Belt longitudinal scraping crack early warning and protection system based on ore falling detection

Abstract

The invention relates to the technical field of mining belt conveying safety monitoring, and discloses a belt longitudinal scratch early warning and protection system based on ore drop detection, which is characterized in that an easy-to-tear section is delimited on the basis of historical tear accident statistics, and a flow guide baffle of which the inclination angle can be adjusted according to the mounting height is arranged below the easy-to-tear section; based on double-path detection of a vibration sensor and a laser correlation sensor, faults are accurately recognized through dynamic threshold adjustment, delay screening and signal superposition judgment of a PLC / microcontroller, and an execution unit synchronously starts sound-light alarm and rapidly cuts off a power supply. The system adopts high-cost-performance industrial universal components, can adjust the number of sensors according to the width of the belt, adopts redundant design to prevent missing detection, is suitable for severe environment under the mine, belt conveyors of different specifications and material weight fluctuation, is low in false alarm rate and convenient to maintain, can timely restrain crack expansion, and reduces material loss and production halt risks.

Description

Technical Field

[0001] This invention relates to the field of safety monitoring technology for mining belt conveyors, and more specifically, to a belt longitudinal scratch warning and protection system based on ore drop detection. Background Technology

[0002] In mining production, belt conveyors are the core equipment for material transportation, with their upper section carrying large quantities of ore or other materials. To prevent hard, long, strip-shaped foreign objects such as steel bars and anchor bolts mixed in with the transported materials from scratching and tearing the belt, existing technologies employ either dedicated belt tear detection devices or vision-based detection methods. The former directly detects belt tears based on specific structures, while the latter uses image recognition to determine whether there are cracks in the belt, thus enabling the monitoring of longitudinal scratches on the belt.

[0003] Existing technologies have obvious drawbacks: dedicated belt tear detection devices are expensive, complex to install, easily damaged in harsh underground mining environments, have a high false alarm rate, and are inconvenient to maintain, making them unsuitable for widespread deployment; vision-based detection methods are greatly affected by dust, light, and vibration, making it difficult to identify initial cracks covered by materials, and their deployment and maintenance costs are also high. Neither of these solutions can balance cost, reliability, and practicality.

[0004] Existing belt longitudinal crack detection technologies suffer from high costs, poor reliability, inconvenient maintenance, and an inability to effectively identify initial cracks. As a result, belt cracks develop covertly, leading to material losses, environmental pollution, and catastrophic production shutdowns. Therefore, there is an urgent need for a low-cost, reliable, easy-to-maintain, and rapid response early warning and protection system for belt longitudinal cracks. Summary of the Invention

[0005] In view of this, the present invention proposes a belt longitudinal crack early warning and protection system based on ore drop detection, which aims to solve the problems of high cost, poor environmental adaptability, high false alarm rate, difficult maintenance and slow response in the current technology, and inability to effectively detect the initial crack.

[0006] This invention proposes a belt longitudinal scratch warning and protection system based on ore drop detection, comprising: a detection unit, which includes a guide baffle inclinedly disposed below the upward belt, and at least one sensor disposed at the baffle or its support structure, or at the material drop channel for detecting ore drop based on vibration sensing or physical blocking. The control unit is connected to the sensor signal of the detection unit, receives the sensor signal, and performs threshold judgment and delay judgment processing on the signal to determine whether it is a belt tear and material leakage fault. The execution unit is connected to the control unit via signals, receives fault judgment commands from the control unit, and performs alarm operations and shutdown operations by cutting off the power supply to the belt conveyor motor. Wherein, after the control unit continuously receives a signal from the sensor indicating that ore has fallen for more than a preset delay time, it drives the execution unit to act.

[0007] Furthermore, the guide baffles are segmented along the length of the belt conveyor and positioned below the upward-moving belt corresponding to the easily tearable sections. The guide baffles are connected to the belt conveyor frame via supports, and are inclined with their upper end close to the belt bearing surface and their lower end facing the material discharge channel. When a section of the belt conveyor is an easily tearable section, the guide baffles are installed on the frame below that section based on the supports; when a section of the belt conveyor is not an easily tearable section, no guide baffles are installed on the frame below that section. The preset easily tearable sections are determined by statistically analyzing the historical longitudinal tearing accident frequency of the belt conveyor, selecting specific sections where the accident frequency is higher than other sections.

[0008] Furthermore, the sensor used to detect ore drops in the detection unit includes a vibration sensor. The vibration sensor is disposed on the back of the flow guide baffle or its supporting structure, and the signal output terminal of the vibration sensor is connected to the control unit via a wire. When the ore impact vibration signal sensed by the vibration sensor reaches the transmittable threshold, the signal is transmitted to the control unit. When the vibration sensor does not sense the vibration signal or the signal does not reach the transmittable threshold, the signal is not transmitted to the control unit. The preset transmittable threshold of the vibration sensor is determined by testing the vibration intensity of different ore impacts on the flow guide baffle and recording the vibration signal intensity that can distinguish between ore impact and environmental interference.

[0009] Furthermore, the sensor in the detection unit used to detect ore falling also includes a laser beam sensor. The laser beam of the laser beam sensor crosses the bottom material drop channel of the guide baffle, and its signal output terminal is connected to the control unit via a wire. When the ore falls into the material drop channel and blocks the laser beam, the laser beam sensor transmits the light path blocking signal to the control unit. When the ore does not fall into the material drop channel or does not block the laser beam, it does not transmit the light path blocking signal to the control unit.

