Health monitoring and temperature measuring protection device of fast-assembly belt roller

Abstract

The invention provides a health monitoring and temperature measurement protection device for a fast-assembly belt roller. The health monitoring and temperature measurement protection device comprises a fast-assembly structure, a temperature measurement module, a micro-vibration module, a processing module, a transmission module and a self-calibration module. The fast assembly structure comprises a shell and a dovetail clamping rail arranged on the shell and used for being connected with an underground belt conveyor support in a clamping mode. The temperature measuring module, the micro-vibration module, the processing module, the transmission module and the self-calibration module are arranged on the outer surface of the shell. According to the invention, a dovetail clamping rail quick-mounting structure of an original device is reserved, a micro-vibration sensor is integrated, a three-level health state is judged through temperature-micro-vibration-temperature change rate coupling, interface multiplexing data transmission and low-power-consumption intermittent sampling are adopted, and field self-calibration and detection window pollution degree self-diagnosis design are matched; the device is more suitable for temperature measurement and health monitoring of a belt roller of a coal mine underground belt conveyor, realizes high-reliability identification and low maintenance amount, and ensures safe operation of equipment.

Description

Technical Field

[0001] This invention belongs to the field of safety monitoring technology for underground belt conveyors in coal mines, and relates to a health monitoring and temperature protection device for quick-installation belt rollers. Background Technology

[0002] Existing quick-installation belt temperature monitoring and protection devices offer advantages such as convenient installation and reliable temperature measurement, but they can only detect a single temperature and cannot identify the health status of the belt / drum. When the drum bearing is slightly worn or the belt is subtly jammed, the temperature change is slight, which can easily lead to false alarms or missed alarms, making it difficult to meet the safety requirements of "early prevention and control" for underground belt conveyors.

[0003] Existing industrial equipment health monitoring technologies (such as motor health monitoring devices) mostly adopt a dual-parameter design of "temperature + vibration", but there are three major adaptation problems: complex structure, additional modules require extra space, which destroys the compact structure of quick-installation devices; high power consumption (the power consumption of conventional vibration sensors is ≥100mW), which leads to a shortened service life of the device; lack of underground scenario-based judgment logic, and single parameter anomalies are easily affected by load fluctuations and dust interference, with a false judgment rate of over 15%, and disassembly and calibration are required for maintenance, which violates the original intention of "maintenance-free".

[0004] In summary, there is an urgent need for an underground conveyor belt temperature monitoring and protection device that combines quick installation, low power consumption, and high reliability in health identification, in order to address the compatibility and practicality deficiencies of existing technologies. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the present invention aims to provide a quick-installation health monitoring and temperature protection device for belt conveyors, particularly a quick-installation device for belt conveyor health monitoring and temperature protection based on multi-parameter coupling judgment. In this invention, the original device's dovetail rail quick-installation structure is retained, and a micro-vibration sensor is integrated. A three-level health status is determined through temperature-micro-vibration-temperature change rate coupling. Data transmission is achieved via interface multiplexing, and low-power intermittent sampling is used. Combined with on-site self-calibration and self-diagnosis design of detection window contamination, this invention is more suitable for temperature measurement and health monitoring of belt conveyor belts in underground coal mines, achieving highly reliable identification, low maintenance, and ensuring safe equipment operation.

[0006] To achieve this objective, the present invention adopts the following technical solution:

[0007] This invention provides a quick-installation health monitoring and temperature protection device for belt conveyors. The device includes a quick-installation structure, a temperature measurement module, a micro-vibration module, a processing module, a transmission module, and a self-calibration module. The quick-installation structure includes a housing and a dovetail rail mounted on the housing for engaging with a downhole belt conveyor support. The outer surface of the housing is provided with the temperature measurement module, the micro-vibration module, the processing module, the transmission module, and the self-calibration module, which are distributed on the inner wall of the housing. An experimental button is also provided on the outer surface of the housing. The self-calibration module is triggered by the experimental button to receive a standard signal from the central control terminal to correct the judgment threshold.

[0008] In this invention, the original device retains the dovetail rail quick-installation structure and integrates a micro-vibration sensor. It determines the three-level health status through temperature-micro-vibration-temperature change rate coupling, adopts interface multiplexing for data transmission, low-power intermittent sampling, and is equipped with on-site self-calibration and detection window contamination self-diagnosis design. It is more suitable for temperature measurement and health monitoring of belt rollers of belt conveyors in underground coal mines, achieving high reliability identification, low maintenance, and ensuring safe operation of equipment.

