Potentiometric analysis system for state of carrier roller of sealing-tape machine

Abstract

The invention discloses an adhesive tape machine carrier roller state potentiometry analysis system. The adhesive tape machine carrier roller state potentiometry analysis system comprises a potential sensing assembly, a signal acquisition system and a service assembly. The service assembly is connected with the potential sensing assembly through the signal acquisition system; the device has the beneficial effects that the potential sensor is mounted on the belt of the sealing-tape machine and used for monitoring the carrier roller state of the whole belt, the potential sensor adopts a monitoring mode of converting friction force into resistance, and the carrier roller state is monitored in three working conditions; full-automatic detection is achieved, and manual intervention is not needed.

Description

Technical Field

[0001] This invention relates to the field of belt conveyor idler condition analysis technology, and specifically to a belt conveyor idler condition potential method analysis system. Background Technology

[0002] In sintering and pelletizing, belt conveyors are key equipment for material transport between various processes. The production status of belt conveyor idlers is an important operating parameter of the equipment. Wear, breakage, and other causes leading to idler slippage or jamming directly affect the performance and service life of the belt conveyor, and in severe cases, can even cause the belt to stop operating, resulting in significant losses. Currently, the condition monitoring of belt idlers in China mainly relies on manual monitoring. Some factories with the resources have introduced expensive sensors installed on the idlers, but this has the following drawbacks: manual inspection is extremely labor-intensive, and with tens of thousands of idlers in a factory, inspecting the entire plant is time-consuming and labor-intensive; installing expensive sensors on each idler requires a huge investment, which is unaffordable for most factories, and the technology is difficult to promote.

[0003] A prior art technology discloses a mining conveyor idler roller condition detection system and method (publication number CN120213438A), which determines whether abnormal noise occurs in the operation of each idler roller by analyzing the relationship between the real-time noise decibels of each idler roller. However, this technical solution does not detect the idler roller condition through tension, and therefore cannot achieve fully automatic detection. Summary of the Invention

[0004] To overcome the problems of time-consuming and labor-intensive traditional manual inspection of conveyor belt idler roller status and the high cost of traditional sensor equipment, this invention provides a conveyor belt idler roller status potential method analysis system.

[0005] The belt conveyor roller state potential analysis system includes a potential sensing component, a signal acquisition system, and a service component; the service component is connected to the potential sensing component through the signal acquisition system.

[0006] Preferably, the potential sensing component includes a potentiometer, a tensioning mechanism, and a friction block. The potentiometer is connected to the friction block via the tensioning mechanism. When the belt is running, the potential sensing component under the belt moves forward with the belt and continuously contacts and rubs against the idler roller below. The idler roller drives the friction block, which in turn drives the tensioning mechanism to slide the potentiometer slider, thereby changing the resistance value of the potentiometer. Generally, three monitoring states are presented: off-belt state: no contact occurs, the friction block has no displacement, and the potentiometer output is 0; normal state: the idler roller is driven, the friction block is subjected to force and undergoes slight displacement, generating a small resistance; jammed state: the idler roller is jammed, the friction block is subjected to force and undergoes greater displacement, generating a larger resistance.

[0007] Preferably, the potential sensing component includes a connecting piece and a housing. The potentiometer, tensioning mechanism, and friction block are attached to the inner side of the belt via the connecting piece, and the housing covers the outer side of the potentiometer, tensioning mechanism, and friction block. A potential sensing component is installed on the belt of a conveyor belt to monitor the status of the idler rollers along the entire belt. The potential sensing component is located between the belt and the idler rollers and moves with the belt in a cyclical motion.

[0008] Preferably, the minimum resistance of the potentiometer is 100Ω to 1000Ω. The maximum resistance of the potentiometer can be adjusted according to the actual working conditions.

[0009] Preferably, the tensioning mechanism is a spring.

[0010] Preferably, the signal acquisition system includes two flat cables, which are wound around the outside of the belt. Each flat cable is connected to one end of a potentiometer. The flat cables are fully attached to the belt and move synchronously with it. At the point where the belt is empty, they connect to the PLC system via a sliding contact structure, transmitting the potentiometer's resistance signal to the PLC system. This allows the PLC system to measure the resistance value and analyze the changes in the resistance signal.

[0011] Preferably, the resistance of each flat cable is composed of two resistors connected in parallel, and the resistance value changes as the cable slides. Since the cable circumference is a fixed value, R11 + R112 is a constant. Considering a circumference of 200 meters and a resistance of 2 mm... 2 The resistance of the cable cross-section is approximately 1 ohm. According to the principle of parallel resistance, the resistance of each flat cable can be considered to be less than 1Ω. Since the minimum resistance of the potentiometer is generally 100Ω to 1000Ω, it can be considered to have no impact on the qualitative analysis of the monitoring.

