Anti-tearing method and system for conveying belt of belt conveyor and electronic equipment

Abstract

The invention provides an anti-tearing method and system for a conveying belt of a belt conveyor and electronic equipment, and belongs to the technical field of conveying belts. The method comprises the steps that a real-time induction signal generated when an induction coil embedded in the conveying belt is excited by an excitation magnetic field is obtained; performing digital sampling on the real-time sensing signal after signal conditioning to obtain a real-time digital signal; judging whether the real-time digital signal meets an alarm condition or not; and when the real-time digital signal meets an alarm condition, a tear alarm and / or a protection action are / is triggered. According to the scheme, the anti-tearing effect of the conveying belt can be improved.

Description

Technical Field

[0001] The present application relates to the technical field of conveyor belts, and in particular to a method, system and electronic equipment for preventing the conveyor belt of a belt conveyor from tearing. Background Art

[0002] Belt conveyors are the arteries of coal production, washing, and processing, and their operation directly impacts the safety and efficiency of coal transportation. During coal transportation, belt conveyors often encounter a mix of materials and debris, which can scratch or pierce the conveyor belt, causing it to tear, spill material, and disrupt transportation.

[0003] At present, in the prior art, a manual inspection mode is adopted to monitor the operation of the conveyor belt, or a longitudinal tear alarm is performed using a detection method to prevent the conveyor belt from tearing. However, the effect of the conveyor belt tear prevention method in the prior art is relatively poor.

[0004] Therefore, how to improve the anti-tear effect of the conveyor belt becomes a problem that needs to be solved. Summary of the Invention

[0005] The purpose of this application is to provide a method for preventing the conveyor belt from tearing, which can solve the problem that the conveyor belt anti-tearing method in the prior art has a poor effect.

[0006] In a first aspect, an embodiment of the present application provides a method for preventing a conveyor belt from tearing, the method comprising: Acquire the real-time induction signal generated by the induction coil embedded in the conveyor belt when it is excited by the excitation magnetic field; Digitally sampling the real-time sensing signal after signal conditioning to obtain a real-time digital signal; Determine whether the real-time digital signal meets the alarm conditions; When the real-time digitized signal meets the alarm condition, the tearing alarm and / or protection action is triggered.

[0007] In a possible implementation of the first aspect, the signal conditioning includes: amplifying the real-time sensing signal, and filtering out environmental electromagnetic noise and power frequency interference outside the operating frequency band.

[0008] In a possible implementation of the first aspect, the alarm conditions include: the signal strength of the real-time digitized signal is less than the alarm threshold, the drop rate of the signal strength of the real-time digitized signal is greater than a preset threshold, and the duration of the drop in the signal strength of the real-time digitized signal exceeds a preset time window.

[0009] In a possible implementation of the first aspect, the method further includes: dynamically determining an alarm threshold value based on a signal strength baseline value of the real-time digitized signal, historical data, and a preset safety margin.

[0010] In a possible implementation of the first aspect, the method further includes: The real-time sensing signals of adjacent monitoring points are analyzed for correlation to locate the location where the tear occurs. The monitoring point is the location where the RF receiving probe is installed. When the conveyor belt is torn, the induction coil breaks, the induced current disappears, the real-time sensing signal becomes invalid, and the signal strength of the real-time sensing signal continues to drop sharply.

[0011] In a possible implementation manner of the first aspect, the method further includes: storing fault analysis and system status monitoring data before and after the fault occurs, and uploading the fault analysis and system status monitoring data to a host computer.

[0012] In a second aspect, an embodiment of the present application provides a belt conveyor belt tear prevention system, the system comprising: A magnetic field generating module, used for generating an excitation magnetic field of specific frequency and intensity; A signal receiving module is used to receive a real-time induction signal generated by an induction coil embedded in the conveyor belt when it is excited by an excitation magnetic field; The analog-to-digital conversion module is used to digitally sample the real-time sensing signal after signal conditioning to obtain a real-time digital signal; The control module is used to determine whether the real-time digitized signal meets the alarm condition, and trigger the tearing alarm and / or protection action when the real-time digitized signal meets the alarm condition.

[0013] In a possible implementation manner of the second aspect, the system further includes: a signal conditioning module, configured to amplify the real-time sensing signal and filter out environmental electromagnetic noise and power frequency interference outside the operating frequency band.

[0014] In a possible implementation of the second aspect, the control module is further configured to generate an alarm message and send a safety stop instruction to the drive motor of the belt conveyor. The drive motor stops driving according to the safety stop instruction, and the belt conveyor stops running.

[0015] In a possible implementation of the second aspect, the system further includes: a host computer and an alarm module; The host computer is used to display the location where the tearing occurs and the time when the alarm is triggered according to the alarm information, and to trigger the alarm module; the alarm module is used to issue a tearing alarm.