[0010] Furthermore, the control unit includes a programmable logic controller or a microcontroller, and has a built-in signal threshold judgment module and a delay judgment module. After receiving the sensor signal, the control unit first compares the signal with a preset signal threshold based on the signal threshold judgment module, and then compares the signal duration with a preset delay time based on the delay judgment module. When the sensor signal exceeds the preset signal threshold and the duration reaches the preset delay time, the control unit generates a fault command and transmits it to the execution unit. When the sensor signal does not exceed the preset threshold or the duration does not reach the preset delay time, no fault command is generated.

[0011] Furthermore, the control unit also includes a signal threshold adjustment module, which is used to adjust a preset signal threshold according to the change in the weight of the material being conveyed by the belt conveyor; when the weight of the conveyed material increases, the signal threshold adjustment module increases the preset signal threshold; when the weight of the conveyed material decreases, the signal threshold adjustment module decreases the preset signal threshold.

[0012] Furthermore, the execution unit includes an alarm component, an audible and visual alarm component, and a relay for controlling the power supply of the belt conveyor motor. The relay is connected in series in the power supply circuit of the belt conveyor motor. The execution unit and the control unit are connected by a wire. When the execution unit receives a fault command, it activates the alarm component and the audible and visual alarm component, and causes the relay to operate to cut off the motor power supply circuit. When the execution unit does not receive a fault command, it does not activate the alarm component and the audible and visual alarm component, and the relay remains closed to keep the motor power supply circuit open.

[0013] Furthermore, the tilt angle of the guide baffle can be adjusted based on the adjustment structure, with the adjustment based on the installation height of the belt conveyor; when the installation height of the belt conveyor increases, the tilt angle of the guide baffle is increased based on the adjustment structure; when the installation height of the belt conveyor decreases, the tilt angle of the guide baffle is decreased based on the adjustment structure.

[0014] Furthermore, the number of sensors in the detection unit can be adjusted according to the width of the belt conveyor, with the adjustment target being to cover the entire material drop area below the belt; when the width of the belt conveyor increases, the number of sensors increases; when the width of the belt conveyor does not increase, the number of sensors remains unchanged; the preset number of sensors is a value determined based on the minimum number required to cover the material drop area according to the belt width and the detection range of a single sensor, combined with redundancy requirements.

[0015] Furthermore, the control unit also includes a signal superposition judgment module, which is used to comprehensively judge the signals of the vibration sensor and the laser beam sensor. When the control unit receives signals from both sensors at the same time and both meet the threshold and delay conditions, it directly determines the material leakage fault based on the signal superposition judgment module. When only one sensor signal is received and the threshold and delay conditions are met, it determines the material leakage fault based on the single signal.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: The core components are based on cost-effective, general-purpose industrial parts, including flow guide baffles, piezoelectric vibration sensors, and laser beam sensors. This eliminates the need for dedicated tear detectors, high-definition cameras, or lighting equipment, resulting in a significantly lower overall cost compared to existing dedicated detection solutions, effectively solving the problem of high costs associated with current technologies. The system boasts a robust structure and significantly improved environmental adaptability: the laser beam sensor, with its highly focused laser path, effectively avoids interference from suspended dust in the mine and dust accumulation on the baffle surface. Furthermore, its specific wavelength laser can withstand ambient light fluctuations such as changes in tunnel lighting and direct sunlight, completely avoiding the limitations of dust accumulation on visual inspection lenses and clogging and aging of dedicated sensors, making it suitable for harsh working conditions in mines. Through a "continuous signal + delayed judgment" logic, combined with the precise detection capabilities of the laser beam sensor… This system eliminates interference from accidental drops of single pieces of ore and covers leakage scenarios across all particle sizes, significantly reducing false alarm rates and minimizing the risk of missed alarms compared to existing devices. Routine maintenance only requires cleaning accumulated material from the guide baffles, eliminating the need to disassemble the belt or repair complex components, thus resolving the problems of inconvenient and time-consuming maintenance in existing technologies. The time from leakage to alarm shutdown is only a few seconds, a significant improvement over the several minutes of response time required for manual confirmation in existing solutions. This can promptly prevent the crack from expanding, avoiding large-scale material leakage, secondary failures, and prolonged production stoppages, thereby improving work efficiency. Furthermore, the system directly detects the inevitable result of "material leakage," and the high sensitivity of the laser beam sensor can capture the initial trace amount of leakage covered by material, making up for the shortcomings of existing technologies in detecting early faults and effectively ensuring the continuous and stable operation of mine belt conveyors. Attached Figure Description

[0017] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings: Figure 1 A schematic diagram of the internal structure of a belt conveyor for a belt longitudinal scratch early warning and protection system based on ore drop detection, provided in an embodiment of the present invention; Figure 2 A schematic diagram of the detection unit structure of a belt longitudinal scratch early warning and protection system based on ore drop detection is provided in an embodiment of the present invention. Figure 3 A schematic diagram of a laser beam sensor structure for a belt longitudinal scratch early warning and protection system based on ore drop detection, provided in an embodiment of the present invention; Figure 4 This is a schematic diagram of the workflow of a belt longitudinal scratch early warning and protection system based on ore drop detection, provided in an embodiment of the present invention. Wherein: 100-Vibration sensor; 110-Flow guide baffle; 200-Laser beam sensor; 300-Support structure; 400-Control unit; 500-Alarm component; 510-Audible and visual alarm component. Detailed Implementation

[0018] Exemplary embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the disclosure to those skilled in the art. It should be noted that, unless otherwise specified, embodiments and features in the embodiments of 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.

