System and method for guaranteeing continuous power supply of belt conveyor protection device

Abstract

The invention provides a system and method for guaranteeing continuous power supply of a belt conveyor protection device, and relates to the technical field of continuous power supply, a main power supply module, a fault isolation module, a signal transmission module, a control module, an alarm module and a standby power supply module are used for receiving a signal of the signal transmission module, executing dynamic deviation calculation and dynamic threshold adjustment, and outputting the result. Fault judgment is carried out, and a control instruction is output; a lithium battery pack is adopted by the standby power supply module, emergency power supply is started immediately when main power supply is interrupted or fault isolation acts, continuous operation of the core module and the protection device is ensured, protection function failure caused by power failure is avoided, and the operation reliability of the system is further improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of continuous power supply, in particular to a system and method for guaranteeing continuous power supply of a belt conveyor protection device. BACKGROUND

[0002] As a key conveying equipment in industrial production, the belt conveyor is widely used in the continuous production process of various industrial and trade enterprises, and its stable operation is directly related to production efficiency and job safety. In order to ensure the reliable operation of the belt conveyor, three types of core protection devices are usually configured, namely the pull rope switch, the deviation detection switch and the slip detection switch. Since these protection devices need to be laid on site along the installation track of the belt conveyor, the power supply circuit needs to be laid synchronously along the belt frame, and the pull rope switch and the deviation detection switch usually need to be installed at multiple points. The power supply of multiple detection switches is connected in parallel, resulting in a large number of cable connection heads in the power supply circuit.

[0003] Under complex industrial site conditions, a large number of connection heads are prone to dust accumulation, and cables are prone to damage due to squeezing and impact when the belt conveyor is operating, which can easily cause circuit short circuit or ground fault. In addition, the protection device and the start-stop circuit are powered by the same circuit, so a fault will directly cause the control circuit to trip and the belt conveyor to stop, resulting in production loss and safety risks. Moreover, the existing fault detection and response mechanism generally adopts a static threshold with a simple structure for immediate response. The pre-set and fixed static threshold is directly compared. Once the real-time signal exceeds the static threshold, the system determines that there is a fault and immediately triggers an alarm or even performs power-off tripping. This method cannot effectively filter transient interference, has a high false alarm rate, is not sensitive to slowly deteriorating hidden dangers, and has a high risk of missed judgment.

[0004] Therefore, it is necessary to provide a new system and method for guaranteeing continuous power supply of a belt conveyor protection device to solve the above technical problems. SUMMARY

[0005] To solve the above technical problems, the present application provides a system and method for guaranteeing continuous power supply of a belt conveyor protection device.

[0006] The system and method for guaranteeing continuous power supply of a belt conveyor protection device provided by the present application include: a main power supply module for providing main power input for a start-stop circuit, each module and a protection device;

[0007] A fault isolation module is used to connect the main power supply module and the protection device, and cut off the power supply of the faulty protection device.

[0008] A signal transmission module is used to collect fault signals of the fault isolation module and transmit them to a control module.

[0009] The control module is used to receive signals from the signal transmission module, perform dynamic deviation calculation and dynamic threshold adjustment, determine faults, and output control commands.

[0010] The alarm module is used to receive instructions from the control module and execute tiered alarms. In the event of a real fault, it triggers an audible and visual alarm and a pop-up alarm on the screen. In the event of a hidden hazard, it only triggers a pop-up warning on the screen and marks it.

[0011] The backup power supply module is used to temporarily supply power to each module after the main power supply module is temporarily interrupted or the fault isolation module is activated.

[0012] The control module includes:

[0013] This system is used for fault diagnosis. It obtains the real-time deviation value by comparing the real-time operating parameter value of the protection device with the historical operating parameter value. The calculated real-time deviation value is compared with the deviation level range pre-stored in the storage unit to determine the level to which the real-time deviation belongs. The duration of the deviation at a specific deviation level is timed and analyzed to determine whether the deviation state is instantaneous or continuous. If the real-time deviation is instantaneous and recovers quickly, a positive real-time compensation value for the basic threshold is output. If the real-time deviation is continuous or shows a stable increasing trend, a negative real-time compensation value is output. Combined with recent continuous real-time deviation data, the system analyzes its direction and rate of change to determine whether the deviation tends to increase, decrease, or remain stable. If the real-time deviation fluctuates randomly within the normal range, a real-time compensation value of zero is output. The real-time dynamic threshold is obtained by adding the real-time compensation value to the basic threshold of the protection device, thereby achieving accurate fault diagnosis and avoidance of false alarms.