[0016] In a possible implementation of the second aspect, the magnetic field generating module is a radio frequency transmitting probe, the signal receiving module is a radio frequency receiving probe, the analog-to-digital conversion module is an analog-to-digital converter, and the control module is a programmable logic controller.

[0017] In a third aspect, an embodiment of the present application provides an electronic device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, the belt conveyor belt anti-tearing method of any one of the above-mentioned first aspects is implemented.

[0018] In a fourth aspect, an embodiment of the present application provides a computer-readable storage medium, which stores a computer program. When the computer program is executed by a processor, it implements the belt conveyor belt tear prevention method of any one of the above-mentioned first aspects.

[0019] In a fifth aspect, an embodiment of the present application provides a computer program product. When the computer program product is run on an electronic device, the electronic device executes the belt conveyor belt anti-tearing method of any one of the above-mentioned first aspects.

[0020] The present application solution first obtains the real-time induction signal generated by the induction coil embedded in the conveyor belt when it is excited by the excitation magnetic field, then converts the real-time induction signal after signal conditioning into a real-time digital signal, and finally determines whether the real-time digital signal meets the alarm condition. When the real-time digital signal meets the alarm condition, the tearing alarm and / or protection action is triggered to prevent large-scale longitudinal tearing of the conveyor belt.

[0021] The present application utilizes the real-time induction signal generated by the induction coil when stimulated by the excitation magnetic field to prevent the conveyor belt from tearing. There is no need for manual inspection or detection through exposure detection to see if the conveyor belt is torn. The possibility of missed detection is small, the detection accuracy is high, and the anti-tear effect of the conveyor belt can be improved. It has strong ease of use and practicality.

[0022] Other features and advantages of the present application will be described in detail in the subsequent detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following briefly introduces the drawings required for use in the embodiments or descriptions of the prior art. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0024] Figure 1 Schematic diagram of an application scenario of the belt conveyor belt tear prevention method provided in an embodiment of the present application; Figure 2 1 is a schematic diagram of the steps of a method for preventing a conveyor belt from tearing provided in an embodiment of the present application; Figure 3 1 is a schematic structural diagram of a belt conveyor belt tear prevention system provided in an embodiment of the present application; Figure 4 1 is a schematic structural diagram of a belt conveyor belt tear prevention system provided in an embodiment of the present application; Figure 5 It is a structural diagram of an electronic device provided in an embodiment of the present application. DETAILED DESCRIPTION

[0025] In the following description, specific details such as specific system structures and technologies are provided for illustration rather than limitation to facilitate a thorough understanding of the embodiments of the present application. However, it should be clear to those skilled in the art that the present application may be implemented in other embodiments without these specific details. In other cases, detailed descriptions of well-known systems, devices, circuits, and methods are omitted to avoid obstructing the description of the present application with unnecessary details.

[0026] It will be understood that when used in this specification and the appended claims, the term "comprising" indicates the presence of described features, integers, steps, operations, elements and / or photovoltaic components, but does not preclude the presence or addition of one or more other features, integers, steps, operations, elements, photovoltaic components and / or groups thereof.

[0027] It should also be understood that the terms used in this specification are for the purpose of describing specific embodiments only and are not intended to limit the present application. As used in this specification and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly indicates otherwise.

[0028] It should be further understood that the term "and / or" used in this specification and the appended claims refers to and includes any and all possible combinations of one or more of the associated listed items.

[0029] As used in this specification and the appended claims, the term "if" can be interpreted as "when" or "upon" or "in response to determining" or "in response to detecting," depending on the context. Similarly, the phrase "if it is determined" or "if [described condition or event] is detected" can be interpreted as meaning "upon determination" or "in response to determining" or "upon detection of [described condition or event]" or "in response to detecting [described condition or event]," depending on the context.

[0030] In addition, in the description of the present application, the terms "first", "second", "third", etc. are only used to distinguish the description and cannot be understood as indicating or implying relative importance.

[0031] References to "one embodiment" or "some embodiments" in this specification mean that a particular feature, structure, or characteristic described in conjunction with that embodiment is included in one or more embodiments of the present invention. Thus, phrases such as "in one embodiment," "in some embodiments," "in some other embodiments," and "in some other embodiments" appearing in various places in this specification do not necessarily refer to the same embodiment, but rather mean "one or more but not all embodiments," unless otherwise specifically emphasized. The terms "including," "comprising," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.

[0032] Belt conveyors are the arteries of coal production, washing, and processing, and their operation directly impacts the safety and efficiency of coal transportation. During coal transportation, belt conveyors often encounter a mix of materials and debris. These debris can scratch or pierce the conveyor belt, causing it to tear, spill material, and disrupt transportation, posing a significant risk to material transport.

