Belt conveyor state detection device and detection method

Abstract

The invention relates to a belt conveyor state detection device, the detection device comprises a set of PLC control box, a sensor assembly and a cable, the PLC control box is installed on a frame structure near a head pulley or a tail pulley of a belt conveyor, the PLC control box comprises a touch screen, a power supply, a CPU, a wiring terminal, a switch and a DC power supply, and a controller in the control box, the switch and an L / L circuit of the DC power supply are arranged in the control box. The N is connected with an external AC 220V power supply, the DC power supply provides DC power supplies for the touch screen and external sensors, namely DC 24V + and DC 24V-, and signal lines of all the sensors are connected in parallel and are connected to an A interface and a B interface of the controller. The device can collect data of 250 sensors with RS485 communication interfaces, can collect and analyze key data such as speed, temperature, vibration and the like of a belt conveyor, and outputs an alarm or chain shutdown signal. Only one group of power cables and one group of communication cables need to be laid. The touch screen visually displays operation data of the belt conveyor and can send the collected data to a control system of the original belt conveyor through communication.

Description

Technical Field

[0001] This invention relates to a belt conveyor condition detection device and detection method, belonging to the field of metallurgical equipment condition detection technology. Background Technology

[0002] Belt conveyors are widely used in industries such as mining and steel. As operating equipment, the safety of belt conveyor operation has always been a major concern. To address the risk of fires caused by high temperatures resulting from belt-pulley jamming and friction between the belt and pulley during operation, many belt conveyors have incorporated speed detection for the drive pulley, driven pulley, and guide pulley, as well as temperature detection for the drive pulley, driven pulley, guide pulley, and idler rollers. Once an abnormal temperature is detected, the system issues an alarm or triggers a shutdown, eliminating potential hazards at their source. Typically, these detection devices utilize electrical and automation technologies to connect each sensor signal to a PLC for data acquisition, analysis, and output of alarm or shutdown signals, ensuring the inherent safety of the equipment.

[0003] In the metallurgical industry, the speed and temperature of belt conveyors are generally connected to the existing control system. The disadvantages of this method are as follows: (1) a large number of cables need to be laid, and each signal needs to be laid to the original control system PLC cabinet; (2) a large number of AI channels are occupied by the PLC cabinet, and the reserved points of the original system are generally insufficient for large-scale transformation, so it is necessary to add PLC cabinets and reconfigure; (3) the transformation cost is high.

[0004] To address the aforementioned issues, this paper proposes a method for monitoring the condition of belt conveyors and develops a monitoring device. This device can collect data from 250 sensors equipped with RS485 communication interfaces, enabling the acquisition, analysis, and output of alarm or interlocking shutdown signals for key data such as speed, temperature, and vibration of a single belt conveyor. Only one set of power cable and one set of communication cable are required. The touchscreen displays the belt conveyor's operating data visually and can transmit the collected data to the existing belt conveyor control system via communication. Summary of the Invention

[0005] This invention addresses the technical problems existing in the prior art by providing a belt conveyor condition detection device. This technical solution can collect speed data of the belt conveyor's drive pulley, driven pulley, and steering pulley in a timely and accurate manner, as well as temperature and vibration data of the drive motor and reducer, and relevant data such as temperature of the belt's drive pulley, driven pulley, steering pulley, and idler rollers. It can then perform diagnostics and issue alarm or fault signals.

[0006] To achieve the above objectives, the technical solution of the present invention is as follows: a belt conveyor status detection device, the detection device comprising a PLC control box, sensor components and cables, wherein the PLC control box is installed on a frame structure near the head pulley or tail pulley of the belt conveyor for easy viewing by personnel.