[0014] The digital input unit is used to receive the digital signal converted by the signal transmission module;

[0015] The digital output unit is used to output control commands to the alarm module, fault isolation module and backup power supply module;

[0016] The storage unit is used to store the operating parameters, deviation data, deviation level range, basic threshold, and fault records of the protection device.

[0017] The real-time deviation value is obtained by matching the real-time parameter with the corresponding historical benchmark one-to-one. The absolute deviation is calculated as the real-time value minus the benchmark value, and the relative deviation is calculated as the real-time value minus the benchmark value divided by the benchmark value multiplied by 100%. The final real-time deviation value is determined according to the principle of relative deviation priority. In case of an anomaly, the absolute deviation is switched to serve as the core quantitative basis for subsequent deviation level determination.

[0018] The protection device includes a pull rope switch, a deviation detection switch, and a slippage detection switch. The power terminals of each switch are connected in parallel to the output terminals of the fault isolation module.

[0019] The fault isolation module includes a 6A miniature circuit breaker. When the 6A miniature circuit breaker is in the closed state, the power from the main control power supply is delivered to the protection device circuit through the 6A miniature circuit breaker to continuously supply power to the pull rope, deviation and slippage switches.

[0020] The signal transmission module includes an intermediate relay, which has two sets of structures: a coil and contacts. The coil is the input terminal, and the contacts are the output terminals. It serves as a signal bridge connecting the fault isolation module and the control module, converting the mechanical status signal of the 6A miniature circuit breaker into an electrical signal that the control module can recognize. At the same time, it amplifies the signal and achieves electrical isolation.

[0021] Fault determination is divided into normal operation, potential hidden dangers, and fault alarm. Normal operation: the real-time deviation does not exceed the real-time dynamic threshold and the deviation is stable. There are no alarms or warning actions. Only the operating parameters are continuously recorded to accumulate data for the optimization of the benchmark parameters.

[0022] Potential hazard: The real-time deviation does not exceed the real-time dynamic threshold, but the deviation is increasing, triggering a pop-up warning on the screen, marking the potential hazard, without cutting off the power supply or starting the backup power supply, and continuously tracking the change in deviation;

[0023] Fault alarm: If the real-time deviation exceeds the real-time dynamic threshold and shows an increasing trend, or if the real-time deviation significantly exceeds the threshold, a graded alarm will be triggered immediately, and the 6A miniature circuit breaker will be tripped to isolate the fault circuit. The backup power supply module will be started to ensure the continuous operation of the core module and protection device.

[0024] The backup power supply module uses a lithium battery pack as an emergency power source, with a rated output voltage consistent with the main power supply module, providing continuous emergency power supply capability.

[0025] A method for ensuring continuous power supply to a belt conveyor protection device includes the following steps:

[0026] S1: System startup self-test: After the system is powered on, the main power supply module initializes, the control module performs a self-test of each module and protection device, retrieves historical parameters and preset thresholds, and enters standby mode if there are no abnormalities.

[0027] S2: Main power supply is turned on: The control module commands the 6A miniature circuit breaker to close, and the main power supply is transmitted to each protection device through the circuit. The system starts real-time monitoring.

[0028] S3: Data Acquisition and Threshold Calculation: The signal transmission module acquires the circuit breaker status and protection device operating parameters, converts and transmits them to the control module. The control module calculates the real-time deviation, determines the level to which the real-time deviation belongs, performs timing analysis on the duration of the deviation at a specific level, and analyzes the direction and rate of change by combining recent continuous real-time deviation data. Based on the real-time dynamic threshold being equal to the basic threshold plus the real-time compensation value, false alarms are avoided.

