prevent the copper wire from being corroded by sulfides and moisture in the coal powder, and thus reduce the safety risks under dust and high temperature conditions. This embodiment is suitable for harsh working conditions such as high-sulfur coal, humid environments and large-angle belts.

[0059] Among them, by coating the surface of the copper wire with a wear-resistant, insulating and flexible polyurethane coating (or directly embedding it into the polyurethane material), and then embedding it into the belt, this design aims to solve the safety risks caused by repeated bending, friction static electricity / heating of the copper wire during long-term operation of the belt, which can significantly improve the service life of the copper wire and reduce safety risks.

[0060] Example 4 like Figure 1-5 As shown, based on Examples 1, 2, and 3, the present invention provides a technical solution. This embodiment provides a coal conveyor belt status monitoring solution. Through efficient energy harvesting and intelligent power management, the system implements a periodic self-test function in a tear-free state, thereby improving the reliability of the entire coal conveyor belt. The core component of the system is a piezoelectric generator, which consists of a piezoelectric ceramic plate and a stainless steel substrate, secured to the belt support via an optimized cantilever beam structure. When the coal conveyor belt is in operation, the mechanical vibration generated drives the piezoelectric plate to deform and generate electricity, which, after passing through a bridge rectifier circuit, outputs pulsating direct current. The collected energy is stored in a capacitor, trickle-charging the capacitor. When the voltage reaches the controller startup voltage threshold, the controller is triggered to start once. After startup, a quick self-test process is first performed: detecting the copper wire loop impedance, measuring the microswitch contact resistance, and verifying the wireless module status. After initialization, the controller performs status detection and information transmission. After status information transmission is completed or the capacitor is discharged, a GPIO pin sends a control signal to the MOSFET, actively shutting down the power supply, thus achieving the task of transmitting status signals in the tear-free state. The signal includes the device ID and the capacitor voltage reflecting the health status. If the program control system fails to receive status information from a single controller three times, it will determine that the node is faulty, shut down the system, and prompt the staff to check.

[0061] Building on the previous implementation, a coal conveyor belt condition monitoring solution was proposed. Its core feature is an optimized cantilever-beam piezoelectric generator (piezoelectric ceramics and a stainless steel substrate) that captures the belt's mechanical vibrations during operation and converts them into electrical energy. This energy is rectified and used as pulsating DC to trickle charge the capacitor. Furthermore, the system employs intelligent power management: when the capacitor voltage reaches a threshold, the controller is triggered to start. It then performs a rapid self-test (checking the copper wire loop impedance, microswitch contact resistance, and wireless module status), and collects and wirelessly transmits health information such as the device ID and capacitor voltage.

[0062] In addition, after the status is reported or the capacitor is discharged, the controller actively cuts off the power supply and completes the scheduled self-inspection task under non-tearing conditions. If the upper-level program control system does not receive the status information of a node for three consecutive times, it will determine that the node is faulty and trigger a shutdown inspection alarm, thereby significantly improving the operating reliability of the coal conveyor belt system.

[0063] The preferred embodiments of the present invention disclosed above are intended only to help illustrate the present invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the present invention to the specific embodiments described. Obviously, many modifications and variations are possible based on the content of this specification. These embodiments are selected and described in detail in this specification to better explain the principles and practical applications of the present invention, thereby enabling those skilled in the art to better understand and utilize the present invention. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. A coal conveyor belt with anti-tear function, which is composed of a distributed sensor network, a tension trigger unit, an energy storage power supply unit, a signal processing unit, a wireless communication unit and an execution control unit, characterized in that: Distributed sensor network: Multiple independent closed-loop copper wire loops are embedded in the interlayer of the coal conveyor belt. Each copper wire loop adopts a cross-stakes distribution within the belt cross section, forming a continuous topology of cross-stakes at the left and right turning points. Tension trigger unit: A micro switch connected to each section of copper wire, used to detect changes in the tension of the copper wire, and is normally in the disconnected state; Energy storage power supply unit: The energy storage battery connected to the output end of the micro switch is physically isolated from the warning circuit under normal conditions; Signal processing unit: A controller containing a unique ID code, with the input end connected to a micro switch and the power end connected to an energy storage battery; Wireless communication unit: 2.4GHz wireless transmitter module built into the controller; Execution control unit: A program-controlled system that receives wireless signals and configures hierarchical response strategies.