[0007] The PLC control box includes a touch screen, power supply, CPU (with RS485 communication interface), terminal blocks, switch, and DC power supply. The controller, switch, and DC power supply in the control box are connected to an external AC220V power supply via L and N pins. The DC power supply provides DC power to the touch screen and external sensors: DC24V+, DC24V-. All sensor signal lines are connected in parallel to the controller's A and B interfaces. The sensor components all support the RS485 communication protocol and mainly include speed detection sensors, temperature detection sensors, and vibration detection sensors. The sensors are installed at the locations that need to be detected to collect data.

[0008] Speed ​​sensors are installed on the drive wheel, driven wheel, and steering wheel where speed measurement is required. They can be installed according to the technical requirements of the sensor. During debugging, the sensor should be able to read data stably. Collision protection can be added as appropriate.

[0009] Vibration sensors require a base to be welded to the area to be detected. The vibration sensor is then connected to the base with bolts. There are many types of temperature sensors. This device uses an infrared temperature sensor. After the sensor is installed and fixed, the sensor is aligned with the area to be detected using a positioning red light. The sensor power line and communication cable are laid along the conveyor belt frame. All sensor A terminals are connected to A terminals, and B terminals are connected to B terminals, and finally connected to the A and B terminals of the controller.

[0010] Among them, the speed detection sensor, temperature detection sensor and vibration detection sensor all need to be set with addresses in the range of 0 to 250, and the addresses must be unique and not repeated.

[0011] The touchscreen displays data from each sensor and allows for threshold settings. Users can choose between outputting an alarm signal or an interlocking shutdown signal based on the importance of the detection point. Two output signal formats are provided: one is a passive dry contact signal, facilitating connection to the main equipment control loop for control and interlocking; the other is a communication interface that can send signals to the user's large system PLC. Users can choose the appropriate format based on their needs and the actual site conditions. A belt conveyor status detection method includes the following steps:

[0012] Step 1: The user makes initial settings on the touchscreen according to the actual number and location of sensors installed on the belt conveyor. After the belt conveyor status detection device is activated, it will read data according to the number and type of sensors set by the user.

[0013] Step 2: During installation, pre-set the address and number (1-250) of each sensor. By default, the controller assigns speed sensors (1-20), temperature sensors (21-40), and vibration sensors (41-60).

[0014] Step 3: After the device starts up, it first reads the initial addresses and quantities of various sensors set by the user. After reading, it calls the speed sensor data reading program, starting from the initial address of sensor 1. After reading the address of sensor 1, the speed sensor address is automatically incremented by 1; the next loop will read the data of sensor 2.

[0015] Next, the temperature and velocity sensor data reading program is called, starting from the initial address of temperature sensor #21. After reading the address of sensor #21, the temperature sensor address is automatically incremented by 1. The next loop will read data from sensor #22. Then, the vibration sensor data reading program is called, starting from the initial address of vibration sensor #41. After reading the address of sensor #41, the temperature sensor address is automatically incremented by 1. The next loop will read data from sensor #42. Then, the program returns and calls the velocity sensor data reading program again to begin the next loop. Figure 2 As shown.

[0016] When the address number of any sensor exceeds the sum of its initial address and quantity, the current address number is restored to the initial address. The initial address number and quantity are user-defined, and the control logic remains unchanged.

[0017] Step 4: The read data will be compared with the threshold set by the user and output in the form of dry contacts, which can be customized by the user as an alarm or interlocking shutdown signal.

[0018] Compared to existing technologies, this invention has the following advantages: 1. High number of data collection points: This device can collect data from 250 sensors equipped with RS485 communication interfaces, which can meet the needs of collecting, analyzing, and outputting alarm or interlocking shutdown signals for key data such as speed, temperature, and vibration of a conveyor belt. 2. Minimal cable laying and simple construction: To collect the same amount of sensor data, this device requires very little cable laying, only one set of power cables and one set of communication cables. 3. No occupation of existing control system locations: All collected data is transmitted via fiber optic communication, requiring minimal modification to the existing system. The existing control system does not need additional hardware, resulting in good economic efficiency. Attached Figure Description

[0019] Figure 1 This is a hardware schematic diagram of a belt conveyor condition detection device;

[0020] Figure 2 This is a flowchart of the belt conveyor status detection logic. Detailed Implementation

[0021] To enhance understanding of the present invention, the embodiments will be described in detail below with reference to the accompanying drawings.