[0033] Due to the long conveying distances, high drive power, and high operating speeds of most conveyor belts, if longitudinal tears occur and are not detected and shut down in time, they will tear the entire conveyor belt, causing coal to scatter and congestion in the feeding production line, resulting in significant labor and material costs, affecting normal production, and causing significant direct and indirect losses. This is especially true for high-speed, long-distance, and high-angle steel cord conveyor belts, which can cause even greater losses and can sometimes even cause serious safety accidents.

[0034] Conveyor belt tears are very hidden. At present, the existing technology adopts manual inspection mode to monitor the operation of the conveyor belt, or adopts the exposure method to alarm the longitudinal tear to prevent the conveyor belt from tearing. The core idea is to judge the tear by detecting whether there is material protruding from the belt crack or material leakage at the tear point of the conveyor belt.

[0035] In the prior art, a belt conveyor belt tear prevention device is mainly used to monitor the belt status in real time and prevent the expansion of tears. The core structure includes: Sensor modules: installed on both sides of the belt, used to detect the tension, vibration and surface condition of the belt. Emergency braking device: When the sensor detects an abnormality (such as a sudden change in local tension or signs of tearing), the braking system is immediately activated to stop the conveyor operation. Control system: Using a PLC (programmable logic controller) or embedded system to process sensor data in real time and control the braking device. Advantages: Strong real-time performance and the ability to quickly respond to the risk of belt tearing. Simple structure, easy to install and maintain. Suitable for high-load, long-distance belt conveyors.

[0036] A sensor network-based belt tear warning system is currently in use, designed to detect and warn of belt tear risks in advance. Core components include: a sensor module, including tension sensors, vibration sensors, and temperature sensors, located at key locations along the belt. A data acquisition module collects sensor data in real time and transmits it to a control center. An early warning algorithm analyzes the changing trends of sensor data to predict belt tear risks and issue a warning signal. Advantages: Provides early warning and reduces the risk of sudden tearing. Can be integrated with other monitoring systems for intelligent management. Suitable for long-distance, high-load belt conveyors.

[0037] At present, there are many forms and types of belt longitudinal tear monitoring devices developed at home and abroad, mainly including three types: contact method, embedding method and exposure method.

[0038] (1) Contact method: This method typically does not modify the belt, but instead uses contact between the sensing device and the belt to detect the belt's condition. In practical applications, rollers are a common sensing device. In one method, rollers directly contact the belt to detect physical parameters such as speed, tension, and pressure. When a longitudinal tear occurs, the belt's tension (transverse or longitudinal), pressure, speed, or other physical parameters will differ from those during normal operation, indirectly indicating a longitudinal tear. However, this method suffers from limited reliability.

[0039] The other method uses rollers as the transmitter and receiver of detection signals. Devices mounted on the rollers generate and receive electrical, magnetic, optical, and acoustic signals, and analyze these signals to determine whether longitudinal belt tears have occurred. Because rollers are in constant contact with the belt during operation, they are subject to significant wear. Furthermore, the presence of large amounts of coal slime and dust on site, combined with the poor production environment, can easily lead to damage to the rollers, which act as the sensing device, and cause them to malfunction.

[0040] (2) Exposure method: The core idea behind the longitudinal tear detection method is that after a longitudinal tear occurs, material will protrude from the belt crack or leak out of the belt. This led to the development of rod-type detectors, string-type devices, and material leakage detectors.

[0041] A rod-type detector is a rod or tube bent into a trough roller shape, installed between the buffer rollers beneath the trough conveyor belt. If material punctures the conveyor belt, spilling it, the material will deflect the trough rod, forcing the limit switch or load cell to operate, causing the belt conveyor to stop.

[0042] Similar to rod detectors, string-type devices use a nylon string as a probe. It's placed between the buffer rollers, passing through a small hole and contacting the underside of the troughed belt. A spring-loaded limit switch is attached to one end of the string. When material piercing the conveyor belt catches the string, breaking the string or increasing its tension activates the limit switch.

[0043] The leakage detector consists of a tray, a fulcrum, a counterweight, and a switch. When the conveyor belt is torn longitudinally, the material on the conveyor belt leaks into the tray through the tear. The weight of the material overcomes the weight of the counterweight, causing the entire device to rotate around the fulcrum, forcing the limit switch to operate.

[0044] Since the detection method is based on the principle that a longitudinal tear in the belt causes the tear to widen, thus causing material to leak out or leak, once the belt is torn, if the belt is not torn or the tear is not wide enough, no material will leak out of the belt crack and this method will not work. When the conveyor belt is torn longitudinally, this device will only work if there is material on the conveyor belt and the tear is wide enough to allow the material to leak out. Otherwise, it will not work.