2. The coal conveyor belt with tear-resistant function according to claim 1, characterized in that: The cross-pile-circling distribution is specifically the following steps: a. A single copper wire loop forms a closed loop path within the belt cross section; b. The copper wire turns back and crosses at the left and right ends of the cross section through the turning piles; c. The copper wires between adjacent sections are continuously connected through extension sections.

3. The coal conveyor belt with tear-resistant function according to claim 1, characterized in that: The micro switch is a normally open self-resetting switch with a trigger threshold set at 5-15N. It automatically resets and disconnects when the tension is lower than the threshold. When a metal foreign object tears the belt and causes the tension of the copper wire to exceed the threshold, the micro switch closes and connects the energy storage battery. The controller generates an early warning signal containing an ID and transmits it to the program control system via a wireless link, triggering a graded response.

4. The coal conveyor belt with tear-resistant function according to claim 1, characterized in that: The early warning circuit is normally in a high-impedance state, and there is a physical breakpoint between the energy storage battery and the controller. A power supply path is formed only when the micro switch is closed.

5. The coal conveyor belt with tear-resistant function according to claim 1, characterized in that: The controller performs the following steps: a. Complete hardware self-test after power on; b. Encode the unique ID and pre-stored location identifier into a data packet; c. Send warning signals via the 2.4GHz frequency band with a delay of ≤500ms.

6. The coal conveyor belt with tear-resistant function according to claim 1, characterized in that: The hierarchical response strategy includes a primary response, a secondary response, and a tertiary response, specifically the following steps: Level 1 response: When the program control system detects a pulsed on / off signal (on / off frequency ≥ 2Hz), it will shut down immediately; Secondary response: upon receiving an emergency stop signal lasting ≥10s, the system will be shut down; Level 3 response: When a short-term trigger signal lasting ≤5s is received, the speed is reduced to 30%-50% of the rated speed and the manual confirmation timer is started.

7. The coal conveyor belt with tear-resistant function according to claim 6, characterized in that: The pulse on-off signal is generated by the high-frequency on-off of the micro switch caused by the breakage of multiple copper wires. The emergency stop signal is triggered by the continuous tension of a single copper wire and the micro switch remaining closed. The short-time trigger signal is generated by the instantaneous closure of the micro switch caused by the deformation of the belt surface.

8. The coal conveyor belt with tear-resistant function according to claim 1, characterized in that: An anti-interference mechanism is also provided, which includes mechanical anti-interference, circuit anti-interference and communication anti-interference; a. Mechanical anti-interference, the micro switch has a built-in coil spring buffer mechanism to filter mechanical vibrations with a frequency greater than 50Hz; b. For circuit anti-interference, the controller signal input terminal is equipped with an RC low-pass filter network with a cut-off frequency of ≤10Hz; c. Communication is anti-interference and adopts a feedback verification mechanism. When the controller does not receive the ACK signal from the program control system, it will resend with a delay of 2ⁿ increments (n=1,2,3...).

9. The coal conveyor belt with tear-resistant function according to claim 1, characterized in that: The energy storage battery is a lithium thionyl chloride battery with a self-discharge rate of ≤1% / year, or a supercapacitor with an equivalent capacitance value of ≥100F.

10. The coal conveyor belt with tear-resistant function according to claim 5, characterized in that: The position identifier is bound to the physical coordinates of the belt, and the mapping relationship between the ID code and the position identifier is pre-stored in the program control system database.

Images