[0022] Example 1: See Figure 1 , Figure 2A belt conveyor condition detection device includes a PLC control box, sensor components, and cables. The PLC control box is installed on a frame structure near the head pulley or tail pulley of the belt conveyor for easy inspection by personnel.

[0023] The PLC control box includes a touch screen, power supply, CPU (with RS485 communication interface), terminal blocks, switch, and DC power supply. The controller, switch, and DC power supply in the control box are connected to an external AC220V power supply via L and N pins. The DC power supply provides DC power to the touch screen and external sensors: DC24V+, DC24V-. All sensor signal lines are connected in parallel to the controller's A and B interfaces. The sensor components all support the RS485 communication protocol and mainly include speed detection sensors, temperature detection sensors, and vibration detection sensors. The sensors are installed at the locations that need to be detected to collect data.

[0024] Speed ​​sensors are installed on the drive wheel, driven wheel, and steering wheel where speed measurement is required. They can be installed according to the technical requirements of the sensor. During debugging, the sensor should be able to read data stably. Collision protection can be added as appropriate.

[0025] Vibration sensors require a base to be welded to the area to be detected. The vibration sensor is then connected to the base with bolts. There are many types of temperature sensors. This device uses an infrared temperature sensor. After the sensor is installed and fixed, the sensor is aligned with the area to be detected using a positioning red light. The sensor power line and communication cable are laid along the conveyor belt frame. All sensor A terminals are connected to A terminals, and B terminals are connected to B terminals, and finally connected to the A and B terminals of the controller.

[0026] The speed, temperature, and vibration sensors all require unique addresses within the range of 0-250. Once activated, the detection device polls and reads data from all sensors according to a preset pattern. A communication data area has also been allocated for easy data exchange with the existing belt conveyor control system.

[0027] The touchscreen is used to display data from each sensor and set relevant thresholds; the PLC control box is used to receive sensor data, perform logical judgments, and output the judgment results in the form of dry contacts.

[0028] Example 2: See Figure 1 , Figure 2 A method for detecting the condition of a belt conveyor, the method comprising the following steps:

[0029] Step 1: The user makes initial settings on the touchscreen according to the actual number and location of sensors installed on the belt conveyor. After the belt conveyor status detection device is activated, it will read data according to the number and type of sensors set by the user.

[0030] Step 2: During installation, pre-set the address and number (1-250) of each sensor. By default, the controller assigns speed sensors (1-20), temperature sensors (21-40), and vibration sensors (41-60).

[0031] Step 3: After the device starts up, it first reads the initial addresses and quantities of various sensors set by the user. After reading, it calls the speed sensor data reading program, starting from the initial address of sensor 1. After reading the address of sensor 1, the speed sensor address is automatically incremented by 1; the next loop will read the data of sensor 2.

[0032] Next, the temperature and velocity sensor data reading program is called, starting from the initial address of temperature sensor #21. After reading the address of sensor #21, the temperature sensor address is automatically incremented by 1. The next loop will read data from sensor #22. Then, the vibration sensor data reading program is called, starting from the initial address of vibration sensor #41. After reading the address of sensor #41, the temperature sensor address is automatically incremented by 1. The next loop will read data from sensor #42. Then, the program returns and calls the velocity sensor data reading program again to begin the next loop. Figure 2 As shown.

[0033] When the address number of any sensor exceeds the sum of its initial address and quantity, the current address number is restored to the initial address. The initial address number and quantity are user-defined, and the control logic remains unchanged.

[0034] Step 4: The read data will be compared with the threshold set by the user and output in the form of dry contacts, which can be customized by the user as an alarm or interlocking shutdown signal.