[0045] (3) Embedding method: This method usually involves pre-embedding metal wires, coils, magnetic materials, or some conductive or magnetic materials in the belt or on the belt surface. The detection equipment determines whether the belt has longitudinal tears by monitoring the integrity of the pre-embedded materials in the belt.

[0046] A typical application is the metal coil detector. Its construction involves placing a set of metal coils transversely within the belt core every 20-50 meters on the bottom layer of the conveyor belt. Electromagnetic wave transmitters and receivers are installed on either side of the belt, close to the belt. The transmitters emit electromagnetic waves toward the belt. As the coils pass through the belt, they induce currents, which are then intercepted by the receiving sensors on the other side. If the conveyor belt tears longitudinally, the coils are severed, and the receiving sensors lose their signal, indicating a longitudinal tear.

[0047] The embedded detection device also has limitations in practical applications: (1) It cannot be applied to the detection of a large number of belts that have been installed and in operation; (2) Since the detection material is embedded in the belt, it places higher requirements on the maintenance of the belt user; (3) Due to the long-term continuous movement of the belt, continuous rolling stress will inevitably be generated, causing the metal wires, coils or other embedded materials to wear and break, thereby causing misjudgment of the detection.

[0048] However, existing methods for preventing conveyor belts from tearing are not very effective, with drawbacks such as low detection accuracy and slow response speed, and are unable to meet the needs of modern industrial production. Therefore, how to improve the effectiveness of preventing conveyor belts from tearing has become an unresolved issue.

[0049] In response to the above-mentioned defects, an embodiment of the present application provides a method for preventing conveyor belts from tearing. First, a real-time induction signal generated by an induction coil embedded in the conveyor belt when excited by an excitation magnetic field is obtained. Then, the real-time induction signal after signal conditioning is converted into a real-time digital signal. Finally, it is determined whether the real-time digital signal meets the alarm condition. When the real-time digital signal meets the alarm condition, a tearing alarm and / or protection action is triggered to prevent large-scale longitudinal tearing of the conveyor belt.

[0050] The present application utilizes the real-time induction signal generated by the induction coil when stimulated by the excitation magnetic field to prevent the conveyor belt from tearing. There is no need for manual inspection or detection through exposure detection to see if the conveyor belt is torn. The possibility of missed detection is small, the detection accuracy is high, and the anti-tear effect of the conveyor belt can be improved. It has strong ease of use and practicality.

[0051] The specific process implemented in this application is introduced below through specific embodiments.

[0052] See Figure 1 , Figure 1 It is a schematic diagram of an application scenario of the belt conveyor belt tear prevention method provided in an embodiment of the present application.

[0053] In one embodiment, Figure 1 As shown, a belt conveyor is connected to a conveyor belt (rubber belt / belt). A feeding port is located near the conveyor belt end, where coal and other materials can be added. The conveyor belt then transports the coal. Specially designed induction coils (sensor coils) are pre-embedded within the conveyor belt at evenly spaced intervals (eight coils per group), forming a monitoring network that runs the length of the conveyor belt.

[0054] Install signal detectors (including paired RF transmitting probes and RF receiving probes) at key locations along the belt conveyor (such as loading points, tension change points and other tear-prone areas). The probes are precisely aligned and maintain a non-contact gap with the conveyor belt.

[0055] The signal transmitter is connected to a front-end signal conditioning circuit (including amplifiers, bandpass filters and other devices, not shown in the figure), and the control element is connected to the front-end signal conditioning circuit and the drive motor of the belt conveyor. The control element can be a PLC (Programmable Logic Controller).

[0056] In one embodiment, an RF transmitter probe continuously generates an excitation magnetic field (an alternating magnetic field, a spatial electromagnetic field) of a specific frequency and intensity. When an induction coil, along with the conveyor belt, passes beneath the RF transmitter probe, it is stimulated by the excitation magnetic field to generate an induced current (eddy current). This induced current generates a real-time sensing signal, thus becoming a signal source itself. The real-time sensing signal is coupled to an RF receiver probe in close proximity to the RF transmitter probe via the excitation magnetic field. The RF receiver probe uses the strength of the captured real-time sensing signal (typically expressed as voltage or current amplitude) as a core monitoring parameter.

[0057] In order to overcome the disadvantage of the metal coil being easily broken due to wear in the embedding method, the United Conveyor Belt Manufacturer uses a special coil rubber formula to ensure the best adhesion of the coil and vulcanizes it inside the belt to protect the wire from fatigue damage. The smaller size ensures that the coil will not be damaged by the cleaning equipment of the conveying system during use, and will not damage the surface cover rubber, thereby extending the service life.

