Self-inspection type tearing detection sensor of belt conveyor

Abstract

The invention relates to the field of infrared sensors, in particular to a self-inspection type tearing detection sensor of a belt conveyor. The device comprises a mounting frame, an infrared correlation sensor, a triggering mechanism and a self-checking mechanism, two mounting assemblies are arranged on the mounting frame side by side. The infrared correlation sensor comprises an infrared correlation sensor transmitting end and an infrared correlation sensor receiving end which are oppositely distributed and are respectively arranged on the two groups of mounting components; the triggering mechanism comprises a rotating seat arranged on the mounting frame, a rotating rod rotationally arranged on the rotating seat, a connecting rod arranged at the lower part of the rotating rod, a receiving hopper arranged on the connecting rod and a detection rod arranged at the upper part of the rotating rod; the self-checking mechanism comprises a push rod and a driving motor driving the push rod to rotate. Different types of abnormal conditions caused by foreign matters such as coal falling from a crack of the conveying belt and anchor rods penetrating through the conveying belt can be detected through the infrared correlation sensors, then remote alarm is performed, and in addition, self-inspection of the infrared correlation sensors can also be performed.

Description

Technical Field

[0001] This invention relates to the field of infrared sensors, and in particular to a self-testing tear detection sensor for belt conveyors. Background Technology

[0002] Belt conveyors are used to transport coal. The upper part of the conveyor belt is V-shaped, allowing the coal to be transported on the inside and preventing it from falling off the sides. During the operation of belt conveyors, belt tearing is a common but serious problem. The main causes of conveyor belt tearing are as follows: (1) Aging of conveyor belt: Conveyor belts are generally made of rubber. After long-term use, they will age, resulting in reduced elasticity and easy cracking and tearing.

[0003] (2) Impact of coal dumping: When coal is added from the silo onto the conveyor belt, the coal will impact the conveyor belt. After prolonged use, this will cause cracks and tears in the conveyor belt. In particular, when the coal contains sharp foreign objects such as anchor bolts, the sharp foreign objects may puncture the conveyor belt and remain on it.

[0004] To prevent conveyor belt tearing, workers need to regularly inspect and maintain the belt conveyor to ensure its normal operation. At the same time, when conveying materials, materials containing sharp objects should be avoided as much as possible to reduce damage to the belt.

[0005] However, when a conveyor belt tears or is punctured, workers may not be near the conveyor and may not be able to notice the abnormality in time. This abnormality can easily lead to equipment damage and pose a safety hazard. Summary of the Invention

[0006] The purpose of this invention is to address the problems existing in the background technology by proposing a self-inspection tear detection sensor for belt conveyors. This sensor can detect different types of abnormalities caused by coal falling from the conveyor belt tear and foreign objects such as anchor rods inserted into the conveyor belt through an infrared beam sensor, and then issue a remote alarm. In addition, it can also perform remote self-inspection of the infrared beam sensor.

[0007] The technical solution of this invention is a self-testing tear detection sensor for a belt conveyor, comprising a mounting frame, an infrared beam sensor, a triggering mechanism, and a self-testing mechanism. Two sets of mounting components are arranged side-by-side on the upper part of the mounting frame. The infrared beam sensor includes an infrared beam sensor transmitter and an infrared beam sensor receiver, distributed opposite each other and respectively mounted on the two sets of mounting components. The triggering mechanism includes a rotating seat mounted on the mounting frame, a rotating rod rotatably mounted on the rotating seat, a connecting rod located below the rotating rod, a receiving hopper mounted on the connecting rod, and a detection rod located above the rotating rod. When coal falls from a tear in the conveyor belt into the receiving hopper, it blocks the detection path of the infrared beam sensor. When a foreign object inserted into the conveyor belt pushes the detection rod, the detection rod drives the receiving hopper to rotate via the rotating rod and the connecting rod, blocking the detection path of the infrared beam sensor. When the detection rod is not pushed, the receiving hopper presses against the mounting frame. The self-testing mechanism includes a push rod and a drive motor that drives the push rod to rotate. The drive motor is a geared motor, and the rotation of the push rod drives the rotating rod to rotate.