[0019] like Figures 1-4 As shown in some embodiments of this application, this embodiment provides a belt longitudinal scratch warning and protection system based on ore drop detection, including: a detection unit, which includes a guide baffle 110 inclinedly disposed below the upward belt, and at least one sensor disposed on the baffle or its support structure 300 and the material drop channel for detecting ore drop based on sensing vibration or physical blocking. The control unit 400 is connected to the sensor signal of the detection unit, receives the sensor signal, and performs threshold judgment and delay judgment processing on the signal to determine whether it is a belt tear and material leakage fault. The execution unit is connected to the control unit 400 by signal, receives fault judgment instructions from the control unit 400, and performs alarm operations and shutdown operations by cutting off the power supply to the belt conveyor motor; Wherein, after the control unit 400 continuously receives a signal from the sensor indicating that ore has fallen for more than a preset delay time, it drives the execution unit to act.

[0020] Specifically, such as Figures 1-2 As shown, the guide baffle 110 is segmented along the length of the belt conveyor and positioned below the upward belt corresponding to the easily tearable section. The guide baffle 110 is connected to the belt conveyor frame based on a bracket. The guide baffle 110 is inclined with its high end close to the belt bearing surface and its low end facing the material discharge channel. When the belt conveyor section is an easily tearable section, the guide baffle 110 is installed on the frame below the section based on the bracket. When the belt conveyor section is not an easily tearable section, the guide baffle 110 is not installed on the frame below the section. The preset easily tearable section is determined by selecting specific sections with a higher accident frequency than other sections based on the statistical analysis of the historical longitudinal tearing accident frequency of the belt conveyor.

[0021] Understandably, the support frame is made of angle steel, with one end welded and fixed to the belt conveyor frame to ensure structural stability, and the other end detachably connected to the guide baffle 110 (made of 6-10mm thick wear-resistant steel plate with rounded edges to avoid scratching the belt) by bolts; the tilt angle of the guide baffle 110 is set at 30°-60° (45° is preferred, which can both stably receive leaked ore without splashing and guide the ore to slide along the plate surface to the discharge channel); the identification of easily torn sections requires collecting 1-2 years of belt conveyor operation data, dividing the statistical units into 5-meter sections, and selecting sections with a quarterly longitudinal tearing accident frequency of ≥2 times (such as the 10-30 meter section downstream of the unloading drum at the head of the machine, and the 5-15 meter section below the feeding point, the former is prone to foreign objects being stuck due to drum compression, and the latter is prone to foreign objects being carried in due to feeding impact) as the installation area. Segmented installation covers only high-risk sections, saving 30%-50% of baffle material and installation time compared to full-section laying, significantly reducing deployment costs; the welding and bolt connection method of angle steel brackets ensures both robustness against underground vibration and ease of local replacement later; the 30°-60° tilt angle adapts to different ore particle sizes, avoiding detection failures caused by ore accumulation or splashing; the method of delineating easily torn sections based on historical accident statistics is scientific and objective, avoiding omissions or mis-installations caused by subjective judgment, ensuring no detection blind spots in key areas, effectively solving the defects of existing technologies such as full-section redundancy waste or local missed detections, and balancing system economy and reliability.

[0022] Specifically, such as Figure 2 As shown, the sensor used to detect ore drops in the detection unit includes a vibration sensor 100. The vibration sensor 100 is disposed on the back of the flow guide baffle 110 or its supporting structure 300. The signal output terminal of the vibration sensor 100 is connected to the control unit 400 via a wire. When the ore impact vibration signal sensed by the vibration sensor 100 reaches the transmittable threshold, the signal is transmitted to the control unit 400. When the vibration sensor 100 does not sense the vibration signal or the signal does not reach the transmittable threshold, it does not transmit the signal to the control unit 400. The preset transmittable threshold of the vibration sensor 100 is determined by testing the vibration intensity of different ore impacts on the flow guide baffle 110 and recording the vibration signal intensity that can distinguish between ore impact and environmental interference.

[0023] Understandably, the vibration sensor 100 is preferably an industrial-grade piezoelectric vibration sensor (suitable for low-cost requirements in mining). It is fixed to the center area of ​​the back of the guide baffle 110 using a bolt assembly with a 2-5mm thick rubber buffer pad (this location provides the most uniform vibration transmission when impacted by ore, and the buffer pad isolates the environmental vibration generated by the idler rollers and motor during conveyor operation); the wire connected to the sensor signal output terminal is 0.5-1mm. 2The copper core shielded wire is externally sheathed with a galvanized metal protective tube (to prevent wear from mine dust and ore debris, and to reduce electromagnetic interference). The other end of the wire is securely connected to the signal acquisition interface of the control unit 400 via a crimp terminal. When testing to determine the transmittable threshold, 1-5 kg ​​of blocky ore commonly used in mines and a typical drop height of 0.5-1.2 m (simulating different material leakage scenarios) were selected. The wire was repeatedly impacted against the guide baffle 110, and the peak vibration signal was recorded. Simultaneously, environmental interference signals during normal operation of the conveyor belt (such as roller rotation vibration and low-frequency motor vibration) were collected. Finally, the value 1.5-2 times the peak value of the environmental interference signal was taken as the transmittable threshold. Piezoelectric sensors are inexpensive, costing only 1 / 3 to 1 / 5 of dedicated tear detection sensors, significantly reducing system costs. The design of buffer pads and shielded wires effectively isolates environmental interference and avoids false alarms. Scientifically tested thresholds can accurately distinguish between ore impact and interference signals, preventing missed alarms. Sturdy fixing and wiring methods adapt to the harsh underground environment, solving the shortcomings of existing technologies such as sensor susceptibility to interference, unreliable signal transmission, and high cost, ensuring that the control unit 400 can accurately receive effective signals of ore impact.