[0012] Preferably, the service components include a server, a PLC system, and a control terminal. The PLC system is connected to the server and the control terminal, and the control terminal enables operation and monitoring.

[0013] Preferably, the server includes a potentiometric analysis module.

[0014] Preferably, the analysis method of the potentiometric analysis module is as follows: The total number of idlers on the conveyor belt is n, the belt speed is s meters per second, and the distance between the idlers is L. 拖 The distance of the belt running idle section between the head and tail idlers is L. 空 ,but: The time it takes for the potentiometer (11) to pass through the two idlers of the conveyor belt is: t = L 拖 / s; The time it takes for the potentiometer (11) to pass through all the idlers: t 料 = (n-1)×t; The time it takes for the potentiometer (11) to pass through all the idlers: t空 =L 空 / s; t 料 It is an objective time, occurring along the same path as the material, with the potentiometer mounted on the belt and moving with it. Because the distance between any two potentiometers is the same, t is the time it takes for the potentiometer to pass two adjacent idler rollers. 空 This refers to the potentiometer's return time, also known as the idle time, which is the time from leaving the last idler roller to returning to the first idler roller, expressed as the distance L between the last and first idler rollers. 空 In addition to speed.

[0015] Belt running single cycle time: t 总 =t 料 +t 空 ; Where: L 空 ≈n×t; belt running single cycle time t 总 The time structure is regular; the data returned by the potentiometer generally presents {n-1 t, t... 空 Based on the cyclic characteristics of the data, an array is established to store the resistance data. A software algorithm is used to establish a primary model for data relationship analysis and an analysis process model is established. The resistance data is mapped one-to-one with the roller positions in the analysis process model to form a potentiometric analysis module. The potentiometric analysis module monitors and analyzes the real-time data of each parameter. During normal production, the resistance data will present a conventional value and be fixed within a certain data range. The conventional value = the real-time value of the potentiometer + the resistance of the flat cable. The resistance of the flat cable is a negligible constant. The conventional value is the resistance value output by the potentiometer when it is stretched, and it is set to ±20% of the real-time resistance value within a certain data range. When the potentiometer passes a roller and the returned resistance data shows the following abnormalities, a roller fault is determined, and an alarm is triggered: The first abnormal situation: when the potentiometer resistance value is less than 1 / 10 of the minimum value of the potentiometer resistance range, it is determined to be off-track. The first abnormal situation: when the potentiometer resistance is greater than the maximum value of the potentiometer resistance range, it is determined to be a stuck state.

[0016] The beneficial effects of this invention are: a potential sensor is installed on the belt of the conveyor belt to monitor the status of the idler rollers of the entire belt. The potential sensor uses the method of converting friction into resistance for monitoring and monitors the status of the idler rollers under three working conditions; achieving fully automatic detection without manual intervention. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of a belt conveyor idler roller state potential method analysis system; Figure 2 This is a schematic diagram of a potential sensing component; Figure 3 This is a potential measurement diagram.

[0018] In the diagram: 1. Potential sensing component; 2. Signal acquisition system; 3. Service component; 4. Potentiometric analysis module; 5. Belt; 6. Idler roller; 11. Potentiometer; 12. Tensioning mechanism; 13. Friction block; 14. Connecting piece; 15. Housing; 31. Server; 32. PLC system; 33. Control terminal. Detailed Implementation

[0019] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0020] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0022] Example 1: This example provides a system for analyzing the state potential of conveyor belt idlers, see attached document. Figure 1 The belt conveyor roller state potential analysis system includes a potential sensing component 1, a signal acquisition system 2, and a service component 3; the service component 3 is connected to the potential sensing component 1 through the signal acquisition system 2.

[0023] See appendix Figure 2The potential sensing component 1 includes a potentiometer 11, a tensioning mechanism 12, and a friction block 13. The potentiometer 11 is connected to the friction block 13 through the tensioning mechanism 12. When the belt 5 is running, the potential sensing component 1 under the belt 5 moves forward with the belt 5 and continuously contacts and rubs against the idler roller 6 below. The idler roller 6 drives the friction block 13, which in turn drives the tensioning mechanism 12 to slide the slider of the potentiometer 11, thereby changing the resistance value of the potentiometer 11. Generally, three monitoring states are presented: off-belt state: no contact occurs, the friction block 13 has no displacement, and the output of the potentiometer 11 is 0; normal state: the idler roller 6 is driven, the friction block 13 is subjected to force and undergoes slight displacement, generating a small resistance; jammed state: the idler roller 6 is jammed, the friction block 13 is subjected to force and undergoes more displacement, generating a larger resistance.

