Monitoring device and monitoring method applied to belt conveyor

Abstract

The invention relates to the technical field of belt conveyors, and discloses a monitoring device and method applied to a belt conveyor, the belt conveyor comprises a support and a conveying belt, the monitoring device applied to the belt conveyor comprises a controller, a base installed on the support and an installation part arranged on the base, and a plurality of monitoring units are arranged on the installation part; the monitoring unit comprises a shell arranged on the mounting part, a pressure sensor arranged in the shell, and a sliding part which is arranged in the shell in a sliding manner and extends out of the top of the shell; the pressure sensor is electrically connected with the controller, one end of the sliding piece is connected with an ejector rod of the pressure sensor through a spring, and a rolling body is arranged at the other end of the sliding piece and makes contact with the conveying belt. By arranging the spring, the pressure sensor is prevented from being damaged due to direct bearing of overlarge external force, and by arranging the rolling body, abrasion of the conveying belt to the monitoring unit can be relieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of belt conveyors, in particular to a monitoring device and method applied to a belt conveyor. BACKGROUND

[0002] In the production process of the mining industry, belt conveyors are widely used to transport materials such as ores. In the prior art, a belt conveyor mainly includes a support, a driving device, a drum, a carrier roller, a belt, a tensioning mechanism, and a brake device. The driving device provides a power source for the equipment. The drum cooperates with the carrier roller to realize the support and guidance of the conveyor belt. The tensioning mechanism adjusts the tension of the conveyor belt to ensure its effective adhesion to the transmission components. The brake device is used for safe shutdown in emergency conditions. The conveyor belt, as the only working component directly contacting the ore, is the core of ensuring the transportation capacity of the equipment, and its performance state directly affects the overall service life of the belt conveyor.

[0003] In the actual mining operation process, the loader transports the collected large raw ores to the crusher. After the crusher crushes the ores into small ores with uniform particle size, the ores are transported to the belt conveyor. The belt conveyor transports the ores to the downstream sorting, storage, or external transport link through the circulation of the conveyor belt. In this process, the belt conveyor becomes the key of the mining production chain. Once it stops, it will directly cause the interruption of the entire mining production process, causing serious economic losses.

[0004] However, under the complex working conditions of mining operations, the conveyor belt is prone to failure. The main causes of failure are as follows: on the one hand, the collected ores are in a mixed form of lumps and powders. The sharp edges of the lumps will impact and scratch the conveyor belt when they fall onto the surface of the conveyor belt, causing cracks, cuts, or even penetrating damage on the surface of the conveyor belt, and the initial defects will continue to expand over time. On the other hand, the tensioning mechanism needs to continuously provide tension to ensure the normal operation of the conveyor belt. This tension will further enlarge the existing defects such as cracks and damage of the conveyor belt, accelerate the defect expansion, and eventually cause the conveyor belt to break down.

[0005] The breaking of the conveyor belt will cause serious harm. In actual production, to meet the long-distance transportation needs of mining operations, the length of the belt conveyor is usually more than 1000 meters, and to ensure production efficiency, a high running speed is required. At the same time, the daily load of the conveyor belt can reach ten to hundreds of tons. Therefore, when the belt breaks, the ores on the conveyor belt will fall at high speed due to inertia, which can easily injure the surrounding operators or damage the on-site equipment.

[0006] At present, the monitoring methods of mining enterprises for belt conveyor faults mainly include two types: the first type is manual inspection method, which relies on the experience of inspection personnel and has significant limitations. On the one hand, a single kilometer-level belt conveyor needs multiple inspection personnel to check in sections, which cannot realize 24-hour real-time monitoring and has low monitoring efficiency. On the other hand, the identification ability of inspection personnel for early defects such as subtle cracks and internal damage of the conveyor belt is limited, and subjective judgment deviation may cause missed inspection and false inspection, so that early faults cannot be found in time and maintenance opportunity is missed. The second type is sensor monitoring method: some enterprises try to introduce sensors to realize automatic monitoring, but the existing sensor technology cannot adapt to complex working conditions. The main reasons are as follows: 1. The sensor needs to be installed close to the conveyor belt. The friction and impact of the conveyor belt with the ore during operation will directly act on the sensor, causing problems such as damage of the sensor shell and failure of internal components. Therefore, the sensor monitoring method has the problem of short service life of the sensor and frequent replacement. 2. The installation position of the sensor is fixed and cannot be adjusted adaptively according to the actual working condition changes (such as ore particle size adjustment and conveyor belt tension change), so the monitoring range and sensitivity cannot match the actual demand, resulting in decreased monitoring accuracy and difficulty in effectively capturing early fault signals of the conveyor belt. SUMMARY