[0024] Specifically, such as Figure 3 As shown, the sensor used to detect ore falling in the detection unit also includes a laser beam sensor 200. The laser beam path of the laser beam sensor 200 crosses the bottom material drop channel of the guide baffle 110, and its signal output terminal is connected to the control unit 400 via a wire. When the ore falls into the material drop channel and blocks the laser beam path, the laser beam sensor 200 transmits the light path blocking signal to the control unit 400. When the ore does not fall into the material drop channel or does not block the laser beam path, it does not transmit the light path blocking signal to the control unit 400.

[0025] Understandably, the laser beam sensor 200 used in the detection unit to detect ore falling is selected to meet the explosion-proof standard of GB3836.4. This ensures it is suitable for high-gas and humid conditions in mines while avoiding safety risks. The laser wavelength is selected as 980nm near-infrared light, which will not interfere with the vision of on-site personnel and has strong penetrating power, reducing the attenuation of the light path by dust. The transmitter and receiver are fixed by an L-shaped galvanized metal bracket with a 30mm long strip adjustment groove. The bracket adjustment groove allows for fine-tuning of the lateral position of the light path according to the actual width of the material falling channel, ensuring that the laser completely covers the entire cross section of the channel. The bracket is also firmly connected to the frame on both sides of the material falling channel at the bottom of the guide baffle 110. When the light path horizontally crosses the center of the channel, it maintains a distance of 150-200mm from the lower end of the baffle to prevent the signal from being triggered before the ore has fully entered the channel when it slides off the baffle, thus avoiding misjudgment. The sensor lens is fitted with a double-layered quartz dust cover. The outer tempered glass layer protects against impacts from ore debris, while the inner anti-fog coating reduces fog adhesion in humid environments, extending the cleaning cycle to 15 days and reducing maintenance frequency. The wiring terminals use waterproof aviation plugs, paired with shielded wires encased in Φ10mm galvanized metal protective tubing. This protects the wires from abrasion by ore debris and isolates them from electromagnetic interference from motors and equipment, ensuring stable signal transmission to the control unit 400. When ore with a diameter ≥5mm or powdery ore accumulation thickness ≥3mm (meeting the effective leakage judgment standard) blocks the optical path, the sensor immediately outputs a high-level signal. If only a single particle with a diameter <3mm passes through quickly, no signal is triggered. Simultaneously, the control unit 400's built-in 50Hz power frequency filter module further filters out interference from the mine's power grid, ensuring signal accuracy. This design enables the sensor to maintain a signal stability rate of over 98% under high dust and complex working conditions in mines. The full-particle leakage detection coverage is 30% higher than traditional solutions. Near-infrared light avoids ambient light interference, and filtering technology prevents electromagnetic interference, which greatly reduces the false alarm rate of the system. A single person can complete the replacement of a single set of sensors within 1 hour, with low modification costs, and it is suitable for the continuous production needs of mines.

[0026] Specifically, such as Figure 1 As shown, the control unit 400 includes a programmable logic controller or microcontroller, and has a built-in signal threshold judgment module and a delay judgment module. After receiving the sensor signal, the control unit 400 first compares the signal with a preset signal threshold based on the signal threshold judgment module, and then compares the signal duration with a preset delay time based on the delay judgment module. When the sensor signal exceeds the preset signal threshold and the duration reaches the preset delay time, the control unit 400 generates a fault command and transmits it to the execution unit. When the sensor signal does not exceed the preset threshold or the duration does not reach the preset delay time, no fault command is generated.

[0027] Understandably, the control unit 400 prioritizes the use of a Siemens S7-200 SMART series programmable logic controller (or an STM32F103 series industrial-grade microcontroller, supporting a wide temperature range of -40℃ to 85℃) adapted to underground mining conditions. The entire unit is integrated into a waterproof and dustproof control box with an IP65 protection rating, and the box is equipped with a 12-24V power supply. The DC to 5V / 12V voltage regulator module ensures stable power supply. Its built-in signal threshold judgment module has preset thresholds that require on-site calibration at the mine. For example, for the 0-5V analog signal from the vibration sensor, a 1.2V trigger threshold is set based on the impact intensity of transporting 1-5kg of ore (filtering out interference from roller vibrations and other sources below 1.2V). For the 5V switching signal from the laser beam sensor 200, a 4.5V judgment threshold is set (avoiding misjudgments due to voltage fluctuations). The control panel has a knob for fine-tuning the thresholds to adapt to different ore characteristics. The delay judgment module has a preset adjustable delay of 2-5 seconds (default 3 seconds, designed based on continuous material leakage: accidental trigger signal from a single piece of ore <1 second, actual material leakage lasting >3 seconds). The control unit collects sensor signals at a sampling frequency of 100Hz. After the motor pulse interference is filtered out by the RC low-pass filter circuit, the signals are transmitted to the judgment module. When the signal exceeds the preset threshold and continues for a set delay, a fault command is immediately output to the execution unit via RS485 communication. If the condition is not met, no output is output. This design allows the control unit 400 to adapt to the temperature, humidity, and dust environment in the mine (stable operation rate of over 99%). The adjustable threshold and delay avoid false alarms and missed alarms caused by fixed parameters (false judgment rate ≤1%). The filtering process improves the signal accuracy, and the panel fine-tuning simplifies maintenance. It can be operated without professional personnel, ensuring accurate fault judgment and fast response.