[0008] Preferably, the receiving hopper has a U-shaped flared opening.

[0009] Preferably, the lower part of both ends of the receiving hopper has baffles. When the receiving hopper is pressed on the mounting frame, the baffles avoid the detection path of the infrared beam sensor. When the receiving hopper is removed from the mounting frame, the baffles block the detection path of the infrared beam sensor.

[0010] Preferably, the top of the rotating rod is provided with a placement assembly, which includes a mounting platform with a mounting groove at the end of the rotating rod. The detection rod includes a contour rod portion and two mounting rod portions respectively disposed at both ends of the contour rod portion, with the mounting rod portions placed inside the mounting groove.

[0011] Preferably, a second connecting platform is provided on the top of the mounting platform, and a first connecting platform is rotatably connected to the second connecting platform via a rotating shaft. A top cover is provided on the first connecting platform, and a torsion spring is sleeved on the outer periphery of the rotating shaft between the first connecting platform and the second connecting platform.

[0012] Preferably, the outer side of the mounting platform is provided with a side plate, the upper part of which is bent outward or inclined.

[0013] Preferably, the rotating rod includes a rotating rod portion rotatably mounted on a rotating seat, two inclined rod portions integrally connected to both ends of the rotating rod portion, and a connecting rod portion integrally connected to the outer end of the inclined rod portion, wherein the push rod pushes the inclined rod portion when it rotates.

[0014] Preferably, the self-inspection mechanism further includes a fixed plate mounted on the mounting bracket, a slide rod slidably mounted on the fixed plate, a stop and a push plate respectively mounted at the bottom and top of the slide rod, a spring connected between the fixed plate and the push plate, and a pushing assembly that can push the push plate to move obliquely downward, with the spring sleeved on the outer periphery of the slide rod.

[0015] Preferably, the pushing assembly includes a bracket mounted on the mounting frame, a mounting shaft rotatably mounted on the bracket, a turntable mounted on the mounting shaft, a push rod and a pressure rod mounted on the turntable, and a torsion spring II sleeved on the outer periphery of the mounting shaft and connected at both ends to the bracket and the turntable respectively. The push rod and the pressure rod are distributed in a "V" shape, with the pressure rod located obliquely above the push plate and the push rod located on the rotation path of the push rod.

[0016] Compared with existing technologies, the present invention has the following beneficial technical effects: The present invention can detect different types of abnormalities caused by coal falling from cracks in the conveyor belt and foreign objects such as anchor bolts embedded in the conveyor belt using an infrared beam sensor. Then, it remotely sends signals to the central control terminal via a communication module to trigger an alarm. Furthermore, it can perform remote self-checks, determining whether the infrared beam sensor is faulty based on whether it triggers an alarm. The remote detection and self-checking processes are highly efficient. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of an embodiment of the present invention; Figure 2 This is a schematic diagram illustrating the rotation principle structure of the rotating rod, receiving hopper, and detection rod in an embodiment of the present invention. Figure 3 This is a partial structural diagram of an embodiment of the present invention; Figure 4 for Figure 3 Enlarged view of the structure at point A in the middle; Figure 5 This is a partial structural sectional view of the mounting position of the mounting rod.

[0018] Reference numerals: 1. Mounting bracket; 201. Side plate one; 202. Side plate two; 31. Infrared beam sensor transmitter; 32. Infrared beam sensor receiver; 41. Protective cover one; 42. Protective cover two; 5. Rotating seat; 6. Rotating rod; 61. Rotating rod part; 62. Diagonal rod part; 63. Connecting rod part; 7. Connecting rod; 8. Receiving hopper; 81. Baffle; 9. Detection rod; 91. Contouring rod part; 92. Mounting rod part; 10. Mounting platform; 101. Mounting groove; 11. Top cover; 12. Connecting platform one; 13. Connecting platform two; 14. Torsion spring one; 15. Side plate; 16. Fixing plate; 17. Sliding rod; 18. Baffle; 19. Push plate; 20. Spring; 21. Bracket; 22. Turntable; 23. Push rod; 24. Pressure rod; 25. Torsion spring two; 26. Drive motor; 27. Push rod. Detailed Implementation