[0009] Preferably, the length of the shell is 120mm to 140mm, for example, it can be 120mm, 122mm, 124mm, 126mm, 128mm, 130mm, 132mm, 134mm, 136mm, 138mm, 140mm, etc., but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0010] Preferably, the width of the housing is 80mm to 90mm, for example, it can be 80mm, 82mm, 84mm, 86mm, 88mm, 90mm, etc., but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0011] Preferably, the height of the housing is 50mm to 60mm, for example, it can be 50mm, 52mm, 54mm, 56mm, 58mm, 60mm, etc., but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0012] Preferably, the temperature measurement module uses a temperature sensor.

[0013] Preferably, the temperature sensor is an infrared temperature sensor.

[0014] Preferably, the temperature detection range of the infrared temperature sensor is -70℃ to 380℃, for example, it can be -70℃, 100℃, 150℃, 200℃, 250℃, 300℃, 350℃, 380℃, etc., but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0015] Preferably, the temperature detection accuracy of the infrared temperature sensor is ±0.5℃.

[0016] Preferably, the weight detection range of the micro-vibration module is ±2g.

[0017] Preferably, the weight detection accuracy of the micro-vibration module is ±0.01g.

[0018] Preferably, the processing module includes a microcontroller unit, which is configured with a coupled judgment algorithm of temperature-temperature change rate-micro-vibration to output a three-level health status signal.

[0019] Preferably, the three-level health status signal output by the coupled temperature-temperature change rate-micro-vibration determination algorithm is:

[0020] Normal signals include temperature ≤80℃, temperature change rate ≤2℃ / min, and vibration ≤0.05g;

[0021] The warning signals include a temperature of 80℃~100℃, a temperature change rate of 2℃ / min~5℃ / min, and a vibration of 0.05~0.1g;

[0022] Fault signals include temperature > 100℃, temperature change rate > 5℃ / min, and vibration > 0.1g.

[0023] Preferably, in the normal signal, the warning signal, and the fault signal, at least two of the temperature parameter, the temperature change rate parameter, and the vibration parameter must be in the corresponding range for the signal level to be determined.

[0024] Preferably, the micro-vibration module employs an intermittent sampling method.

[0025] Preferably, the intermittent sampling method includes:

[0026] When the quick-installation belt pulley is operating normally, a sample is taken every 5 seconds.

[0027] When the quick-release belt roller malfunctions, switch to real-time sampling with an average power consumption of ≤45mW. For example, it can be 45mW, 40mW, 35mW, 30mW, 25mW, 20mW, etc., but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0028] Preferably, the inner wall of the housing is provided with a polytetrafluoroethylene (PTFE) moisture-proof layer, which is used to withstand 95% RH humidity.

[0029] Preferably, both the temperature measuring module and the micro-vibration module have a dust filter layer on their surfaces.

[0030] Preferably, the dust filter layer is dust filter cotton.

[0031] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of the present invention, nor is it intended to limit the scope of the invention. Other features of the invention will become readily apparent from the following description.

[0032] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0033] The health monitoring and temperature protection device of this invention solves the problems of existing quick-installation belt temperature measuring devices, such as limited functionality, lack of standards for health status determination, and the potential for damage to the quick-installation structure, increased power consumption, and complex maintenance caused by adding identification functions. It retains the original device's dovetail rail quick-installation structure, integrates a micro-vibration sensor, and determines a three-level health status through temperature-micro-vibration-temperature change rate coupling. It adopts interface multiplexing for data transmission, low-power intermittent sampling, and is equipped with on-site self-calibration and detection window contamination self-diagnosis design. It is used for temperature measurement and health monitoring of belts / rollers in underground coal mines, achieving highly reliable identification, low maintenance, and ensuring safe equipment operation. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0035] Figure 1 A schematic diagram of a health monitoring and temperature protection device provided in a specific embodiment of the present invention;

[0036] Figure 2 A side view of a health monitoring and temperature measurement protection device provided in a specific embodiment of the present invention;

[0037] Figure 3 A schematic diagram of the installation structure of the original waterproof aviation plug in a health monitoring and temperature measurement protection device provided in a specific embodiment of the present invention;

[0038] Among them, 1-shell; 2-dovetail rail; 3-temperature measurement module; 4-self-calibration module; 5-experiment button; 6-polytetrafluoroethylene moisture-proof layer; 7-original waterproof aviation plug. Detailed Implementation