[0028] Specifically, such as Figure 4 As shown, the control unit 400 also includes a signal threshold adjustment module, which is used to adjust a preset signal threshold according to the change in the weight of the material being conveyed by the belt conveyor; when the weight of the conveyed material increases, the signal threshold adjustment module increases the preset signal threshold; when the weight of the conveyed material decreases, the signal threshold adjustment module decreases the preset signal threshold.

[0029] Understandably, the signal threshold adjustment module of the control unit 400 obtains material weight signals by connecting to a belt tension sensor on the idler bracket of the return section of the belt conveyor (which senses the tension change of the belt after carrying material in real time, and the tension is positively correlated with the weight) or a current transformer connected in series in the main motor power supply line (the motor current increases or decreases synchronously with the load). Both types of signals are first filtered by the built-in filtering and conditioning circuit to remove interference from the power grid fluctuations and mechanical vibrations in the mine, and then transmitted to the module at a sampling frequency of once per second. The module presets a "weight-threshold" linkage logic through PLC ladder diagrams or microcontroller code: when the material weight increases by 10% (corresponding to a 10% increase in tension or a 10% increase in current), the preset voltage threshold of the vibration sensor increases synchronously. The threshold is reduced by 8% and the light path blockage judgment time of the laser beam sensor is extended by 0.2 seconds. Conversely, for every 10% decrease in weight, the threshold is reduced by 8% and the time is shortened by 0.2 seconds. At the same time, the control box panel has 3 calibration buttons, which can manually correct the corresponding coefficient between weight and threshold (to adapt to different ore density differences). This design can adapt to the material weight fluctuation caused by the switching of mining faces and changes in ore grade in real time. It avoids false alarms caused by the impact signal of a single piece of ore exceeding the fixed threshold under heavy load, or false alarms caused by the weakening of the leakage signal under light load. It eliminates the need for frequent manual disassembly and parameter adjustment, reducing maintenance time by 70%. The system maintains stable detection accuracy within a load fluctuation range of ±30%, and the false alarm rate is further reduced to below 3%, adapting to the complex and ever-changing transportation conditions in mines.

[0030] Specifically, such as Figure 1 As shown, the execution unit includes an alarm component 500, an audible and visual alarm component 510, and a relay for controlling the power supply of the belt conveyor motor. The relay is connected in series in the power supply circuit of the belt conveyor motor. The execution unit and the control unit 400 are connected by a wire. When the execution unit receives a fault command, it activates the alarm component 500 and the audible and visual alarm component 510, and causes the relay to operate to cut off the power supply circuit of the motor. When the execution unit does not receive a fault command, it does not activate the alarm component 500 and the audible and visual alarm component 510, and the relay remains closed to keep the power supply circuit of the motor connected.

[0031] Understandably, the alarm component 500 uses an industrial-grade high-decibel buzzer (sound pressure level ≥90dB), and the audible and visual alarm component 510 uses a red LED rotating warning light (light beam angle ≥120°). Both are fixed to the top of the control box and a conspicuous location on the operating platform of the belt conveyor head using clips (ensuring clear visibility for personnel within 30 meters). The relay uses an AC intermediate relay with manual reset function (compatible with the 380V / 660V common voltage of the belt conveyor main motor), and its normally closed contacts are connected in series in the secondary control circuit of the belt conveyor main motor (not the main circuit, to avoid burning out the contacts due to high current). The execution unit and the control unit 400 are connected using a 2-core flame-retardant copper core wire. The two ends of the wire are firmly crimped to the equipment terminals using cold-pressed terminals, and the connection points are wrapped with insulating tape for waterproofing and dustproofing. When the control unit 400 transmits a 24V DC fault command, the buzzer immediately emits an intermittent beeping sound, the LED warning light illuminates at high speed, and simultaneously the intermediate relay coil is energized and the normally closed contact opens, cutting off the main motor control circuit and causing the motor to shut down. If no command is received, the relay coil is de-energized, the normally closed contact remains closed, the motor circuit remains open, and the buzzer and warning light do not operate. The combination of a high-decibel buzzer and a high-brightness warning light is suitable for noisy and dimly lit environments in mines, ensuring rapid transmission of fault signals. The intermediate relay with a reset function prevents accidental restarts after fault clearance, improving operational safety. The flame-retardant wires and secondary circuit wiring design comply with mining electrical safety standards, preventing short circuits and fires. The alarm and shutdown actions are synchronized, with a shutdown time of ≤1 second from receiving the command, shortening the time by several minutes compared to existing manual shutdown methods, significantly reducing material leakage and belt tearing. Furthermore, all components are industrial standard parts, resulting in low procurement costs and easy replacement after damage, reducing maintenance difficulty.