[0029] S4: Deviation Comparison and Delay Monitoring: Based on the real-time dynamic threshold, deviation monitoring is carried out. When the real-time deviation is within the threshold, the main power supply mode is maintained, parameters are continuously collected and updated to the storage unit to accumulate data for historical benchmark optimization and dynamic threshold adjustment. When the deviation exceeds the threshold, the delay confirmation mechanism is immediately activated. The deviation is sampled and recorded at fixed intervals to provide accurate basis for subsequent classification judgment.

[0030] S5: Tiered Response: If the deviation continues to exceed the threshold and meets the fault characteristics, it is determined to be a real fault. First, the 6A miniature circuit breaker is tripped to isolate the fault circuit. Then, the audible and visual alarms and the screen pop-up alarm are triggered. Simultaneously, the lithium battery pack is started for emergency power supply to ensure the continuous operation of the core module and protection device. If the deviation exceeds the threshold but does not meet the fault judgment standard and shows a potential growth trend, only the screen pop-up warning is triggered and the type of hidden danger is marked. The power supply is not cut off and the backup power supply is not started. The subsequent deviation change trend is continuously tracked to ensure the balance between fault handling and production continuity.

[0031] S6: Fault Repair and Recovery: After troubleshooting and repairing the fault, reset the circuit breaker. If the control module is checked and no abnormality is found, switch back to the main power supply mode and clear the alarm.

[0032] S7: Emergency response to main power supply interruption: When the main power supply is interrupted, the backup power supply will be activated immediately, and the main power supply will automatically switch back to the main power supply after it is restored.

[0033] Compared with related technologies, the system and method for ensuring continuous power supply to the belt conveyor protection device provided by the present invention have the following beneficial effects:

[0034] 1. By introducing dynamic threshold adjustment, the system systematically solves the problems of frequent false alarms, missed detection of hidden dangers, and rigid response methods caused by static thresholds and instantaneous response structures in traditional protection systems. It ensures accurate quantification of deviation data by quantitatively calculating real-time deviation values ​​through both absolute and relative deviations. It combines deviation level, duration, and direction of change for multi-dimensional combined analysis, and a delay confirmation mechanism with multiple periodic sampling effectively filters instantaneous interference. Through dynamic threshold adjustment of basic threshold plus real-time compensation value, it adapts to the deviation characteristics under different operating conditions, achieving accurate differentiation between instantaneous interference, real faults, and hidden dangers. This solves the problems of frequent false alarms, unplanned shutdowns caused by fault misjudgment, and missed detection of hidden dangers, significantly improving the reliability of fault identification and the stability of system operation.

[0035] 2. By using a fault isolation module, the power supply circuit of the protection device is independently isolated from the start-stop control circuit. In the event of a fault, the fault link is quickly cut off to prevent the fault from spreading and causing the control circuit to trip. This fundamentally avoids unplanned equipment shutdowns and ensures stable production operation.

[0036] 3. The backup power supply module uses a lithium battery pack, which immediately starts the emergency power supply when the main power supply is interrupted or the fault isolation is activated, to ensure the continuous operation of the core module and protection device, avoid the failure of protection function due to power failure, and further improve the reliability of system operation. Attached Figure Description

[0037] Figure 1 A schematic diagram of a preferred embodiment of a system and method for ensuring continuous power supply to a belt conveyor protection device provided by the present invention;

[0038] Figure 2 This is a flowchart of the programmable logic controller shown in this invention;

[0039] Figure 3 This is a flowchart of a method for ensuring continuous power supply to a belt conveyor protection device, as shown in this invention. Detailed Implementation

[0040] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0041] Please refer to the following: Figures 1-3 ,in, Figure 1 A schematic diagram of a preferred embodiment of a system and method for ensuring continuous power supply to a belt conveyor protection device provided by the present invention; Figure 2 This is a flowchart of the programmable logic controller shown in this invention; Figure 3 This is a flowchart of a method for ensuring continuous power supply to a belt conveyor protection device, as shown in this invention.