[0039] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0040] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0041] It should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "set," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0042] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0043] In one specific embodiment, the present invention provides a quick-installation belt roller health monitoring and temperature protection device, such as... Figure 1 , Figure 2 , Figure 3As shown, the health monitoring and temperature protection device includes a quick-release structure, a temperature measurement module 3, a micro-vibration module, a processing module, a transmission module, and a self-calibration module 4. The quick-release structure includes a housing 1 and a dovetail rail 2 mounted on the housing 1 for engaging with the underground conveyor belt support. The outer surface of the housing 1 is provided with the temperature measurement module 3, the micro-vibration module, the processing module, the transmission module, and the self-calibration module 4, which are distributed on the inner sidewall of the housing. The outer surface of the housing 1 is also provided with an experimental button 5, which triggers the self-calibration module 4 to receive a standard signal from the central control terminal to correct the judgment threshold.

[0044] It should be noted that the technical problems solved by this invention include: existing quick-installation belt temperature measuring devices can only measure temperature and have no health status recognition function, so they cannot provide early warning of hidden faults; adding a health recognition function is easy to damage the quick-installation structure and increase power consumption, which conflicts with the requirements of "easy installation and long life"; the high humidity and dust environment underground leads to low reliability of the health recognition module, and there is no scenario-based judgment logic, resulting in a high false judgment rate; health status recognition requires disassembly and calibration, which is costly and does not meet the "non-disassembly" operation and maintenance requirements underground.

[0045] This invention retains the original device's dovetail rail 2 quick-installation structure and achieves health identification through "modular integration + scenario-based coupling judgment." The specific solution includes:

[0046] (1) Hardware module integration includes: Temperature measurement module 3 adopts an infrared temperature sensor with a detection range of -70℃ to 380℃ and an accuracy of ±0.5℃; Micro-vibration module integrates an industrial-grade sensor, which is attached to the inner wall of the outer shell near the roller side, with a detection range of ±2g and an accuracy of ±0.01g; Processing module uses a low-power MCU with a built-in coupling judgment algorithm; Transmission module reuses two redundant pins of the original waterproof aviation plug 7 (6 pins) and uses "differential signal + CRC check" to transmit temperature and health data; Self-calibration module 4 triggers the calibration mode through the "experiment button 5" on the surface of the device, receives the standard signal (simulated early warning / fault parameters) from the central control terminal, and automatically corrects the judgment threshold.

[0047] (2) The multi-parameter coupling judgment logic includes: based on three months of downhole measured data, a three-level health status judgment model of temperature-temperature change rate-micro-vibration is established, and the specific rules are as follows:

[0048] Normal signals include temperature ≤80℃, temperature change rate ≤2℃ / min, and vibration ≤0.05g; the output model display is as follows: no prompt.

[0049] The warning signals include a temperature range of 80℃~100℃, a temperature change rate of 2℃ / min~5℃ / min, and a vibration range of 0.05~0.1g; the output model is displayed as an audio-visual prompt from the central control terminal.

[0050] Fault signals include temperature > 100℃, temperature change rate > 5℃ / min, and vibration > 0.1g; the output model display shows a shutdown signal and an audible and visual alarm.

[0051] When a single parameter exceeds the threshold, at least one of the other two parameters must be within the corresponding range before it is determined to be of that level to avoid misjudgment.

[0052] (3) Low power consumption and harsh environment resistance design: The low power consumption adopts the "intermittent sampling algorithm" - real-time temperature sampling, micro-vibration sampling once every 5 seconds, and switching to real-time sampling when abnormal, with an average power consumption of ≤45mW; the inner wall of the anti-interference shell is coated with polytetrafluoroethylene moisture-proof layer 6 (resistant to 95%RH), and dust filter cotton is pasted on the sensor surface. The data transmission adopts differential signal to resist electromagnetic interference.

[0053] In some embodiments, the length of the housing 1 is 120mm to 140mm, for example, it can be 120mm, 122mm, 124mm, 126mm, 128mm, 130mm, 132mm, 134mm, 136mm, 138mm, 140mm, etc., but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0054] In some embodiments, the width of the housing 1 is 80mm to 90mm, for example, it can be 80mm, 82mm, 84mm, 86mm, 88mm, 90mm, etc., but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0055] In some embodiments, the height of the housing 1 is 50mm to 60mm, for example, it can be 50mm, 52mm, 54mm, 56mm, 58mm, 60mm, etc., but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0056] In some implementations, the temperature measurement module 3 uses a temperature sensor.