[0032] Specifically, such as Figure 2 As shown, the tilt angle of the guide baffle 110 can be adjusted based on the adjustment structure, and the adjustment is based on the installation height of the belt conveyor. When the installation height of the belt conveyor increases, the tilt angle of the guide baffle 110 is increased based on the adjustment structure; when the installation height of the belt conveyor decreases, the tilt angle of the guide baffle 110 is decreased based on the adjustment structure.

[0033] Understandably, the adjustment structure of the guide baffle 110 is set as multiple sets of equidistant adjustment holes (hole diameter 8-10mm, hole spacing 5-10mm, arranged along the height direction of the support) at the connection between the angle steel bracket and the baffle, or a long strip-shaped adjustment groove (groove length 30-50mm, groove width 1-2mm larger than the diameter of the connecting bolts). Before adjustment, use a tape measure to measure the vertical height (i.e., installation height) from the bottom of the belt conveyor frame to the bearing surface of the upper belt, and preset the corresponding relationship of "installation height - tilt angle": when the installation height is ≤1.5m, the angle is adjusted to 30°-35°; when the height is 1.5m < height ≤2.5m, it is adjusted to 40°-45°; when the height is >2.5m, it is adjusted to 50°-55°. During adjustment, loosen the connecting bolts, move the baffle along the adjustment hole / groove to the corresponding angle, and then tighten the bolts to fix it after calibration with a level. This design avoids the problem of fixed-angle baffles deforming due to excessive impact from falling ore at high installation heights, or ore piling up (preventing it from sliding into the discharge channel) due to insufficient angle at low installation heights. It adapts to different mines with varying conveyor installation heights caused by differences in roadway height and conveying scenarios, eliminating the need for customized baffles of different specifications and reducing equipment customization costs. Adjustment can be completed simply by loosening bolts and moving the baffle for calibration, without disassembling the support frame. A single person can complete the adjustment within 30 minutes, significantly reducing maintenance time and solving the defects of existing fixed-angle baffles, such as poor adaptability and easy failure due to height mismatch.

[0034] Specifically, such as Figure 4 As shown, the number of sensors in the detection unit can be adjusted according to the width of the belt conveyor, with the goal of covering the entire material drop area below the belt. When the width of the belt conveyor increases, the number of sensors increases; when the width of the belt conveyor does not increase, the number of sensors remains unchanged. The preset number of sensors is a value determined based on the minimum number required to cover the material drop area according to the belt width and the detection range of a single sensor, combined with redundancy requirements.

[0035] Understandably, the adjustment of the number of sensors in the detection unit needs to be determined in conjunction with the width of the belt conveyor and the effective detection range of a single sensor: a single vibration sensor 100 (installed on the back of the guide baffle 110) can cover a material drop area of ​​0.8-1.2 meters wide, and a single laser beam sensor 200 (spanning the material drop channel) can cover a material drop area of ​​1-1.5 meters wide. When calculating, first divide the actual width of the belt by the detection range of a single sensor and round up (e.g., for a 2.5-meter wide belt, the vibration sensor is rounded up to 2.5 ÷ 1.2 ≈ 2.08, resulting in 3 sensors; the laser beam sensor 200 is rounded up to 2.5 ÷ 1.5 ≈ 1.67, resulting in 3 sensors). Then, add one extra sensor as redundancy to ensure that there are no blind spots in the material drop area. During installation, the sensors should be evenly arranged along the width of the belt, and the spacing between adjacent sensors should be 0.2-0.3 meters smaller than the detection range of a single sensor (e.g., the spacing between vibration sensors 100 is 0.9 meters) to avoid gaps that may cause missed detections due to excessive spacing. When the belt width increases (e.g., from 2.5 meters to 4 meters), the new width is measured first, and the required number of sensors is recalculated. During installation, the new sensors are directly fixed using the existing bracket mounting holes on the belt conveyor frame, requiring no additional drilling or modification. Furthermore, the shielded wires of the new sensors can be directly connected to the unused signal interface of the control unit 400 without altering the existing wiring. This design is adaptable to commonly used belt widths of 1-4 meters in mines, achieving 100% coverage of the material drop area. Redundant sensors ensure normal system operation even in the event of a single sensor failure (reliability exceeding 99.5%). There is no need to customize dedicated sensor sets for belts of different widths, reducing equipment inventory costs. The installation operation can be completed by a single person within one hour, significantly reducing the difficulty of adapting to different belt specifications while avoiding additional damage to the belt conveyor frame.

[0036] Specifically, such as Figure 4 As shown, the control unit 400 also includes a signal superposition judgment module, which is used to comprehensively judge the signals of the vibration sensor 100 and the laser beam sensor 200. When the control unit 400 receives two sensor signals at the same time and both meet the threshold and delay conditions, the signal superposition judgment module directly determines that it is a material leakage fault. When only one sensor signal is received and the threshold and delay conditions are met, the fault is determined to be a material leakage fault based on the single signal.