[0007] In order to solve the above technical problems, the present application provides a monitoring device and method applied to a belt conveyor.

[0008] In a first aspect, the present application provides a monitoring device applied to a belt conveyor, the belt conveyor comprising a support and a conveyor belt, the monitoring device comprising a controller, a base mounted on the support, a mounting member arranged above the base and capable of moving up and down relative to the base, a plurality of monitoring units arranged at intervals along the width direction of the conveyor belt on the mounting member; the monitoring unit comprises an outer shell arranged on the mounting member, a pressure sensor arranged in the outer shell, and a sliding member slidingly arranged in the outer shell and extending out of the top of the outer shell; the pressure sensor and the controller are electrically connected, one end of the sliding member and the top rod of the pressure sensor are connected through a spring, the other end of the sliding member has a rolling body capable of rolling, and the rolling body is in contact with the conveyor belt.

[0009] Optionally, the monitoring unit further comprises a supporting rod, one end of the supporting rod is a mounting end, the other end is a threaded end, the mounting end is located inside the outer shell and can place the pressure sensor, and the threaded end extends out of the outer shell and is threadedly connected with the mounting member.

[0010] Optionally, the sliding member comprises a sliding block slidingly arranged in the outer shell, the bottom of the sliding block is connected with the spring, the top of the sliding block has an extension part extending out of the outer shell, the extension part is connected with a bull eye bearing, and the rolling body is arranged in the bearing seat of the bull eye bearing.

[0011] Optionally, a through hole capable of passing through the cable of the pressure sensor is formed on the outer shell.

[0012] Optionally, the mounting member is slidably provided with slide rails at both ends of the length direction, and the two slide rails are mounted on the support, and the mounting member can slide up and down along the slide rails.

[0013] Optionally, a plurality of openings one are arranged on the mounting member at intervals, and a plurality of openings two are arranged on the base at positions corresponding to the openings one, and a bolt is arranged in each opening two, and the head of each bolt is below the base, and the end of each bolt away from the head extends into and out of the corresponding opening one; a nut is arranged on the upper and lower sides of each opening one and on the upper side of each opening two, and all the nuts are threadedly connected to the corresponding bolts.

[0014] Optionally, the device further comprises a tensioning wheel mounted on the support and capable of tensioning the conveying belt.

[0015] Optionally, the device further comprises an alarm electrically connected to the controller.

[0016] In a second aspect, the application provides a monitoring method of a monitoring device applied to a belt conveyor, comprising: Before installing the conveying belt of the belt conveyor, the monitoring data of all the pressure sensors are cleared; The conveying belt is installed, and the distance between the mounting member and the base is adjusted so that the rolling bodies of all the monitoring units are in contact with the conveying belt; All the monitoring units are adjusted so that the monitoring values of all the pressure sensors are the same; The belt conveyor is started, the plurality of monitoring units monitors the conveying belt in real time, and the controller determines whether the conveying belt has a fault and the fault type when the fault occurs according to the monitoring data.

[0017] By arranging the plurality of monitoring units, the plurality of monitoring units arranged along the width direction of the conveying belt can monitor different positions of the conveying belt at the same time, and then the monitoring data of the plurality of monitoring units are fused to analyze the fault type of the conveying belt, thereby providing a basis for the maintenance of the conveying belt.