[0057] In some implementations, the temperature sensor is an infrared temperature sensor.

[0058] In some implementations, the temperature detection range of the infrared temperature sensor is -70℃ to 380℃, such as -70℃, 100℃, 150℃, 200℃, 250℃, 300℃, 350℃, 380℃, etc., but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0059] In some implementations, the temperature detection accuracy of the infrared thermometer is ±0.5℃.

[0060] In some implementations, the weight detection range of the micro-vibration module is ±2g.

[0061] In some implementations, the weight detection accuracy of the micro-vibration module is ±0.01g.

[0062] In some implementations, the processing module includes a microcontroller unit configured with a temperature-temperature change rate-micro-vibration coupling judgment algorithm for outputting a three-level health status signal.

[0063] In some implementations, the three-level health status signal output by the coupled temperature-temperature change rate-micro-vibration determination algorithm is:

[0064] Normal signals include temperature ≤80℃, temperature change rate ≤2℃ / min, and vibration ≤0.05g;

[0065] The warning signals include a temperature of 80℃~100℃, a temperature change rate of 2℃ / min~5℃ / min, and a vibration of 0.05~0.1g;

[0066] Fault signals include temperature > 100℃, temperature change rate > 5℃ / min, and vibration > 0.1g.

[0067] In some implementations, the temperature parameter, temperature change rate parameter, and vibration parameter in normal signals, warning signals, and fault signals must all have at least two parameters in the corresponding range to be determined as the corresponding signal level.

[0068] In some implementations, the micro-vibration module employs an intermittent sampling method.

[0069] In some implementations, intermittent sampling methods include:

[0070] When the quick-installation belt pulley is operating normally, a sample is taken every 5 seconds.

[0071] When the quick-release belt roller malfunctions, switch to real-time sampling with an average power consumption of ≤45mW. For example, it can be 45mW, 40mW, 35mW, 30mW, 25mW, 20mW, etc., but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0072] In some embodiments, the inner wall of the housing 1 is provided with a polytetrafluoroethylene (PTFE) moisture barrier 6, which is used to withstand 95% RH humidity.

[0073] In some implementations, both the temperature measuring module 3 and the micro-vibration module have a dust filter layer on their surfaces.

[0074] In some implementations, the dust filter layer is dust filter cotton.

[0075] It should be noted that the "three-parameter coupled health judgment" model for downhole belts / rollers proposed in this invention is novel and distinct from existing single-parameter or general health monitoring technologies. It retains the quick-installation structure, with an installation time of ≤10 minutes, an average power consumption of ≤45mW (service life ≥2 years), a health identification accuracy of ≥98.2%, and a false judgment rate of <2%. Through moisture-proof and dust-proof design, the MTBF is ≥10,000 hours, and on-site self-calibration does not require disassembly (5 minutes / time), meeting the needs of downhole operation and maintenance. It provides early warning of hidden faults 5-10 minutes in advance, avoiding accidents such as belt burnout and roller jamming, and improves the safety protection level by 30% compared with existing devices.

[0076] Example 1

[0077] This embodiment provides a quick-installation belt roller health monitoring and temperature protection device, wherein:

[0078] Take the No. 3 belt conveyor (800mm drum diameter, 1.2m / s belt speed) in a coal mine of Kailuan Group as an example.

[0079] Connect the health monitoring and temperature protection device to the side bracket of the roller via the dovetail rail 2 (50mm from the roller surface), insert the original waterproof aviation plug 7, and complete the wiring (takes 8 minutes).

[0080] Parameter initialization: The central control terminal sends a calibration signal (temperature 80℃, rate of change 2℃ / min, vibration 0.05g). Press the experimental button 5 on the device, and the MCU automatically stores the normal threshold.

[0081] When the roller bearing is slightly worn, the temperature rises to 85℃, the rate of change is 3℃ / min, and the vibration is 0.07g. The device will determine this as an early warning, and the central control terminal will issue an audible and visual alert. Maintenance personnel will complete the bearing lubrication within 2 hours to prevent the fault from escalating.

[0082] When the belt jams, the temperature rises sharply to 105℃, the rate of change is 6℃ / min, and the vibration is 0.13g. The health monitoring and temperature protection device immediately sends a shutdown signal and at the same time, a local audible and visual alarm is triggered. The belt conveyor stops within 10 seconds, and no equipment damage is caused.