[0019] Example 1: As Figures 1-5As shown in the figure, the self-testing tear detection sensor for belt conveyors proposed in this embodiment includes a mounting frame 1, an infrared beam sensor, a triggering mechanism, and a self-testing mechanism. The entire self-testing tear detection sensor is located inside the conveyor belt of the belt conveyor.

[0020] Mounting frame 1 is installed on the side frame of the belt conveyor. Two sets of mounting components are arranged side by side on the upper part of mounting frame 1. One set of mounting components consists of side plate 1 201 and protective cover 1 41, and the other set of mounting components consists of side plate 202 and protective cover 2 42. The side plates are mounted on mounting frame 1, and the protective covers are mounted on the side plates of the same set.

[0021] like Figure 1 As shown, the infrared beam sensor includes an infrared beam sensor transmitter 31 and an infrared beam sensor receiver 32, which are arranged opposite to each other and respectively mounted on two sets of mounting components. A protective cover is placed over the infrared beam sensor to shield and protect the infrared beam sensor transmitter 31 and the infrared beam sensor receiver 32.

[0022] The triggering mechanism includes a rotating seat 5 mounted on the mounting frame 1, a rotating rod 6 rotatably mounted on the rotating seat 5, a connecting rod 7 located at the lower part of the rotating rod 6, a receiving hopper 8 mounted on the connecting rod 7, and a detection rod 9 located at the upper part of the rotating rod 6. The receiving hopper 8 has a U-shaped flared opening, making it easier for coal falling from the conveyor belt crack to be received by the receiving hopper 8 and slide to the middle, effectively blocking the detection path of the infrared beam sensor. The detection rod 9 has a U-shaped flared opening with the flared opening facing upwards, corresponding to the area below the conveyor belt of the belt conveyor. The rotating rod 6 includes a rotating rod part 61 rotatably mounted on the rotating seat 5, two inclined rod parts 62 integrally connected to both ends of the rotating rod part 61, and a connecting rod part 63 integrally connected to the outer end of the inclined rod parts 62.

[0023] When the conveyor belt of the belt conveyor tears, the coal being conveyed will fall from the tear into the receiving hopper 8. The coal will block the detection path of the infrared beam sensor. The infrared beam sensor transmitter 31 will emit an infrared signal, but the infrared beam sensor receiver 32 will not receive the infrared signal, thus triggering an alarm. The infrared beam sensor will then send an alarm signal to the central control terminal remotely through the communication module. The central control terminal will automatically shut down the belt conveyor, and the staff at the central control terminal will arrange for personnel to go to the site for repair.

[0024] When adding coal from the silo to the belt conveyor, foreign objects such as anchor bolts may be mixed in with the coal falling from the silo. These anchor bolts fall and penetrate the conveyor belt, and the foreign objects embedded in the belt move with it. Because the bottom of the anchor bolt penetrates the conveyor belt and extends into its inner side, it can push the detection rod 9. The detection rod 9, through the rotating rod 6 and connecting rod 7, drives the receiving hopper 8 to rotate, causing it to block the detection path of the infrared beam sensor. This also triggers the infrared beam sensor alarm, enabling an emergency shutdown of the belt conveyor via the central control terminal. When the detection rod 9 is not pushed, the receiving hopper 8 rests on the mounting frame 1 under its own weight, or a counterweight can be added to the bottom of the receiving hopper 8, so that in its natural state, the bottom of the receiving hopper 8 is in contact with the mounting frame 1, and the rotating rod 6 and detection rod 9 are in a tilted position.