[0018] Optionally, the controller determines whether the conveying belt has a fault and the fault type when the fault occurs according to the monitoring data, comprising: When the monitoring values of all the pressure sensors are within the normal value range, it is determined that the conveying belt has no fault; When the monitoring value of the leftmost pressure sensor becomes zero, the fault type of the conveying belt is running deviation to the right side; When the monitoring value of the rightmost pressure sensor becomes zero, the fault type of the conveying belt is running deviation to the left side; When the monitoring values of some pressure sensors deviate from the monitoring values of the remaining pressure sensors, and the deviation reaches a preset value, the fault type of the conveying belt is damage, cracking or loss; When all pressure sensor readings are zero for a short period of time, the conveyor belt malfunction is classified as broken.

[0019] The technical solution provided by the embodiments of the present invention has the following advantages compared with the prior art: 1. By incorporating a spring, when the conveyor belt vibrates or impacts, the spring absorbs energy through elastic deformation, preventing the pressure sensor from being damaged by excessive external force. Therefore, by incorporating a spring, the service life of the pressure sensor can be extended.

[0020] 2. By setting rolling elements, the friction between the monitoring unit and the conveyor belt can be significantly reduced, thereby reducing the wear of the monitoring unit by the conveyor belt.

[0021] 3. By setting up mounting components that can move up and down, the monitoring unit can be flexibly adjusted according to the position of the conveyor belt, so that the rolling elements can make stable contact with the conveyor belt. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of a monitoring device for a belt conveyor provided in Embodiment 1 of the present invention.

[0023] Figure 2 for Figure 1 The main view.

[0024] Figure 3 for Figure 2 A sectional view along line AA.

[0025] Figure 4 This is a schematic diagram of the monitoring unit provided in Embodiment 1 of the present invention, which is installed on the mounting component.

[0026] Figure 5 This is a schematic diagram of the monitoring unit provided in Embodiment 1 of the present invention.

[0027] Figure 6 for Figure 5 Top view.

[0028] Explanation of reference numerals in the attached drawings: 1. Conveying assembly; 101. Roller; 2. Conveyor belt; 3. Monitoring unit; 301. Pressure sensor; 302. Cable; 303. Bullseye bearing; 304. Bearing housing; 305. Top cover; 306. Housing; 307. Spring; 308. Top rod; 309. Support rod; 310. Screw; 4. Bracket; 5. Tensioning wheel; 6. Slide rail; 7. Mounting component; 8. Bolt; 9. Base. Detailed Implementation

[0029] The following detailed description of a specific embodiment of the present invention is provided in conjunction with the accompanying drawings. However, it should be understood that the scope of protection of the present invention is not limited to the specific embodiment.

[0030] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the technical solution of this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0031] Example 1: like Figures 1-5 As shown, this embodiment provides a monitoring device for a belt conveyor. The belt conveyor includes a support 4 and a conveying assembly 1 mounted on the support 4. The conveying assembly 1 includes a conveyor belt 2, a controller, a base 9 mounted on the support 4, and a mounting member 7 located above the base 9 and capable of moving up and down relative to the base 9. Multiple monitoring units 3 are spaced apart on the mounting member 7 along the width direction of the conveyor belt 2. The monitoring unit 3 includes a housing 306 located on the mounting member 7, a pressure sensor 301 located inside the housing 306, and a sliding member slidably located inside the housing 306 and extending from the top of the housing 306. The pressure sensor 301 is electrically connected to the controller. One end of the sliding member is connected to the top rod 308 of the pressure sensor 301 by a spring 307. The other end of the sliding member has a rolling element capable of rolling, and the rolling element contacts the conveyor belt 2.

[0032] In this embodiment, the push rod 308 is part of the pressure sensor 301 and is in rigid contact with the sensitive element of the pressure sensor.

[0033] In this embodiment, the conveying component 1 is based on existing technology and includes a drive motor and rollers 101 (drive roller and driven roller), etc.

[0034] like Figure 5 and Figure 6 As shown, in this embodiment, the top of the housing 306 is open, and the housing 306 has a top cover 305 that can close the top opening. The top cover 305 and the housing 306 are connected by screws 310.