[0042] In the specific implementation process, such as Figures 1-3 As shown, the main power supply module is used to provide main power input for the start / stop circuit, various modules, and protection devices;

[0043] The fault isolation module is used to connect the main power supply module and the protection device, and to cut off the power supply to the protection device in case of a fault.

[0044] The signal transmission module is used to collect fault signals from the fault isolation module and transmit them to the control module;

[0045] The control module is used to receive signals from the signal transmission module, perform dynamic deviation calculation and dynamic threshold adjustment, determine faults, and output control commands.

[0046] The alarm module is used to receive instructions from the control module and execute tiered alarms. In the event of a real fault, it triggers an audible and visual alarm and a pop-up alarm on the screen. In the event of a hidden hazard, it only triggers a pop-up warning on the screen and marks it.

[0047] The backup power supply module is used to temporarily supply power to each module after the main power supply module is temporarily interrupted or the fault isolation module is activated.

[0048] The control module includes:

[0049] The central processing unit (CPU) is used to perform fault diagnosis. It obtains the real-time deviation value by comparing the real-time operating parameter values ​​of the protection device with historical operating parameters. It compares the calculated real-time deviation value with the deviation level range pre-stored in the storage unit to determine the level to which the real-time deviation belongs. It performs timing analysis on the duration of the deviation at a specific deviation level to determine whether the deviation state is instantaneous or continuous. If the real-time deviation is instantaneous and recovers quickly, it outputs a positive real-time compensation value for the base threshold. If the real-time deviation is continuous or shows a stable increasing trend, it outputs a negative real-time compensation value. It analyzes the direction and rate of change of recent continuous real-time deviation data to determine whether the deviation tends to increase, decrease, or remain stable. If the real-time deviation fluctuates randomly within the normal range, it outputs a real-time compensation value of zero. Based on the fact that the real-time dynamic threshold is equal to the base threshold plus the real-time compensation value, false alarms are avoided.

[0050] Deviation level range: low level is real-time relative deviation less than or equal to 3% or absolute deviation less than or equal to 2% of rated parameter; medium level is 3% less than relative deviation less than 6% or 2% less than absolute deviation less than 4%; high level is relative deviation greater than 6% or absolute deviation greater than 4%. The duration of the deviation at a specific deviation level is analyzed to determine whether the deviation is instantaneous or persistent. At the same time, combined with recent continuous real-time deviation data, the direction and rate of change are analyzed to determine whether the deviation tends to increase, decrease or remain stable. Low level is normal range random fluctuation, output zero compensation value; medium level is likely to persist or increase steadily, output negative compensation value; high level often occurs instantaneously and recovers quickly, output basic threshold positive compensation value. The determination is based on relative deviation.

[0051] Determine the level to which this real-time deviation belongs:

[0052] High-level deviations, which occur instantaneously and recover quickly, last for 3 sampling cycles. The system outputs a positive compensation value for the basic threshold, sends a voltage compensation command to the main power supply module to offset the disturbance, records the deviation information, does not trigger alarms or isolate faults, and avoids accidental shutdowns.

[0053] For medium-level deviations, i.e., those that persist or steadily increase, a negative compensation value is output, dynamically adjusted to the base threshold, and continuously monitored for a fixed sampling period. If the deviation does not disappear, a real fault is determined, triggering the 6A miniature circuit breaker to trip and isolate the fault circuit, triggering a red pop-up alarm, and starting the lithium battery pack for backup power supply to ensure the continuous operation of core functions.

[0054] Low-level deviation, i.e., fluctuation within the normal range, outputs a base threshold of zero, only records deviation data, does not interfere with operation, and improves system efficiency;

[0055] Determining the direction of change: positive increase, meaning the deviation approaches or exceeds the upper limit of the level threshold for three or more consecutive sampling periods, and the difference with the same period in history increases positively; negative decrease, meaning the deviation falls back to the rated range for two or more consecutive sampling periods without repetition; stable fluctuation, meaning the deviation fluctuates within the current level range.