[0025] like Figures 1-3 As shown, the receiving hopper 8 has baffles 81 at both ends of its lower part. When the receiving hopper 8 is pressed against the mounting frame 1, the baffles 81 avoid the detection path of the infrared beam sensor. When the receiving hopper 8 is detached from the mounting frame 1, the baffles 81 block the detection path of the infrared beam sensor.

[0026] The self-testing mechanism includes a push rod 27 and a drive motor 26 that drives the push rod 27 to rotate. The drive motor 26 is a geared motor, mounted on the mounting bracket 1. The output of the drive motor 26 can rotate in both directions and has an integrated encoder, controlled by a controller for easy control of the direction and rotation angle of the drive motor 26. Operators can remotely control the operation of the drive motor 26 via a communication module at the central control terminal. When the drive motor 26 drives the push rod 27 to rotate clockwise, the push rod 27 pushes the inclined rod 62 to rotate the rotating rod 6. The rotating rod 6 drives the receiving hopper 8 to rotate via the connecting rod 7. The receiving hopper 8 blocks the detection path of the infrared beam sensor. If the infrared beam sensor alarms, it indicates that the infrared beam sensor is in normal monitoring mode. If the infrared beam sensor does not alarm, it indicates that the infrared beam sensor is faulty and requires on-site repair or replacement. After the self-test is completed, the output of the drive motor 26 is controlled to rotate counterclockwise to adjust the push rod 27 to its initial state.

[0027] This embodiment can detect different types of anomalies caused by foreign objects such as coal falling from a crack in the conveyor belt (only used to detect whether there are foreign objects blocking the detection path, not to identify coal or other structures) and anchor bolts embedded in the conveyor belt, using an infrared beam sensor. Then, it remotely sends a signal to the central control terminal via a communication module to trigger an alarm. The central control terminal then stops the belt conveyor to prevent further damage. Furthermore, it can remotely perform a self-check to ensure the infrared beam sensor is functioning correctly. The drive motor 26 drives the push rod 27 to rotate, which in turn drives the rotating rod 6. Whether the infrared beam sensor triggers an alarm determines if it is malfunctioning. This remote detection and self-checking method is highly efficient.

[0028] Example 2: Figures 1-5 As shown in this embodiment, a self-testing tear detection sensor for a belt conveyor is proposed. In Embodiment 1, after a foreign object on the conveyor belt pushes the detection rod 9, the detection rod 9 drives the receiving hopper 8 to rotate via the mounting platform 10, rotating rod 6, and connecting rod 7. If the receiving hopper 8 blocks the detection path of the infrared beam sensor but does not trigger the infrared beam sensor alarm, the belt conveyor continues to run, and foreign objects such as anchor rods will continue to drag the detection rod 9, causing structural damage. In this embodiment, a placement assembly is provided at the top of the rotating rod 6. The placement assembly includes a mounting platform 10 with a mounting groove 101 at the end of the rotating rod 6. The detection rod 9 includes a contoured rod portion 91 and two mounting rod portions 92 respectively located at both ends of the contoured rod portion 91. The shape of the contoured rod portion 91 is similar to the upper contour of the conveyor belt of the belt conveyor. The contoured rod portion 91 is located on the upper part of the inner side of the conveyor belt, with a narrow gap between it and the upper surface of the inner side of the conveyor belt. The mounting rod portions 92 are placed inside the mounting groove 101. When the detection rod 9 is dragged but the infrared beam sensor alarm is not triggered, the belt conveyor is not shut down. The detection rod 9 can be pulled off directly without damaging other structures, thus improving safety.

[0029] In addition, a second connecting platform 13 is provided on the top of the mounting platform 10. The second connecting platform 13 is rotatably connected to the first connecting platform 12 via a rotating shaft. A top cover 11 is provided on the first connecting platform 12. A torsion spring 14 sleeved on the outer periphery of the rotating shaft is connected between the first connecting platform 12 and the second connecting platform 13. After the mounting rod 92 is placed inside the mounting groove 101, the top cover 11 is automatically blocked at the top of the mounting groove 101 due to the torque of the torsion spring 14, which can play a certain limiting effect on the detection rod 9. However, when the detection rod 9 is continuously dragged, the mounting rod 92 of the detection rod 9 will push the top cover 11 open, and the detection rod 9 will still fall off.