[0035] The monitoring unit 3 also includes a support rod 309. One end of the support rod 309 is a mounting end, and the other end is a threaded end. The mounting end is located inside the housing 306 and can accommodate the pressure sensor 301. The threaded end extends out of the housing 306 and is threadedly connected to the mounting component 7.

[0036] In the embodiment, the threaded end of the mounting member 7 extends out of the housing 306 and is threaded with a nut, the support rod 309 is locked by the nut, and the monitoring value of the pressure sensor is adjusted by adjusting the length of the support rod 309 extending into the housing (by rotating the support rod).

[0037] The sliding member includes a sliding block slidingly arranged in the housing 306, the bottom of the sliding block is connected with the spring 307, the top of the sliding block is provided with an extension portion extending out of the housing 306, the extension portion is connected with the eye bearing 303, and the rolling body is arranged in the bearing seat 304 of the eye bearing 303.

[0038] The housing 306 is provided with a through hole through which the cable 302 of the pressure sensor 301 can pass.

[0039] The mounting member 7 is slidingly arranged with two slide rails 6 at two ends in the length direction of the mounting member 7, the two slide rails 6 are both mounted on the support 4, and the mounting member 7 can slide up and down along the slide rails 6.

[0040] A plurality of openings one are arranged at intervals on the mounting member 7, the base 9 is provided with an opening two at a position corresponding to the opening one, a bolt 8 is arranged in each opening two, the head of each bolt 8 is located below the base 9, and the end of each bolt 8 away from the head extends into and out of the corresponding opening one; a nut is arranged on the upper and lower sides of each opening one and on the upper side of each opening two, and all the nuts are threaded on the corresponding bolts 8.

[0041] Further comprising a tensioning wheel 5 mounted on the support 4 and capable of tensioning the conveyor belt 2.

[0042] Further comprising an alarm electrically connected with the controller.

[0043] Embodiment two: The embodiment provides a monitoring method of a monitoring device applied to a belt conveyor, which comprises the following steps: Step one, before installing the conveyor belt 2 of the belt conveyor, the monitoring data of all the pressure sensors 301 is cleared; Step two, the conveyor belt 2 is installed, and the distance between the mounting member 7 and the base 9 is adjusted so that the rolling bodies of all the monitoring units 3 are in contact with the conveyor belt 2; Step three, all the monitoring units 3 are adjusted so that the monitoring values of all the pressure sensors 301 are the same. In the embodiment, the monitoring values of all the pressure sensors 301 are the same by adjusting the extension height of the support rod 309 of all the monitoring units 3, i.e. the height of the mounting end of the support rod 309. Step four, the belt conveyor is started, the plurality of monitoring units 3 monitor the conveyor belt 2 in real time, and the controller determines the fault type of the conveyor belt 2 according to the monitoring data.

[0044] The controller determines the fault type of the conveyor belt 2 according to the monitoring data, which comprises the following steps: When the monitoring value of the leftmost pressure sensor 301 becomes zero, the fault type of the conveyor belt 2 is running to the right side; When the monitoring value of the rightmost pressure sensor 301 becomes zero, the fault type of the conveyor belt 2 is running to the left side; When the monitoring value of a part of the pressure sensors 301 and the monitoring value of the rest of the pressure sensors deviate and the deviation reaches a preset value, the fault type of the conveyor belt 2 is breakage, cracking or damage; When the monitoring value of all the pressure sensors 301 is zero in a short time, the fault type of the conveyor belt 2 is breakage.

[0045] In the embodiment, after the controller determines the fault type of the conveyor belt 2, the controller controls the alarm to send an alarm signal to remind the maintenance personnel to maintain.

[0046] The above are only some specific embodiments of the present application, but the embodiments of the present application are not limited to this, any changes that can be thought of by those skilled in the art should fall within the protection scope of the present application.