[0058] The following describes the specific process of implementing the belt conveyor belt tear prevention method provided in the embodiment of the present application based on the above application scenario.

[0059] See Figure 2 , Figure 2 Schematic diagram of the steps of the belt conveyor belt tearing prevention method provided in the embodiment of the present application. Figure 2 As shown, the method includes the following steps: S201 , obtaining a real-time induction signal generated by an induction coil embedded in a conveyor belt when excited by an excitation magnetic field.

[0060] It should be noted that the specific implementation principle of this embodiment has been described in the above application scenario and will not be repeated here.

[0061] S202 , digitally sampling the real-time sensing signal after signal conditioning to obtain a real-time digitized signal.

[0062] In one embodiment, the real-time sensing signal is an analog signal, which can be converted into a real-time digital signal (sampled data) through digital sampling.

[0063] According to one embodiment of the present application, signal conditioning includes: amplifying the real-time sensing signal and filtering out environmental electromagnetic noise and power frequency interference outside the operating frequency band.

[0064] S203: Determine whether the real-time digitized signal meets the alarm condition.

[0065] According to one embodiment of the present application, the alarm conditions include: the signal strength of the real-time digitized signal is less than the alarm threshold, the drop rate of the signal strength of the real-time digitized signal is greater than a preset threshold, and the duration of the drop in the signal strength of the real-time digitized signal exceeds a preset time window.

[0066] According to one embodiment of the present application, the method further includes: dynamically determining an alarm threshold value based on a signal strength baseline value of the real-time digitized signal, historical data, and a preset safety margin.

[0067] In one embodiment, during the startup or initial normal operation of a belt conveyor, the system automatically learns and records the baseline signal strength of the real-time digitized signal converted from the real-time sensing signal at each monitoring point (corresponding to the RF receiving probe). The alarm threshold is a dynamic, adaptively set value, rather than a fixed value, to account for natural signal drift caused by issues such as conveyor belt aging and slight deformation.

[0068] In one embodiment, the signal strength of the real-time digitized signal is continuously analyzed. When a conveyor belt becomes stuck and forcibly torn by a foreign object, the metal loop of the induction coil (the induction loop) is severed. This rupture of the induction coil causes the induced current to disappear, rendering the secondary signal source ineffective. Consequently, the signal strength of the real-time induction signal and its corresponding real-time digitized signal will experience a continuous and significant drop (sudden drop).

[0069] In one embodiment, the signal strength of the real-time digitized signal is compared to an alarm threshold, and the rate of signal strength drop (the amount of drop per unit time) is monitored. A foreign object momentarily cutting the induction coil typically causes a rapid drop in signal strength, which helps distinguish it from slow drift or transient interference. The signal strength drop must persist for more than a very short, configurable time window (e.g., 10-50ms) to filter out transient electromagnetic interference.

[0070] S204: When the real-time digital signal meets the alarm condition, a tearing alarm and / or a protection action is triggered.

[0071] In one embodiment, when the signal strength is determined to be less than the alarm threshold, the drop rate is greater than a preset threshold, and the duration meets the requirements, a high-priority tear alarm is immediately triggered and an alarm message is generated. Based on this alarm message, the host computer clearly displays the tear location and the time the alarm was triggered through the monitoring system (centralized control system), and triggers an audible and visual alarm, which issues a tear alarm.

[0072] In one embodiment, when the alarm information is generated, a protection action is triggered, that is, a safety stop instruction is sent to the drive motor of the belt conveyor. The drive motor stops driving the belt conveyor according to the safety stop instruction, forcing the belt conveyor to stop running.

[0073] It should be noted that when the real-time digital signal meets the alarm conditions, the tearing alarm and protection action can be triggered at the same time; it is also possible to trigger only the tearing alarm and manually stop the belt conveyor; it is also possible to trigger only the protection action and automatically stop the belt conveyor.

[0074] According to one embodiment of the present application, the method further includes: performing correlation analysis on the real-time sensing signals of adjacent monitoring points to locate the location where the tear occurs; wherein the monitoring point is the location where the radio frequency receiving probe is installed; when the conveyor belt is torn, the induction coil breaks, the induced current disappears, the real-time sensing signal fails, and the signal strength of the real-time sensing signal undergoes a continuous and sudden drop.

[0075] In one embodiment, a multi-point monitoring system uses real-time sensing signals from adjacent monitoring points to correlate with the physical location where a tear might occur (e.g., downstream of a loading point). If all adjacent monitoring points at a given location detect a tear, the location is considered highly likely to have experienced a tear, thereby improving positioning accuracy.

[0076] According to an embodiment of the present application, the method further includes: storing fault analysis and system status monitoring data before and after the fault occurs, and uploading the fault analysis and system status monitoring data to a host computer.