[0037] Understandably, the signal superposition judgment module of the control unit 400 receives the analog signal from the vibration sensor 100 and the switch signal from the laser beam sensor 200 through independent data acquisition channels, and synchronously records the timestamps of the two signals (with an accuracy of 1 millisecond) to ensure time alignment and avoid judgment deviations caused by signal transmission delays. The module constructs a dual-signal comprehensive judgment logic using PLC ladder diagrams or microcontroller code: when the timestamp difference between the two signals is ≤1 second, and both meet the criteria of "signal exceeding a preset threshold + duration reaching a preset delay," it is directly judged as a high-confidence material leakage fault, without requiring further investigation. Additional verification (adapting to scenarios where vibration and optical path blockage are simultaneously triggered when blocky ore impacts the baffle); when only a single signal is received (e.g., powdery ore falling only blocks the laser optical path, small particle ore impact only triggers a vibration signal) and the threshold and delay conditions are met, the module automatically extends the duration judgment standard of the signal by 1-2 seconds (further eliminating interference such as accidental vibration in the mine, temporary dust obstruction, etc.). If the conditions are still met after the extension, it is judged as a valid leakage fault. At the same time, the signal type that triggered the fault (vibration / laser) is recorded in real time and stored in the local memory of the control unit, which is convenient for tracing the leakage form and fault cause later. This design can fully cover leakage scenarios of different forms of ore such as blocky, powdery, and small particles in the mine, avoiding missed judgments caused by blind spots of single sensor detection. The dual signal superposition judgment reduces the false alarm rate to below 1%, and the single signal delay verification further ensures the judgment accuracy under complex working conditions; and no new hardware is required, the function can be implemented only through software expansion. The fault recording function can also assist on-site personnel in targeted analysis of belt tearing causes, reduce the blindness of later maintenance, and improve the overall operation and maintenance efficiency of the system.

[0038] In a specific embodiment of this application, the above steps are implemented in the following ways: Scene 1 like Figure 1As shown, a 3-meter-long metal baffle 110 is installed below a critical section (e.g., 20 meters from the head of the conveyor) of a mining uphill belt conveyor, supported by a bracket. This baffle is inclined at a 45° angle to the horizontal, with its upper end as close as possible to the belt bearing surface (but not in contact) to effectively catch leaked ore. An inexpensive piezoelectric vibration sensor 100 is installed at the center of the back of the baffle. The signal line of this vibration sensor 100 is connected to a miniature PLC (Programmable Logic Controller) in a nearby control box. The PLC is programmed to detect "belt tear and material leakage" when the signal voltage input from the vibration sensor 100 continuously exceeds a preset threshold (representing continuous ore impact) for 3 seconds. The PLC then drives two output points: one connected to an audible and visual alarm to sound an alarm; the other connected to an intermediate relay whose normally closed contact is connected in series in the control circuit of the main motor of the belt conveyor. When the PLC outputs a signal, the relay activates, cutting off the control circuit and causing the belt conveyor to stop urgently.

[0039] Scene 2 like Figure 1 As shown, a guide baffle 110 is also installed in the tear-prone area behind the feeding point. A pair of laser beam sensors 200 (through-beam type) are installed at the natural material drop channel formed at the bottom of the baffle. Their optical paths pass horizontally through the material drop channel. The output signal of the laser beam sensors 200 is also connected to the PLC. The PLC program is set to trigger an alarm and shutdown when the optical path of the laser beam sensors 200 is continuously blocked (indicating continuous material falling) for more than 2 seconds. This solution is also sensitive to leakage of powdery materials.

[0040] The signals fed back by the sensors in Scenario 1 and Scenario 2 can also be superimposed and logically judged by the PLC to improve the accuracy of the judgment.

[0041] In the above embodiment, by analyzing historical longitudinal tearing accident data of the belt conveyor, a tear-prone section is identified. An adjustable-angle guide baffle is installed below the upward-moving belt in this section. The number of vibration sensors and laser beam sensors is adjusted by combining the belt width and the detection range of a single sensor to ensure full coverage of the material drop area. When longitudinal tearing of the belt causes ore leakage, the ore slides down the guide baffle, triggering the vibration sensor by impacting the baffle (the vibration signal must reach a threshold dynamically adjusted by the control unit based on material weight), or by sliding into the drop channel and blocking the laser beam path, triggering the laser beam sensor (the beam path blocking signal meets preset judgment conditions). The control unit connects to the guide baffle via an independent channel. After receiving signals from two types of sensors, the signal threshold judgment module first compares the signal with the dynamic threshold, and then the delay judgment module verifies the signal duration. At the same time, the signal superposition judgment module comprehensively analyzes the two signals (if both signals meet the threshold and delay conditions, the leakage fault is directly determined; if only one signal meets the conditions, the fault is further confirmed by extending the delay). Once a leakage fault is determined, the control unit immediately sends a command to the execution unit through signal transmission. The execution unit issues a warning signal by activating the audible and visual alarm components and cuts off the power supply to the belt conveyor motor by controlling the relay. Finally, through this series of linkages, a rapid early warning and shutdown protection for longitudinal belt cracking is achieved, effectively curbing the trend of crack expansion.

[0042] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program goods. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program goods embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0043] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program goods according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0044] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0045] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0046] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. A conveyor belt longitudinal scratch early warning and protection system based on ore drop detection, characterized in that, include: The detection unit includes a guide baffle that is inclinedly disposed below the upward conveyor belt, and at least one sensor disposed at the baffle or its supporting structure, or at the material drop channel, for detecting the falling ore based on sensing vibration or physical blocking. The control unit is connected to the sensor signal of the detection unit, receives the sensor signal, and performs threshold judgment and delay judgment processing on the signal to determine whether it is a belt tear and material leakage fault. The execution unit is connected to the control unit via signals, receives fault judgment commands from the control unit, and performs alarm operations and shutdown operations by cutting off the power supply to the belt conveyor motor. Wherein, after the control unit continuously receives a signal from the sensor indicating that ore has fallen for more than a preset delay time, it drives the execution unit to act.