[0024] The potential sensing component 1 includes a connecting piece 14 and a housing 15. A potentiometer 11, a tensioning mechanism 12, and a friction block 13 are fitted together on the inner side of the belt 5 via the connecting piece 14. The housing 15 covers the outer side of the potentiometer 11, the tensioning mechanism 12, and the friction block 13. A potential sensing component 1 is installed on the belt 5 of the conveyor belt to monitor the status of the idler rollers 6 along the entire belt 5. The potential sensing component 1 is located between the belt 5 and the idler rollers 6 and moves with the belt 5 in a cyclical motion.

[0025] The minimum resistance of the potentiometer 11 is 100Ω to 1000Ω. The maximum resistance of the potentiometer 11 can be adjusted according to the actual working conditions.

[0026] The tensioning mechanism 12 is a spring.

[0027] The signal acquisition system 2 includes two flat cables, which are wound around the outside of the belt 5. Each flat cable is connected to one end of a potentiometer 11. The flat cables are fully attached to the belt 5 and move synchronously with it. At the empty position on the belt 5, they connect to the PLC system 32 via a sliding contact structure, transmitting the resistance signal from the potentiometer 11 to the PLC system 32. This allows the PLC system 32 to measure the resistance value and analyze the changes in the resistance signal.

[0028] The resistance of each flat cable consists of two resistors connected in parallel, and the resistance value changes as the cable slides. Since the cable circumference is fixed, R11 + R112 is a constant. Considering a circumference of 200 meters and a resistance of 2 mm... 2 The resistance of the cross-section of the cable is about 1 ohm. According to the principle of parallel resistance, the resistance of each flat cable can be considered to be less than 1Ω. Compared with the minimum resistance of potentiometer 11, which is generally 100Ω to 1000Ω, it can be considered to have no impact on the qualitative analysis of the monitoring.

[0029] The service component 3 includes a server 31, a PLC system 32, and a control terminal 33. The PLC system 32 is connected to the server 31 and the control terminal 33, and the control terminal 33 performs operation and monitoring.

[0030] The server 31 includes a potentiometric analysis module 4.

[0031] The analysis method of the potentiometric analysis module 4 is as follows: The total number of idler rollers 6 on the conveyor belt is n, the running speed of the belt 5 is s meters per second, and the spacing between the idler rollers 6 is L. 拖 The distance of the idle section of belt 5 between the head and tail idlers 6 is L. 空 ,but: The time it takes for potentiometer 11 to pass through the two idler rollers 6 of the conveyor belt: t=L 拖 / s; The time it takes for potentiometer 11 to pass through all idler rollers 6: t 料 =n-1×t; The time it takes for potentiometer 11 to pass through all idler rollers 6: t 空 =L 空 / s; t 料 It is an objective time, traveling in tandem with the material. Potentiometer 11 is mounted on belt 5 and moves with belt 5. Because the distance between every two sensors is the same, t is the time it takes for potentiometer 11 to pass two adjacent idler rollers 6. 空 This refers to the sensor's return trip time, also known as the idle run time, which is the time from leaving the last idler roller 6 to returning to the first idler roller 6, measured by the distance L between the last idler roller 6 and the first idler roller 6. 空 In addition to speed.

[0032] Belt 5 running single cycle time: t 总 =t 料 +t 空 ; Where: L 空 ≈n×t; Belt 5 running single cycle time t 总 The time structure is regular; the data returned by potentiometer 11 generally presents {n-1 t, t... 空 Based on the cyclic characteristics of the data, an array is created to store the resistance data. A software algorithm is used to establish a preliminary model for data relationship analysis, and an analysis process model is also established. (See appendix.) Figure 3A potentiometric analysis module 4 is formed by mapping the resistance data one-to-one with the position of the idler roller 6 in the analysis process model. The potentiometric analysis module 4 monitors and analyzes the real-time data of each parameter. During normal production, the resistance data will present a conventional value fixed within a certain data range. This conventional value = the real-time value of potentiometer 11 + the resistance of the flat cable. The resistance of the flat cable is a negligible constant. The conventional value presented is the resistance value output by potentiometer 11 when it is stretched, and is set to ±20% of the real-time resistance value within a certain data range. When potentiometer 11 passes a certain idler roller 6 and the returned resistance data shows the following abnormality, it is determined that an idler roller 6 malfunction has occurred, and an alarm is triggered: The first abnormal situation: when the resistance value of potentiometer 11 is less than 1 / 10 of the minimum resistance range of potentiometer 11, it is determined to be off-track. The first abnormal situation: when the resistance of potentiometer 11 is greater than the maximum value of the resistance range of potentiometer 11, it is determined to be a stuck state.