[0056] Combined analysis and linkage: Positive increase combined with medium or low speed to determine fault derivative type, output zero or negative compensation value, start delay monitoring, if deviation exceeds the threshold, isolate the fault and activate backup power supply; Reverse decrease combined with high speed to determine instantaneous disturbance type, output positive compensation value, record relevant information without triggering alarm; Stable fluctuation combined with low speed to determine conventional interference type, output zero compensation value, only continuously monitor without intervention; Positive increase combined with high speed to directly determine emergency fault, trigger fault isolation and backup power supply linkage action;

[0057] If the protection device experiences signal fluctuations due to momentary vibration or slight contact, and the deviation value briefly reaches a high level but quickly returns to normal, it is judged as a momentary disturbance. A positive compensation value of 0.2 is output, the dynamic threshold is increased, no alarm is triggered, no tripping occurs, and only the event is recorded.

[0058] If the protection device is aging or loose, the signal gradually deviates from the reference. The deviation value remains at a medium level and has a slow upward trend, which is judged as a potential fault. A negative compensation value of 0.1 is output, the dynamic threshold is reduced, the system enters the warning state, triggers the screen pop-up warning, but does not cut off the power supply and continues to track changes.

[0059] The protection device is considered a low-level deviation due to normal belt vibration or slight load changes during belt operation. It is judged as a routine interference and outputs a zero compensation value. The threshold remains unchanged, and only the operating data is recorded.

[0060] The digital input unit is used to receive the digital signal converted by the signal transmission module;

[0061] The digital output unit is used to output control commands to the alarm module, fault isolation module, and backup power supply module. The control commands drive the alarm module to provide window alerts for faults or potential hazards, and in the event of a fault, directly control the on / off state of the miniature circuit breaker to cut off the power supply to the fault circuit. After the fault is repaired, a remote power restoration command can be issued. When the main power supply is interrupted or fault isolation is performed, a command to switch to the backup power supply module can be issued.

[0062] The storage unit is used to store the historical operating parameters, deviation data, basic thresholds, and fault records of the protection device.

[0063] Real-time deviation value is obtained by matching real-time parameters with corresponding historical benchmarks. The absolute deviation is equal to the real-time value minus the benchmark value, and the relative deviation is equal to the real-time value minus the benchmark value divided by the benchmark value multiplied by 100%. The final real-time deviation value is determined according to the principle of relative deviation priority. In case of an anomaly, the absolute deviation is switched to serve as the core quantitative basis for subsequent deviation level determination.

[0064] The protection device includes a pull rope switch, a deviation detection switch, and a slippage detection switch. The power terminals of each switch are connected in parallel to the output terminals of the fault isolation module.

[0065] The fault isolation module includes a 6A miniature circuit breaker. When the 6A miniature circuit breaker is in the closed state, the power from the main control power supply is delivered to the protection device circuit through the 6A miniature circuit breaker to continuously supply power to the pull rope, deviation and slip switch.

[0066] The signal transmission module includes an intermediate relay, which has two sets of structures: a coil and contacts. The coil is the input terminal, and the contacts are the output terminal. It serves as a signal bridge connecting the fault isolation module and the control module, converting the mechanical status signal of the 6A miniature circuit breaker into an electrical signal that the control module can recognize. At the same time, it amplifies the signal and achieves electrical isolation.

[0067] Fault determination is divided into normal operation, potential hazards, and fault alarms. In normal operation, the real-time deviation does not exceed the real-time dynamic threshold and the deviation is stable. There are no alarms or warning actions. Only the operating parameters are continuously recorded to accumulate data for benchmark parameter optimization. In potential hazards, the real-time deviation does not exceed the real-time dynamic threshold, but the deviation is increasing. A pop-up warning is triggered, and the potential hazard is marked. The power supply is not cut off or the backup power supply is not activated. The deviation change is continuously tracked. In fault alarm, the real-time deviation exceeds the real-time dynamic threshold and is increasing, or the real-time deviation significantly exceeds the threshold. A graded alarm is immediately triggered, and the 6A miniature circuit breaker is tripped to isolate the fault circuit. The backup power supply module is activated to ensure the continuous operation of the core module and protection device.