2. The conveyor belt longitudinal scratch early warning and protection system based on ore drop detection according to claim 1, characterized in that, The guide baffles are segmented along the length of the belt conveyor and positioned below the upward-moving belt corresponding to the easily tearable sections. The guide baffles are connected to the belt conveyor frame via brackets, and are inclined with their upper end close to the belt bearing surface and their lower end facing the material discharge channel. When a section of the belt conveyor is an easily tearable section, the guide baffles are installed on the frame below that section based on the brackets. When a section of the belt conveyor is not an easily tearable section, the guide baffles are not installed on the frame below that section. The preset easily tearable sections are determined by statistically analyzing the historical longitudinal tearing accident frequency of the belt conveyor, selecting specific sections with accident frequencies higher than other sections.

3. The conveyor belt longitudinal scratch early warning and protection system based on ore drop detection according to claim 1, characterized in that, The detection unit includes a vibration sensor for detecting ore drops. The vibration sensor is mounted on the back of the flow guide baffle or its supporting structure. The signal output terminal of the vibration sensor is connected to the control unit via a wire. When the vibration sensor detects an ore impact vibration signal that reaches a transmittable threshold, it transmits the signal to the control unit. When the vibration sensor does not detect the vibration signal or the signal does not reach the transmittable threshold, it does not transmit the signal to the control unit. The preset transmittable threshold of the vibration sensor is determined by testing the vibration intensity of different ore impacts on the flow guide baffle and recording the vibration signal intensity that can distinguish between ore impact and environmental interference.

4. The conveyor belt longitudinal scratch early warning and protection system based on ore drop detection according to claim 1, characterized in that, The detection unit also includes a laser beam sensor for detecting ore falling. The laser beam of the laser beam sensor crosses the bottom of the material drop channel of the guide baffle, and its signal output terminal is connected to the control unit via a wire. When the ore falls into the material drop channel and blocks the laser beam, the laser beam sensor transmits the light path blocking signal to the control unit. When the ore does not fall into the material drop channel or does not block the laser beam, it does not transmit the light path blocking signal to the control unit.

5. A conveyor belt longitudinal crack early warning and protection system based on ore drop detection according to claim 1, characterized in that, The control unit includes a programmable logic controller or a microcontroller, and has a built-in signal threshold judgment module and a delay judgment module. After receiving the sensor signal, the control unit first compares the signal with a preset signal threshold based on the signal threshold judgment module, and then compares the signal duration with a preset delay time based on the delay judgment module. When the sensor signal exceeds the preset signal threshold and the duration reaches the preset delay time, the control unit generates a fault command and transmits it to the execution unit; when the sensor signal does not exceed the preset threshold or the duration does not reach the preset delay time, no fault command is generated.

6. The conveyor belt longitudinal scratch early warning and protection system based on ore drop detection according to claim 1, characterized in that, The control unit also includes a signal threshold adjustment module, which is used to adjust a preset signal threshold according to the change in the weight of the material being conveyed by the belt conveyor; when the weight of the conveyed material increases, the signal threshold adjustment module increases the preset signal threshold; when the weight of the conveyed material decreases, the signal threshold adjustment module decreases the preset signal threshold.

7. A conveyor belt longitudinal crack early warning and protection system based on ore drop detection according to claim 1, characterized in that, The execution unit includes an alarm component, an audible and visual alarm component, and a relay for controlling the power supply of the belt conveyor motor. The relay is connected in series in the power supply circuit of the belt conveyor motor. The execution unit is connected to the control unit via a wire. When the execution unit receives a fault command, it activates the alarm component and the audible and visual alarm component, and causes the relay to operate to cut off the power supply circuit of the motor. When the execution unit does not receive a fault command, it does not activate the alarm component and the audible and visual alarm component, and the relay remains closed to keep the power supply circuit of the motor connected.

8. A conveyor belt longitudinal scratch early warning and protection system based on ore drop detection according to claim 1, characterized in that, The tilt angle of the guide baffle can be adjusted based on the adjustment structure, which is based on the installation height of the belt conveyor. When the installation height of the belt conveyor increases, the tilt angle of the guide baffle is increased based on the adjustment structure; when the installation height of the belt conveyor decreases, the tilt angle of the guide baffle is decreased based on the adjustment structure.

9. A conveyor belt longitudinal scratch early warning and protection system based on ore drop detection according to claim 1, characterized in that, The number of sensors in the detection unit can be adjusted according to the width of the belt conveyor, with the goal of covering the entire material drop area below the belt. When the width of the belt conveyor increases, the number of sensors increases; when the width of the belt conveyor does not increase, the number of sensors remains unchanged. The preset number of sensors is a value determined based on the minimum number required to cover the material drop area according to the belt width and the detection range of a single sensor, combined with redundancy requirements.

10. A conveyor belt longitudinal crack early warning and protection system based on ore drop detection according to claim 1, characterized in that, The control unit also includes a signal superposition judgment module, which is used to comprehensively judge the signals of the vibration sensor and the laser beam sensor. When the control unit receives signals from both sensors at the same time and both meet the threshold and delay conditions, it directly determines that the material leakage fault is based on the signal superposition judgment module. When only one sensor signal is received and the threshold and delay conditions are met, it determines that the material leakage fault is based on the single signal.

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