[0035] It should be noted that the above embodiments are not intended to limit the scope of protection of the present invention. Equivalent transformations or substitutions made based on the above technical solutions all fall within the scope of protection of the claims of the present invention.

Claims

1. A belt conveyor state detection device characterized by, The detection device includes a set of PLC control box, sensor assembly and cable, wherein the PLC control box is installed on the frame structure near the head wheel or tail wheel of the belt conveyor, The PLC control box contains a touch screen, a power supply, a CPU, a wiring terminal, a switch and a DC power supply, the controller, the switch and the L and N of the DC power supply in the control box are connected to the external AC 220V power supply, the DC power supply provides DC power supply for the touch screen and the external sensor: DC 24V+, DC 24V-, the signal lines of all sensors are connected in parallel and connected to the A and B interfaces of the controller.

2. The belt conveyor state detection apparatus according to claim 1, characterized by The sensor assembly supports RS485 communication protocol, mainly including speed detection sensor, temperature detection sensor and vibration detection sensor, the sensors are installed at the detection positions to collect data.

3. The belt conveyor state detection apparatus according to claim 1, characterized by The speed sensor is installed at the positions where the driving wheel, driven wheel and steering wheel need to be measured, The vibration sensor needs to be welded to the base at the detection position, and the vibration sensor is connected to the base through bolts, The temperature sensor adopts an infrared temperature sensor, after the sensor is installed and fixed, the sensor is aimed at the detection position through the positioning red light, The sensor power supply line and communication cable are laid along the frame of the belt conveyor, all sensor A terminals are connected to each other, B terminals are connected to each other, and finally connected to the A and B terminals of the controller.

4. The belt conveyor state detection apparatus according to claim 1, characterized by The speed detection sensor, temperature detection sensor and vibration detection sensor all need to set addresses in the range of 0-250, and the addresses are unique and not repeated.

5. The belt conveyor condition detection apparatus according to claim 1, characterized by The touch screen is used to display the data of each sensor and set the related threshold value; the user can set whether to output an alarm signal or a chain stop signal through the touch screen according to the importance of the detection point, the output signal provides two forms, one is to output a passive dry contact signal, which is convenient for the user to access the main equipment control loop for control and interlocking; the other is to provide a communication interface, which can send the signal to the user's large system PLC, and the user can use it according to the need, and the user can choose one according to the actual situation on site.

6. A belt conveyor state detection method characterized by, The state detection device of any one of claims 1-5, the detection method comprises the following steps: Step 1: the user sets the initial setting according to the actual installation of the sensor quantity and position of the belt conveyor on the touch screen, after the belt conveyor state detection device is started, the data will be read according to the user's setting of the sensor quantity and type, Step 2: during installation, the address and number (1-250) of each sensor are set in advance, the controller defaults the numbers 1-20 as speed sensors, 21-40 as temperature sensors and 41-60 as vibration sensors, Step 3: after the device is started, the initial address and quantity of each type of sensor set by the user are read first, after the reading is completed, the speed sensor data reading program is called, starting from the initial address 1 of the speed sensor, after reading the address of No. 1 sensor, the speed sensor address is automatically increased by 1; the next cycle will read the data of No. 2 sensor, Then call the temperature speed sensor data reading program, starting from the initial address 21 of the temperature sensor, after reading the address of No. 21 sensor, the temperature sensor address is automatically increased by 1; the next cycle will read the data of No. 22 sensor, Then call the vibration sensor data reading program, from the vibration sensor initial address 41 sensor, read the address of 41 sensor, temperature sensor address automatic add 1; Next cycle will read 42 sensor data, and then return to call the speed sensor data reading program again, the next cycle, When the address number of various sensors is greater than the sum of the initial address and the number, the current address number is restored to the initial address, and the initial number and the number are defined by the user, and the control logic is unchanged, Step 4: The read data is compared with the threshold value set by the user, and output in the form of dry contact, which is defined by the user as alarm or interlock shutdown signal.

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