[0033] Example 2: The belt conveyor roller state potential analysis system includes a potential sensing component 1, a signal acquisition system 2, and a service component 3; the service component 3 is connected to the potential sensing component 1 through the signal acquisition system 2.

[0034] See appendix Figure 2 The potential sensing component 1 includes a potentiometer 11, a tensioning mechanism 12, and a friction block 13. The potentiometer 11 is connected to the friction block 13 through the tensioning mechanism 12. When the belt 5 is running, the potential sensing component 1 under the belt 5 moves forward with the belt 5 and continuously contacts and rubs against the idler roller 6 below. The idler roller 6 drives the friction block 13, which in turn drives the tensioning mechanism 12 to slide the slider of the potentiometer 11, thereby changing the resistance value of the potentiometer 11. Generally, three monitoring states are presented: off-belt state: no contact occurs, the friction block 13 has no displacement, and the output of the potentiometer 11 is 0; normal state: the idler roller 6 is driven, the friction block 13 is subjected to force and undergoes slight displacement, generating a small resistance; jammed state: the idler roller 6 is jammed, the friction block 13 is subjected to force and undergoes more displacement, generating a larger resistance.

[0035] The potential sensing component 1 includes a connecting piece 14 and a housing 15. A potentiometer 11, a tensioning mechanism 12, and a friction block 13 are fitted together on the inner side of the belt 5 via the connecting piece 14. The housing 15 covers the outer side of the potentiometer 11, the tensioning mechanism 12, and the friction block 13. A potential sensing component 1 is installed on the belt 5 of the conveyor belt to monitor the status of the idler rollers 6 along the entire belt 5. The potential sensing component 1 is located between the belt 5 and the idler rollers 6 and moves with the belt 5 in a cyclical motion.

[0036] The minimum resistance of the potentiometer 11 is 100Ω. The maximum resistance of the potentiometer 11 can be adjusted according to the actual working conditions.

[0037] The tensioning mechanism 12 is a spring.

[0038] The signal acquisition system 2 includes two flat cables, which are wound around the outside of the belt 5. Each flat cable is connected to one end of a potentiometer 11. The flat cables are fully attached to the belt 5 and move synchronously with it. At the empty position on the belt 5, they connect to the PLC system 32 via a sliding contact structure, transmitting the resistance signal from the potentiometer 11 to the PLC system 32. This allows the PLC system 32 to measure the resistance value and analyze the changes in the resistance signal.

[0039] The resistance of each flat cable is composed of two resistors connected in parallel, and the resistance value changes as the cable slides.

[0040] The service component 3 includes a server 31, a PLC system 32, and a control terminal 33. The PLC system 32 is connected to the server 31 and the control terminal 33, and the control terminal 33 performs operation and monitoring.

[0041] The server 31 includes a potentiometric analysis module 4.

[0042] The analysis method of the potentiometric analysis module 4 is as follows: The total number of idler rollers 6 on the conveyor belt is n, the running speed of the belt 5 is s meters per second, and the spacing between the idler rollers 6 is L. 拖 The distance of the idle section of belt 5 between the head and tail idlers 6 is L. 空 ,but: The time it takes for potentiometer 11 to pass through the two idler rollers 6 of the conveyor belt: t=L 拖 / s; The time it takes for potentiometer 11 to pass through all idler rollers 6: t 料 =n-1×t; The time it takes for potentiometer 11 to pass through all idler rollers 6: t 空 =L 空 / s; Belt 5 running single cycle time: t 总 =t 料 +t 空 ; Where: L 空 ≈n×t; Belt 5 running single cycle time t 总 The time structure is regular; the data returned by potentiometer 11 generally presents {n-1 t, t... 空 Based on the cyclic characteristics of the data, an array is created to store the resistance data. A software algorithm is used to establish a preliminary model for data relationship analysis, and an analysis process model is also established. (See appendix.) Figure 3A potentiometric analysis module 4 is formed by mapping the resistance data one-to-one with the position of the idler roller 6 in the analysis process model. The potentiometric analysis module 4 monitors and analyzes the real-time data of each parameter. During normal production, the resistance data will present a conventional value fixed within a certain data range. This conventional value = the real-time value of potentiometer 11 + the resistance of the flat cable. The resistance of the flat cable is a negligible constant. The conventional value is the resistance value output by potentiometer 11 when it is stretched, and is set to ±10% of the real-time resistance value within a certain data range. When potentiometer 11 passes a certain idler roller 6 and the returned resistance data shows the following abnormality, it is determined that an idler roller 6 malfunction has occurred, and an alarm is triggered: The first abnormal situation: when the resistance value of potentiometer 11 is less than 1 / 10 of the minimum resistance range of potentiometer 11, it is determined to be off-track. The first abnormal situation: when the resistance of potentiometer 11 is greater than the maximum value of the resistance range of potentiometer 11, it is determined to be a stuck state.