[0068] The backup power supply module uses a lithium battery pack as an emergency power source, with a rated output voltage consistent with the main power supply module, and has continuous emergency power supply capability.

[0069] A method for ensuring continuous power supply to a belt conveyor protection device includes the following steps:

[0070] S1: System startup self-test: After the system is powered on, the main power supply module initializes, the control module performs a self-test of each module and protection device, retrieves historical parameters and preset thresholds, and enters standby mode if there are no abnormalities.

[0071] S2: Main power supply on: The control module commands the 6A miniature circuit breaker to close, and the main power supply is transmitted to each protection device through the circuit. The system starts real-time monitoring. The control module sends a closing command to the fault isolation module. After receiving the command, the 6A miniature circuit breaker closes. The stable power output from the main power supply module is transmitted to the parallel power supply circuit of each protection device through the circuit breaker, realizing the synchronous energization of the pull rope switch, deviation detection switch and slippage detection switch. The system officially enters the real-time operation monitoring mode.

[0072] S3: Data Acquisition and Threshold Calculation: The signal transmission module acquires the circuit breaker status and protection device operating parameters, converts and transmits them to the control module. The control module calculates the real-time deviation, determines the level of the real-time deviation, performs timing analysis on the duration of the deviation at a specific level, and analyzes the direction and rate of change by combining recent continuous real-time deviation data. Based on the formula that the real-time dynamic threshold equals the basic threshold plus the real-time compensation value, false alarms are avoided. The signal transmission module acquires the mechanical status signal of the 6A miniature circuit breaker and the operating parameters of each protection device in real time, converts the mechanical status signal into an electrical signal that the control module can recognize, and transmits it to the control module through the digital input unit after amplification and electrical isolation. The central processing unit of the control module calculates the real-time absolute deviation value and relative deviation value based on the acquired operating parameters, compares them with the deviation level range pre-stored in the storage unit to determine the deviation level, analyzes the fluctuation persistence through timing analysis and the direction and rate of deviation change through linear fitting algorithm, and outputs the real-time compensation value according to the rules. Finally, the dynamic threshold adjustment is completed according to the formula that the real-time dynamic threshold equals the basic threshold plus the real-time compensation value.

[0073] S4: Deviation Comparison and Delay Monitoring: Based on the real-time dynamic threshold, deviation monitoring is carried out. When the real-time deviation is within the threshold, the main power supply mode is maintained, parameters are continuously collected and updated to the storage unit to accumulate data for historical benchmark optimization and dynamic threshold adjustment. When the deviation exceeds the threshold, the delay confirmation mechanism is immediately activated. The deviation is sampled and recorded at fixed intervals to provide accurate basis for subsequent classification judgment.

[0074] S5: Tiered Response: If the deviation continues to exceed the threshold and meets the fault characteristics, it is determined to be a real fault. First, the 6A miniature circuit breaker is tripped to isolate the fault circuit. Then, the audible and visual alarms and the screen pop-up alarm are triggered. Simultaneously, the lithium battery pack is started for emergency power supply to ensure the continuous operation of the core module and protection device. If the deviation exceeds the threshold but does not meet the fault judgment standard and shows a potential growth trend, only the screen pop-up warning is triggered and the type of hidden danger is marked. The power supply is not cut off and the backup power supply is not started. The subsequent deviation change trend is continuously tracked to ensure the balance between fault handling and production continuity.

[0075] S6: Fault Repair and Recovery: After troubleshooting and repairing the fault, reset the circuit breaker. If the control module verifies that there are no abnormalities, switch back to the main power supply mode, clear the alarm, and troubleshoot the fault source based on the alarm information. After completing the repair, manually reset the 6A miniature circuit breaker. The control module verifies the operating parameters of the protection device and the stability of the circuit power supply. After confirming that the deviation has returned to normal and that all modules are working normally, clear the alarm. If the backup power supply module has been started, the control module issues a switching command, and the system automatically switches back to the main power supply mode. The backup power supply module stops working and enters standby mode.