[0077] In one embodiment, key signal data (e.g., real-time digitized signals), timestamps, alarm status, and other fault analysis and system status monitoring data before and after a fault occurs are stored and uploaded to a host computer via an industrial network for post-fault analysis and system status monitoring.

[0078] See Figure 3 , Figure 3 Schematic diagram of the structure of the belt conveyor belt anti-tear system provided in the embodiment of the present application. Figure 3 As shown, the system includes: a magnetic field generating module, a signal receiving module, an analog-to-digital conversion module and a control module.

[0079] The magnetic field generation module is used to generate an excitation magnetic field of a specific frequency and intensity. The signal receiving module is used to receive the real-time induction signal generated by the induction coil embedded in the conveyor belt when stimulated by the excitation magnetic field. The analog-to-digital conversion module is used to digitally sample the real-time induction signal after signal conditioning to obtain a real-time digitized signal. The control module is used to determine whether the real-time digitized signal meets the alarm conditions. If the real-time digitized signal meets the alarm conditions, it triggers the tear alarm and / or protective action.

[0080] See Figure 4 , Figure 4 Schematic diagram of the structure of the belt conveyor belt anti-tear system provided in the embodiment of the present application. Figure 4 As shown, the system also includes a signal conditioning module. The signal conditioning module is used to amplify the real-time sensing signal and filter out the environmental electromagnetic noise and power frequency interference outside the working frequency band.

[0081] In one embodiment, the signal conditioning module is a pre-signal conditioning circuit including an amplifier, a bandpass filter, etc. The amplifier is used to amplify the real-time sensing signal, and the bandpass filter is used to filter out environmental electromagnetic noise and power frequency interference outside the working frequency band.

[0082] According to one embodiment of the present application, the control module is also used to generate an alarm message and send a safety stop instruction to the drive motor of the belt conveyor. The drive motor stops driving according to the safety stop instruction, and the belt conveyor stops running.

[0083] Please continue to see Figure 4 According to one embodiment of the present application, the system further includes: a host computer and an alarm module. The host computer is configured to display the location of the tearing and the time when the alarm is triggered based on the alarm information, and to trigger the alarm module; the alarm module is configured to generate a tearing alarm.

[0084] In one embodiment, the alarm module is an audible and visual alarm.

[0085] According to one embodiment of the present application, the magnetic field generating module is a radio frequency transmitting probe, the signal receiving module is a radio frequency receiving probe, the analog-to-digital conversion module is a high-precision analog-to-digital converter (ADC), and the control module is a programmable logic controller.

[0086] In one embodiment, a shielding shell may be provided on the RF transmitting probe and the RF receiving probe to effectively suppress interference from the complex electromagnetic environment of the industrial site.

[0087] The embodiment of the present application provides a method for preventing the conveyor belt of a belt conveyor from tearing. First, a real-time induction signal is obtained when an induction coil embedded in the conveyor belt is excited by an excitation magnetic field. Then, the real-time induction signal after signal conditioning is converted into a real-time digital signal. Finally, it is determined whether the real-time digital signal meets the alarm condition. When the real-time digital signal meets the alarm condition, a tearing alarm and / or protection action is triggered to prevent large-scale longitudinal tearing of the conveyor belt.

[0088] The present application utilizes the real-time induction signal generated by the induction coil when stimulated by the excitation magnetic field to prevent the conveyor belt from tearing. There is no need for manual inspection or detection through exposure detection to see if the conveyor belt is torn. The possibility of missed detection is small, the detection accuracy is high, and the anti-tear effect of the conveyor belt can be improved. It has strong ease of use and practicality.

[0089] The technology based on pre-embedded anti-tearing coils proposed in this application can timely detect and prevent tearing accidents by real-time monitoring of the conveyor belt status, thereby ensuring the safe operation of the belt conveyor.

[0090] This application scheme has the following advantages: (1) Direct detection and rapid response: Based on the direct detection mechanism of physical coil breakage, the detection of tearing means that damage has occurred, and the alarm and shutdown actions are extremely fast; (2) Strong anti-interference ability: Through dedicated signal conditioning circuits, optimized probe design (such as shielded housing), and multiple means such as filtering, rate of change (drop rate) detection, and duration verification in the core algorithm, it effectively suppresses interference from the complex electromagnetic environment of industrial sites and significantly reduces the false alarm rate; (3) High adaptability and reliability: The dynamic threshold setting mechanism enables the system to adapt to changes in the conveyor belt's operating status and maintain the accuracy of long-term monitoring. Redundant design (such as dual probe arrangement in key areas and ring coil loop design) can further improve system reliability. (4) Positioning capability: By deploying multiple sets of probes in different sections of the conveyor belt and accurately calibrating their positions, the system can preliminarily locate the approximate section where the tear occurred, providing guidance for rapid maintenance; (5) Intelligence and maintainability: The host computer monitoring system provides intuitive system status monitoring, parameter configuration (such as thresholds, time windows), alarm history query and other functions.