Claims

1. A system for analyzing the state potential of conveyor belt idlers, characterized in that: It includes a potential sensing component (1), a signal acquisition system (2), and a service component (3); the service component (3) is connected to the potential sensing component (1) through the signal acquisition system (2).

2. The belt conveyor idler roller state potential analysis system according to claim 1, characterized in that: The potential sensing component (1) includes a potentiometer (11), a tensioning mechanism (12) and a friction block (13), with the potentiometer (11) connected to the friction block (13) via the tensioning mechanism (12).

3. The belt conveyor idler roller state potential method analysis system according to claim 2, characterized in that: The potential sensing component (1) includes a connecting piece (14) and a housing (15). The potentiometer (11), the tensioning mechanism (12) and the friction block (13) are attached to the inside of the belt (5) through the connecting piece (14), and the housing (15) covers the outside of the potentiometer (11), the tensioning mechanism (12) and the friction block (13).

4. The belt conveyor idler roller state potential method analysis system according to claim 1, characterized in that: The minimum resistance of the potentiometer (11) is 100Ω to 1000Ω.

5. The belt conveyor idler roller state potential method analysis system according to claim 4, characterized in that: The tensioning mechanism (12) is a spring.

6. The belt conveyor idler roller state potential method analysis system according to claim 5, characterized in that: The signal acquisition system (2) includes two flat cables, which are installed on the outside of the belt (5) and connected to the two ends of the potentiometer (11) respectively.

7. The belt conveyor idler roller state potential method analysis system according to claim 6, characterized in that: The resistance of each flat cable is composed of two resistors connected in parallel, and the resistance value changes as the cable slides.

8. The belt conveyor idler roller state potential method analysis system according to claim 7, characterized in that: The service component (3) includes a server (31), a PLC system (32) and a control terminal (33), with the PLC system (32) connected to the server (31) and the control terminal (33).

9. The belt conveyor idler roller state potential analysis system according to claim 1, characterized in that: The server (31) includes a potentiometric analysis module (4).

10. The belt conveyor idler roller state potential method analysis system according to claim 1, characterized in that: The analysis method of the potentiometric analysis module (4) is as follows: The total number of idler rollers (6) on the conveyor belt is n, the running speed of the belt (5) is s meters / second, and the spacing between the idler rollers (6) is L. 拖 The distance between the head and tail idlers (6) and the belt (5) running in the empty section is L. 空 ,but: The time it takes for the potentiometer (11) to pass through the two idlers (6) of the conveyor belt: t=L 拖 / s; The time it takes for the potentiometer (11) to pass through all the idlers (6): t 料 = (n-1)×t; The time it takes for the potentiometer (11) to pass through all the idlers (6): t 空 =L 空 / s; Belt (5) single cycle time: t 总 =t 料 +t 空 ; Where: L 空 ≈n×t; Belt (5) single cycle time t 总 The time structure is regular, and the data returned by the potentiometer (11) generally presents {n-1 t, t 空 Based on the cyclic characteristics of}, an array is established to store the resistance data. A primary model for data relationship analysis is established using software algorithms, and an analysis process model is established. The resistance data and the position of the roller (6) in the analysis process model are matched one-to-one to form a potential method analysis module (4). When the potentiometer (11) passes over a certain idler roller (6) and the returned resistance data shows the following abnormality, it is determined that the idler roller (6) is faulty and an alarm is triggered: The first abnormal situation: when the resistance value of potentiometer (11) is less than 1 / 10 of the minimum resistance range of potentiometer (11), it is determined to be off-track; The first abnormal situation: when the resistance of potentiometer (11) is greater than the maximum value of the resistance range of potentiometer (11), it is determined to be a stuck state.

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