[0030] Furthermore, a side plate 15 is provided on the outer side of the mounting platform 10. The upper part of the side plate 15 is bent or tilted outward. The side plate 15 guides and limits the installation of the mounting rod 92, so that the detection rod 9 can be placed neatly.

[0031] In this embodiment, the detection rod 9 is designed as a movable structure. When the detection rod 9 is dragged by foreign objects such as anchor rods but does not trigger the infrared beam sensor alarm or the belt conveyor stops, the detection rod 9 will be directly dragged off without damaging other structures.

[0032] Example 3: Figures 1-5 As shown in this embodiment, a self-testing tear detection sensor for a belt conveyor is proposed. Compared to Embodiment 1, in this embodiment, the self-testing mechanism further includes a fixed plate 16 mounted on the mounting frame 1, a slide rod 17 obliquely slidably mounted on the fixed plate 16, a baffle 18 and a push plate 19 respectively mounted at the bottom and top of the slide rod 17, a spring 20 connected between the fixed plate 16 and the push plate 19, and a pushing assembly that can push the push plate 19 to move obliquely downward. The spring 20 is sleeved on the outer periphery of the slide rod 17. When the push rod 27 rotates clockwise, it can push the push plate 19 to move obliquely downward through the pushing assembly. The slide rod 17 slides on the fixed plate 16, the spring 20 is compressed, and the baffle 18 extends into the inner side of the receiving hopper 8, blocking the detection path of the infrared beam sensor. This can simulate the situation where coal is blocked in the detection path of the infrared beam sensor. The operation of the infrared beam sensor is determined by whether the infrared beam sensor triggers an alarm.

[0033] like Figure 3 and Figure 4 As shown, the pushing assembly includes a bracket 21 mounted on the mounting frame 1, a mounting shaft rotatably mounted on the bracket 21, a turntable 22 mounted on the mounting shaft, a push rod 23 and a pressure rod 24 mounted on the turntable 22, and a torsion spring 25 sleeved on the outer circumference of the mounting shaft and connected at both ends to the bracket 21 and the turntable 22 respectively. The push rod 23 and the pressure rod 24 are arranged in a "V" shape, with the push rod 23 being shorter than the pressure rod 24. The pressure rod 24 is located diagonally above the push plate 19, and the push rod 23 is located on the rotation path of the push rod 27. When push rod 27 rotates clockwise, it pushes push rod 23 to rotate counterclockwise, torsion spring 25 is twisted, and push rod 23 drives pressure rod 24 to rotate counterclockwise via turntable 22. Pressure rod 24 presses down on push plate 19 to move baffle 18 onto the detection path of infrared beam sensor for self-testing. After push rod 27 disengages from push rod 23, torsion spring 25 releases torque, causing push rod 23 and pressure rod 24 to reset. After this self-test is completed, push rod 27 can continue to rotate clockwise to push inclined rod 62 for another type of self-test, that is, to rotate receiving hopper 8 upwards onto the detection path of infrared beam sensor. After this type of self-test is completed, drive motor 26 drives push rod 27 to reverse back to the initial position.

[0034] This embodiment enables the infrared sensor to perform self-testing by extending the baffle 18 diagonally downwards into the detection path of the infrared beam sensor. The baffle 18 can simulate coal material, making the self-testing method more diverse.

[0035] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited thereto. Various changes can be made within the scope of knowledge possessed by those skilled in the art without departing from the spirit of the present invention.