[0091] This application solution utilizes a pre-embedded coil-electromagnetic coupling detection mechanism, combined with high-performance signal conditioning circuitry, a high-speed ADC, an intelligent PLC, and a core algorithm encompassing multiple criteria, including dynamic thresholds, rate-of-change detection, and duration verification. This system has developed a highly reliable, interference-resistant, and fast-response conveyor belt longitudinal tear active protection system. This system accurately detects and triggers an emergency shutdown at the instant a tear occurs, minimizing material loss, equipment damage, and safety risks associated with longitudinal tears.

[0092] This application scheme uses advanced and mature anti-tear technology to ensure that the system will automatically alarm when the coil is damaged at any position during use, and can accurately locate the damaged part of the conveyor belt; it can prevent the potential risk of longitudinal tearing of the conveyor belt from expanding and minimize the loss.

[0093] This application scheme jointly uses a special coil rubber production formula with the manufacturer to ensure the best adhesion of the coil, and the smaller external dimensions ensure that the coil will not be damaged by the cleaning equipment of the conveying system during use, and at the same time will not cause damage to the surface cover rubber, thereby ensuring the longest service life; reducing the possibility of large-scale longitudinal tearing; and avoiding potential secondary chain accidents caused by longitudinal tearing.

[0094] It should be understood that the size of the serial numbers of the steps in the above embodiments does not mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0095] Figure 5 Schematic diagram of the structure of the electronic device 5 provided in the embodiment of the present application. Figure 5 As shown, the electronic device 5 of this embodiment includes: at least one processor 501 ( Figure 5 Only one is shown in the figure), a memory 503 and a computer program 502 stored in the memory 503 and executable on at least one processor 501, wherein the processor 501 implements the steps in the above method embodiment when executing the computer program 502.

[0096] The electronic device 5 may be a device that integrates a programmable logic controller, a signal conditioning circuit, an analog-to-digital converter and other devices. The electronic device 5 may include, but is not limited to, a processor 501 and a memory 503. Those skilled in the art will understand that Figure 5 This is merely an example of the electronic device 5 and does not constitute a limitation on the electronic device 5 . The electronic device 5 may include more or fewer components than shown in the figure, or a combination of certain components, or different components. For example, it may also include input and output devices, network access devices, etc.

[0097] The processor 501 may be a central processing unit (CPU), or other general-purpose processors, digital signal processors (DSP), application-specific integrated circuits (ASIC), field-programmable gate arrays (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, or discrete hardware photovoltaic modules. A general-purpose processor may be a microprocessor or any conventional processor.

[0098] In some embodiments, the memory 503 may be an internal storage unit of the electronic device 5, such as the hard drive or memory of the electronic device 5. In other embodiments, the memory 503 may also be an external storage device of the electronic device 5, such as a plug-in hard drive, a Smart Media Card (SMC), a Secure Digital (SD), or a Flash Card equipped on the electronic device 5. Furthermore, the memory 503 may include both an internal storage unit of the electronic device 5 and an external storage device. The memory 503 is used to store an operating system, application programs, a boot loader, data, and other programs, such as the program code of a computer program. The memory 503 may also be used to temporarily store data that has been output or is about to be output.

[0099] If the above-mentioned integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, when the present application implements all or part of the process in the above-mentioned embodiment method, a computer program can be used to instruct the relevant hardware to complete it. The computer program can be stored in a computer-readable storage medium. When the computer program is executed by the processor, it can implement the steps applied to the above-mentioned method embodiment. Among them, the computer program includes computer program code, which can be in source code form, object code form, executable file or some intermediate form. The computer-readable storage medium may at least include: any entity or device that can carry computer program code to a computing device / electronic device, a recording medium, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunications signal and a software distribution medium, such as a USB flash drive, a mobile hard disk, a magnetic disk or an optical disk.

[0100] An embodiment of the present application further provides a computer-readable storage medium, which stores a computer program. When the computer program is executed by a processor, the steps in the above-mentioned method embodiments are implemented.

[0101] An embodiment of the present application provides a computer program product. When the computer program product is run on an electronic device, the electronic device executes the steps in the above-mentioned various method embodiments.

[0102] In the above embodiments, the description of each embodiment has its own focus. For parts that are not described or recorded in detail in a certain embodiment, reference can be made to the relevant description of other embodiments.