[0083] Every 6 months, a standard calibration signal is sent through the central control terminal. Pressing the experiment button 5 completes the self-calibration without disassembling the health monitoring and temperature protection device.

[0084] In this embodiment, the device operated continuously for 3 months without any fault records, and the health identification accuracy rate was 98.5%, fully meeting the monitoring requirements of underground conveyor belts.

[0085] In summary, this invention retains the original device's dovetail rail 2 quick-installation structure, integrates a micro-vibration sensor, and determines the three-level health status through temperature-micro-vibration-temperature change rate coupling. It adopts interface multiplexing for data transmission, low-power intermittent sampling, and is equipped with on-site self-calibration and detection window contamination self-diagnosis design. It is more suitable for temperature measurement and health monitoring of belt rollers of underground belt conveyors in coal mines, achieving high reliability identification, low maintenance, and ensuring safe operation of equipment.

[0086] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A quick-installation belt roller health monitoring and temperature protection device, characterized in that, The health monitoring and temperature protection device includes a quick-release structure, a temperature measurement module, a micro-vibration module, a processing module, a transmission module, and a self-calibration module. The quick-assembly structure includes a housing and a dovetail rail mounted on the housing for engaging with the downhole conveyor belt support. The outer surface of the housing is provided with the temperature measurement module, the micro-vibration module, the processing module, the transmission module and the self-calibration module, and the micro-vibration module, the processing module, the transmission module and the self-calibration module are distributed on the inner sidewall of the housing; The outer surface of the housing is also provided with an experimental button. The self-calibration module is triggered by the experimental button and is used to receive the standard signal from the central control terminal to correct the judgment threshold.

2. The health monitoring and temperature measurement protection device according to claim 1, characterized in that, The length of the shell is 120mm~140mm; The width of the housing is 80mm~90mm; The height of the shell is 50mm~60mm.

3. The health monitoring and temperature measurement protection device according to claim 1 or 2, characterized in that, The temperature measurement module uses a temperature sensor; The temperature sensor is an infrared temperature sensor; The temperature detection range of the infrared temperature sensor is -70℃ to 380℃; The temperature detection accuracy of the infrared temperature sensor is ±0.5℃.

4. The health monitoring and temperature measurement protection device according to any one of claims 1-3, characterized in that, The weight detection range of the micro-vibration module is ±2g; The weight detection accuracy of the micro-vibration module is ±0.01g.

5. The health monitoring and temperature measurement protection device according to any one of claims 1-4, characterized in that, The processing module includes a microcontroller unit, which is configured with a coupled judgment algorithm of temperature-temperature change rate-micro-vibration to output a three-level health status signal.

6. The health monitoring and temperature measurement protection device according to claim 5, characterized in that, The three-level health status signal output by the coupled judgment algorithm of temperature-temperature change rate-micro-vibration is: Normal signals include temperature ≤80℃, temperature change rate ≤2℃ / min, and vibration ≤0.05g; The warning signals include a temperature of 80℃~100℃, a temperature change rate of 2℃ / min~5℃ / min, and a vibration of 0.05~0.1g; Fault signals include temperature > 100℃, temperature change rate > 5℃ / min, and vibration > 0.1g.

7. The health monitoring and temperature measurement protection device according to claim 6, characterized in that, In the normal signal, the warning signal, and the fault signal, at least two of the temperature parameters, temperature change rate parameters, and vibration parameters must be within the corresponding range to be determined as the corresponding signal level.

8. The health monitoring and temperature measurement protection device according to any one of claims 1-7, characterized in that, The micro-vibration module employs an intermittent sampling method; The intermittent sampling method includes: When the quick-installation belt pulley is operating normally, a sample is taken every 5 seconds. When the quick-installation belt pulley malfunctions, it switches to real-time sampling, with an average power consumption of ≤45mW.

9. The health monitoring and temperature measurement protection device according to any one of claims 1-8, characterized in that, The inner wall of the housing is provided with a polytetrafluoroethylene (PTFE) moisture-proof layer, which is designed to withstand 95% RH humidity.

10. The health monitoring and temperature measurement protection device according to any one of claims 1-9, characterized in that, Both the temperature measurement module and the micro-vibration module have a dust filter layer on their surfaces. The dust filter layer is dust filter cotton.

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