[0076] S7: Emergency Power Supply Interruption: When the main power supply is interrupted, the backup power supply is immediately activated. After the main power supply is restored, it automatically switches back to the main power supply. If the main power supply module experiences a temporary interruption, the control module captures the power interruption signal in real time. Without waiting for the deviation judgment process, it immediately triggers the backup power supply module to start emergency power supply, ensuring that all functional modules and protection devices operate without interruption. After the main power supply is restored to normal, the control module automatically detects and switches back to the main power supply mode. The backup power supply module stops outputting and enters standby mode, waiting for the next call.

[0077] The circuits and controls involved in this invention are all existing technologies and will not be described in detail here.

[0078] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A system for ensuring continuous power supply to the belt conveyor protection device, characterized in that, Includes a main power supply module, which provides main power input to the start / stop circuit, various modules, and protection devices; The fault isolation module is used to connect the main power supply module and the protection device, and to cut off the power supply to the protection device in case of a fault. The signal transmission module is used to collect fault signals from the fault isolation module and transmit them to the control module; The control module is used to receive signals from the signal transmission module, perform dynamic deviation calculation and dynamic threshold adjustment, determine faults, and output control commands. The alarm module is used to receive instructions from the control module and execute tiered alarms. In the event of a real fault, it triggers an audible and visual alarm and a pop-up alarm on the screen. In the event of a hidden hazard, it only triggers a pop-up warning on the screen and marks it. The backup power supply module is used to temporarily supply power to each module after the main power supply module is temporarily interrupted or the fault isolation module is activated. The control module includes: The central processing unit (CPU) is used to perform fault diagnosis. It obtains the real-time deviation value by comparing the real-time operating parameter values ​​of the protection device with historical operating parameters. The calculated real-time deviation value is compared with the deviation level range pre-stored in the storage unit to determine the level to which the real-time deviation belongs. The duration of the deviation at a specific deviation level is timed and analyzed to determine whether the deviation state is instantaneous or continuous. If the real-time deviation is instantaneous and recovers quickly, a positive real-time compensation value for the base threshold is output. If the real-time deviation is continuous or shows a stable increasing trend, a negative real-time compensation value is output. Combining recent continuous real-time deviation data, the CPU analyzes its direction and rate of change to determine whether the deviation tends to increase, decrease, or remain stable. If the real-time deviation fluctuates randomly within the normal range, a real-time compensation value of zero is output. The real-time dynamic threshold is obtained by adding the real-time compensation value to the base threshold of the protection device, thereby achieving accurate fault diagnosis and avoidance of false alarms. The digital input unit is used to receive the digital signal converted by the signal transmission module; The digital output unit is used to output control commands to the alarm module, fault isolation module and backup power supply module; The storage unit is used to store the historical reference parameters, operating parameters, deviation data, deviation level ranges, basic thresholds, fault determinations, and fault records of the protection device.

2. The system for ensuring continuous power supply to the belt conveyor protection device according to claim 1, characterized in that, The real-time deviation value is obtained by matching the real-time parameter with the corresponding historical benchmark parameter. The absolute deviation is calculated as the real-time value minus the benchmark value, and the relative deviation is calculated as the real-time value minus the benchmark value divided by the benchmark value multiplied by 100%. The final real-time deviation value is determined according to the principle of relative deviation priority. In case of an anomaly, the absolute deviation is used as the core quantitative basis for subsequent deviation level determination.

3. The system for ensuring continuous power supply to the belt conveyor protection device according to claim 2, characterized in that, The protection device includes a pull rope switch, a deviation detection switch, and a slippage detection switch, with the power terminals of each switch connected in parallel to the output terminals of the fault isolation module.

4. The system for ensuring continuous power supply to the belt conveyor protection device according to claim 3, characterized in that, The fault isolation module includes a 6A miniature circuit breaker. When the 6A miniature circuit breaker is in the closed state, the power from the main control power supply is transmitted to the protection device circuit through the 6A miniature circuit breaker to continuously supply power to the pull rope, deviation and slippage switches.