[0103] Those skilled in the art will appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professional and technical personnel can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0104] In the embodiments provided in this application, it should be understood that the disclosed devices / electronic devices and methods can be implemented in other ways. The device / electronic device embodiments described above are merely schematic, and the division of the above modules or units is merely a logical function division. In actual implementation, there may be other division methods, such as multiple units or photovoltaic modules can be combined or integrated into another system, and some features can be ignored and not executed. Another point is that the indirect coupling, direct coupling or communication connection between each other shown or discussed can be an indirect coupling, direct coupling or communication connection through some interfaces, devices or units, which can be electrical, mechanical or other forms.

[0105] The units described above as separate components may or may not be physically separate, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed across multiple network units. Some or all of these units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0106] The above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or make equivalent replacements for some of the technical features therein. These modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application, and should all be included in the scope of protection of the present application.

Claims

1. A method for preventing a conveyor belt from tearing, characterized in that: The method comprises: Acquire the real-time induction signal generated by the induction coil embedded in the conveyor belt when it is excited by the excitation magnetic field; Digitally sampling the real-time sensing signal after signal conditioning to obtain a real-time digital signal; Determining whether the real-time digitized signal meets an alarm condition; When the real-time digitized signal meets the alarm condition, a tearing alarm and / or a protective action is triggered.

2. The belt conveyor belt tearing prevention method according to claim 1, characterized in that: The signal conditioning includes: The real-time sensing signal is amplified and the environmental electromagnetic noise and power frequency interference outside the working frequency band are filtered out.

3. The belt conveyor belt tearing prevention method according to claim 1, characterized in that: The alarm conditions include: the signal strength of the real-time digitized signal is less than the alarm threshold, the drop rate of the signal strength of the real-time digitized signal is greater than a preset threshold, and the duration of the drop in the signal strength of the real-time digitized signal exceeds a preset time window.

4. The belt conveyor belt tearing prevention method according to claim 3, characterized in that: The method further comprises: The alarm threshold is dynamically determined based on a signal strength baseline value of the real-time digitized signal, historical data, and a preset safety margin.

5. The belt conveyor belt tearing prevention method according to claim 1, characterized in that: The method further comprises: Conduct correlation analysis on the real-time sensing signals of adjacent monitoring points to locate the location of the tear; Among them, the monitoring point is the location where the RF receiving probe is installed; when the conveyor belt is torn, the induction coil breaks, the induced current disappears, the real-time induction signal fails, and the signal strength of the real-time induction signal continues to drop sharply.

6. The method for preventing a conveyor belt from tearing according to any one of claims 1 to 5, characterized in that: The method further comprises: The fault analysis and system status monitoring data before and after the fault occurs are stored and uploaded to the host computer.

7. A belt conveyor belt tear-proof system, characterized in that: The system comprises: A magnetic field generating module, used for generating an excitation magnetic field of specific frequency and intensity; A signal receiving module, configured to receive a real-time induction signal generated by an induction coil pre-buried in the conveyor belt when excited by the excitation magnetic field; The analog-to-digital conversion module is used to digitally sample the real-time sensing signal after signal conditioning to obtain a real-time digital signal; The control module is used to determine whether the real-time digitized signal meets the alarm condition, and trigger a tearing alarm and / or a protective action when the real-time digitized signal meets the alarm condition.

8. The belt conveyor belt anti-tearing system according to claim 7, characterized in that: The system further comprises a signal conditioning module for amplifying the real-time sensing signal and filtering out the environmental electromagnetic noise and power frequency interference outside the working frequency band.

9. The belt conveyor belt tear-proof system according to claim 7, characterized in that: The control module is further configured to generate an alarm message and send a safety stop instruction to the drive motor of the belt conveyor. The drive motor stops driving according to the safety stop instruction, and the belt conveyor stops running.

10. The belt conveyor belt tear-proof system according to claim 9, characterized in that: The system also includes: a host computer and an alarm module; The host computer is used to display the location where the tearing occurs and the time when the alarm is triggered according to the alarm information, and to trigger the alarm module; The alarm module is used for performing a tearing alarm.

11. The belt conveyor belt anti-tearing system according to any one of claims 7 to 10, characterized in that: The magnetic field generating module is a radio frequency transmitting probe, the signal receiving module is a radio frequency receiving probe, the analog-to-digital conversion module is an analog-to-digital converter, and the control module is a programmable logic controller.

12. An electronic device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein: When the processor executes the computer program, the belt conveyor belt tear prevention method according to any one of claims 1 to 6 is implemented.

13. A computer-readable storage medium storing a computer program, characterized in that: When the computer program is executed by a processor, the method for preventing a conveyor belt from tearing of a belt conveyor according to any one of claims 1 to 6 is implemented.

14. A computer program product, characterized in that When the computer program product is run on an electronic device, the electronic device is enabled to execute the method for preventing a conveyor belt from tearing according to any one of claims 1 to 6.

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