Claims

1. A monitoring device for a belt conveyor, the belt conveyor comprising a support (4) and a conveyor belt (2), characterized in that, The monitoring device includes a controller, a base (9) mounted on the bracket (4), and a mounting component (7) located above the base (9) that can move up and down relative to the base (9). Multiple monitoring units (3) are spaced apart on the mounting component (7) along the width direction of the conveyor belt (2). The monitoring unit (3) includes a housing (306) disposed in the mounting component (7), a pressure sensor (301) disposed in the housing (306), and a sliding member slidably disposed in the housing (306) and extending from the top of the housing (306); the pressure sensor (301) and the controller are electrically connected, one end of the sliding member and the top rod (308) of the pressure sensor (301) are connected by a spring (307), and the other end of the sliding member has a rolling element that can roll, and the rolling element contacts the conveyor belt (2).

2. The monitoring device for belt conveyors as described in claim 1, characterized in that, The monitoring unit (3) also includes a support rod (309), one end of which is an installation end and the other end is a threaded end. The installation end is located inside the housing (306) and can accommodate a pressure sensor (301). The threaded end extends out of the housing (306) and is threadedly connected to the mounting component (7).

3. The monitoring device for belt conveyors as described in claim 1, characterized in that, The sliding component includes a slider that is slidably disposed within the housing (306), the bottom of the slider being connected to a spring (307), the top of the slider having an extension that extends out of the housing (306), a bullseye bearing (303) being connected to the extension, and a rolling element being disposed within the bearing seat (304) of the bullseye bearing (303).

4. The monitoring device for belt conveyors as described in claim 1, characterized in that, The housing (306) has a through hole through which the pressure sensor (301) cable (302) can pass.

5. The monitoring device for belt conveyors as described in claim 1, characterized in that, The mounting component (7) has slide rails (6) slidably installed at both ends of its length direction. Both slide rails (6) are installed on the bracket (4), and the mounting component (7) can slide up and down along the slide rails (6).

6. The monitoring device for belt conveyors as described in claim 5, characterized in that, The mounting component (7) is provided with a plurality of openings 1 at intervals. The base (9) is provided with openings 2 at the positions corresponding to openings 1. Each opening 2 is provided with a bolt (8). The head of each bolt (8) is located below the base (9). The end of each bolt (8) away from its head extends into and out of the corresponding opening 1. Nuts are provided on the upper and lower sides of each opening one and on the upper side of each opening two. All nuts are threaded onto the corresponding bolts (8).

7. The monitoring device for belt conveyors as described in claim 1, characterized in that, It also includes a tensioning wheel (5) mounted on the bracket (4) to tension the conveyor belt (2).

8. The monitoring device for belt conveyors as described in claim 1, characterized in that, It also includes an alarm that is electrically connected to the controller.

9. The monitoring method for a monitoring device applied to a belt conveyor as described in any one of claims 1-8, characterized in that, include: Before installing the conveyor belt (2) of the belt conveyor, reset the monitoring values ​​of all pressure sensors (301) to zero; Install the conveyor belt (2) and adjust the distance of the mounting piece (7) relative to the base (9) so that the rolling elements of all monitoring units (3) are in contact with the conveyor belt (2); Adjust all monitoring units (3) so that the monitoring values ​​of all pressure sensors (301) are the same; Start the belt conveyor, and multiple monitoring units (3) monitor the conveyor belt (2) in real time. The controller determines whether the conveyor belt (2) has malfunctioned based on the monitoring data, and the type of malfunction when it occurs.

10. The monitoring method of the monitoring device applied to a belt conveyor as described in claim 9, characterized in that, The controller determines whether the conveyor belt (2) has malfunctioned based on the monitoring data, and the types of malfunctions include: When the monitored values ​​of all pressure sensors (301) are within the normal range, it is determined that the conveyor belt (2) has not malfunctioned; When the monitoring value of the leftmost pressure sensor (301) becomes zero, the fault type of the conveyor belt (2) is to deviate to the right. When the monitoring value of the rightmost pressure sensor (301) becomes zero, the fault type of the conveyor belt (2) is to deviate to the left. When the monitoring values ​​of some pressure sensors (301) deviate from the monitoring values ​​of the other pressure sensors, and the deviation reaches a preset value, the fault type of the conveyor belt (2) is breakage, cracking or damage. When the monitored values ​​of all pressure sensors (301) are zero for a short period of time, the fault type of the conveyor belt (2) is breakage.

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