5. A system for ensuring continuous power supply to a belt conveyor protection device according to claim 4, characterized in that, The signal transmission module includes an intermediate relay, which has two sets of structures: a coil and contacts. The coil is the input end, and the contacts are the output end. It serves as a signal bridge connecting the fault isolation module and the control module, converting the mechanical status signal of the 6A miniature circuit breaker into an electrical signal that the control module can recognize. At the same time, it amplifies the signal and achieves electrical isolation.

6. A system for ensuring continuous power supply to a belt conveyor protection device according to claim 5, characterized in that, The fault determination is divided into normal operation, potential hidden danger, and fault alarm. Normal operation: the real-time deviation does not exceed the real-time dynamic threshold and the deviation is stable. There are no alarms or warning actions. Only the operating parameters are continuously recorded to accumulate data for the optimization of the benchmark parameters. Potential hazard: The real-time deviation does not exceed the real-time dynamic threshold, but the deviation is increasing, triggering a pop-up warning on the screen, marking the potential hazard, without cutting off the power supply or starting the backup power supply, and continuously tracking the change in deviation; Fault alarm: If the real-time deviation exceeds the real-time dynamic threshold and shows an increasing trend, or if the real-time deviation significantly exceeds the threshold, a graded alarm will be triggered immediately, and the 6A miniature circuit breaker will be tripped to isolate the fault circuit. The backup power supply module will be started to ensure the continuous operation of the core module and protection device.

7. A system for ensuring continuous power supply to a belt conveyor protection device according to claim 6, characterized in that, The backup power supply module uses a lithium battery pack as an emergency power source, with a rated output voltage consistent with the main power supply module, and has continuous emergency power supply capability.

8. A method for ensuring continuous power supply to the belt conveyor protection device, applied to the system described in any one of claims 1-7, characterized in that, Includes the following steps: S1: System startup self-test: After the system is powered on, the main power supply module initializes, the control module performs a self-test of each module and protection device, retrieves historical parameters and preset thresholds, and enters standby mode if there are no abnormalities. S2: Main power supply is turned on: The control module commands the 6A miniature circuit breaker to close, and the main power supply is transmitted to each protection device through the circuit. The system starts real-time monitoring. S3: Data Acquisition and Threshold Calculation: The signal transmission module acquires the circuit breaker status and protection device operating parameters, converts and transmits them to the control module. The control module calculates the real-time deviation, determines the level to which the real-time deviation belongs, performs timing analysis on the duration of the deviation at a specific level, and analyzes the direction and rate of change by combining recent continuous real-time deviation data. Based on the real-time dynamic threshold being equal to the basic threshold plus the real-time compensation value, false alarms are avoided. S4: Deviation Comparison and Delay Monitoring: Based on the real-time dynamic threshold, deviation monitoring is carried out. When the real-time deviation is within the threshold, the main power supply mode is maintained, parameters are continuously collected and updated to the storage unit to accumulate data for historical benchmark optimization and dynamic threshold adjustment. When the deviation exceeds the threshold, the delay confirmation mechanism is immediately activated. The deviation is sampled and recorded at fixed intervals to provide accurate basis for subsequent classification judgment. S5: Tiered Response: If the deviation continues to exceed the threshold and meets the fault characteristics, it is determined to be a real fault. First, the 6A miniature circuit breaker is tripped to isolate the fault circuit. Then, the audible and visual alarms and the screen pop-up alarm are triggered. Simultaneously, the lithium battery pack is started for emergency power supply to ensure the continuous operation of the core module and protection device. If the deviation exceeds the threshold but does not meet the fault judgment standard and shows a potential growth trend, only the screen pop-up warning is triggered and the type of hidden danger is marked. The power supply is not cut off and the backup power supply is not started. The subsequent deviation change trend is continuously tracked to ensure the balance between fault handling and production continuity. S6: Fault Repair and Recovery: After troubleshooting and repairing the fault, reset the circuit breaker. If the control module is checked and no abnormality is found, switch back to the main power supply mode and clear the alarm. S7: Emergency response to main power supply interruption: When the main power supply is interrupted, the backup power supply will be activated immediately, and the main power supply will automatically switch back to the main power supply after it is restored.

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