Claims

1. A self-testing tear detection sensor for belt conveyors, characterized in that, include: Mounting bracket (1) has two sets of mounting components arranged side by side on the upper part; The infrared beam sensor includes an infrared beam sensor transmitter (31) and an infrared beam sensor receiver (32) that are distributed opposite to each other and respectively disposed on two sets of mounting components. The triggering mechanism includes a rotating seat (5) on the mounting frame (1), a rotating rod (6) on the rotating seat (5), a connecting rod (7) at the lower part of the rotating rod (6), a receiving hopper (8) on the connecting rod (7), and a detection rod (9) at the upper part of the rotating rod (6). When the coal falls into the receiving hopper (8), it blocks the detection path of the infrared beam sensor. When the foreign object inserted on the conveyor belt of the belt conveyor pushes the detection rod (9), the detection rod (9) drives the receiving hopper (8) to rotate through the rotating rod (6) and the connecting rod (7). The receiving hopper (8) blocks the detection path of the infrared beam sensor. When the detection rod (9) is not pushed, the receiving hopper (8) presses on the mounting frame (1). The self-testing mechanism includes a push rod (27) and a drive motor (26) that drives the push rod (27) to rotate. When the push rod (27) rotates, it pushes the rotating rod (6) to rotate.

2. The self-testing tear detection sensor for belt conveyors according to claim 1, characterized in that, The receiving hopper (8) is distributed in a "U" shaped flared shape.

3. The self-testing tear detection sensor for belt conveyors according to claim 2, characterized in that, The receiving hopper (8) has baffles (81) at the lower ends. When the receiving hopper (8) is pressed on the mounting frame (1), the baffles (81) avoid the detection path of the infrared beam sensor. When the receiving hopper (8) is removed from the mounting frame (1), the baffles (81) block the detection path of the infrared beam sensor.

4. The self-testing tear detection sensor for belt conveyors according to claim 1, characterized in that, The top of the rotating rod (6) is provided with a placement assembly, which includes a mounting platform (10) provided at the end of the rotating rod (6) and having a mounting groove (101). The detection rod (9) includes a contour rod part (91) and two mounting rod parts (92) respectively provided at both ends of the contour rod part (91). The mounting rod parts (92) are placed inside the mounting groove (101).

5. A self-testing tear detection sensor for belt conveyors according to claim 4, characterized in that, The mounting platform (10) is provided with a connecting platform two (13) on top. The connecting platform two (13) is rotatably connected to the connecting platform one (12) via a rotating shaft. The connecting platform one (12) is provided with a top cover (11). A torsion spring one (14) sleeved on the outer periphery of the rotating shaft is connected between the connecting platform one (12) and the connecting platform two (13).

6. A self-testing tear detection sensor for belt conveyors according to claim 4, characterized in that, The mounting platform (10) has a side plate (15) on its outer side, and the upper part of the side plate (15) is bent or tilted outward.

7. A self-testing tear detection sensor for belt conveyors according to claim 1, characterized in that, The rotating rod (6) includes a rotating rod part (61) rotatably mounted on a rotating seat (5), two inclined rod parts (62) integrally connected to both ends of the rotating rod part (61), and a connecting rod part (63) integrally connected to the outer end of the inclined rod part (62).

8. A self-testing tear detection sensor for belt conveyors according to claim 7, characterized in that, The self-testing mechanism also includes a fixed plate (16) mounted on the mounting bracket (1), a slide bar (17) slidably mounted on the fixed plate (16), a stop (18) and a push plate (19) respectively mounted on the bottom and top of the slide bar (17), a spring (20) connected between the fixed plate (16) and the push plate (19), and a pushing assembly that can push the push plate (19) to move obliquely downward.

9. A self-testing tear detection sensor for belt conveyors according to claim 8, characterized in that, The pushing assembly includes a bracket (21) mounted on the mounting frame (1), a mounting shaft rotatably mounted on the bracket (21), a turntable (22) mounted on the mounting shaft, a push rod (23) and a pressure rod (24) mounted on the turntable (22), and a torsion spring (25) sleeved on the outer periphery of the mounting shaft and connected at both ends to the bracket (21) and the turntable (22) respectively. The push rod (23) and the pressure rod (24) are arranged in a "V" shape. The pressure rod (24) is located diagonally above the push plate (19), and the push rod (23) is located on the rotation path of the push rod (27).

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