A method and system for early warning of belt tearing and slipping based on magneto-electric induction

Abstract

The application discloses a kind of based on magnetoelectric induction's conveyer belt tear and slip early warning method and system, belong to belt conveyor safety monitoring technical field.Solve the problem that existing detection means is difficult to realize early warning and collaborative monitoring.Technical scheme: install passive RFID flexible induction coil in conveyer belt, establish the mapping relationship of label UID and physical coordinates;Along line installation coupling reader, and read initial resonant frequency as base frequency;Real-time read the real-time resonant frequency of label, signal strength and time stamp;If signal loss is judged as serious tear and positioning, if frequency offset is identified as early micro-damage;Slip rate is calculated by time difference using label;Central processing unit according to determination result linkage output alarm, stop or tension adjustment instruction.The beneficial effect: the application realizes tear and slip integration non-contact monitoring, with early warning, accurate positioning, strong anti-interference ability and intelligent linkage advantage.

Description

Technical Field

[0001] This invention relates to the field of safety monitoring technology for belt conveyors, and in particular to a method and system for early warning of conveyor belt tearing and slippage based on magnetoelectric induction. Background Technology

[0002] As a critical continuous transportation device in industries such as mining, ports, and power, the operational stability of belt conveyors directly affects production efficiency and safety. Under long-term high-load operation, conveyor belts are susceptible to impacts from sharp materials, jamming, or abnormal tension, leading to longitudinal tears or slippage. Longitudinal tears are characterized by their sudden onset and rapid spread; once they occur, they often render the entire conveyor belt unusable and may even trigger secondary disasters such as fires or dust explosions. Slippage not only exacerbates wear on the rollers and conveyor belt but can also lead to high-temperature belt burning and material accumulation, severely impacting equipment safety and production efficiency.

[0003] Currently, the detection methods for conveyor belt tearing and slippage mainly rely on manual inspection, mechanical switches, or simple sensors. Manual inspection is difficult to achieve real-time monitoring over all weather conditions and long distances; mechanical anti-tear switches (such as pull cords and rocker arms) are mostly triggered only after the tear has widened, which is a reactive alarm and cannot provide early warning. Slippage detection often uses speed measuring rollers or proximity switches, which are easily affected by factors such as dust and installation misalignment, resulting in a high false alarm rate and delayed response. In addition, existing systems usually monitor tearing and slippage separately, resulting in low integration and difficulty in achieving coordinated early warning and intelligent linkage control.

[0004] In recent years, some studies have attempted to introduce technologies such as lasers, light curtains, and image recognition for non-contact detection. For example, patent application No. 202310322284.5 proposes a tear detection system based on line lasers, which identifies tear features through three-dimensional images. However, it is easily affected by high dust and strong vibration environments, leading to data loss and recognition distortion. Another example is patent application No. 202011258174.X, which uses a light curtain to detect falling materials to determine tears. Although it achieves non-contact detection, it can only be triggered after the tear has penetrated and the material has leaked, and it cannot identify early micro-damage. Yet another example is patent application No. 201310547045.6, which indirectly determines slippage through changes in material level. However, it has a slow response and is easily affected by material fluctuations, making it difficult to quantify the degree of slippage.

[0005] In summary, existing technologies still have significant shortcomings in early detection capabilities, environmental adaptability, system integration, and fault location accuracy. There is an urgent need for an intelligent monitoring system capable of early warning, precise positioning, and multi-parameter fusion to improve the safety and intelligence of conveyor belt operation. Summary of the Invention

[0006] The purpose of this invention is to overcome the problems in the prior art and provide a method and system for early warning of conveyor belt tearing and slippage based on magnetoelectric induction. The core technology involves pre-embedding multiple independently coded passive RFID flexible induction coils in a grid pattern inside the conveyor belt to construct a two-dimensional sensing network. Each coil acts as an LC resonant circuit, and its resonant frequency changes with the stretching and deformation of the conveyor belt. Coupled readers arranged along the conveyor belt continuously read the coil's frequency, signal strength, identification information, and precise timestamp: if the signal is lost, a serious tear is identified and located; if the frequency deviates, early micro-damage is identified. Simultaneously, the real-time belt speed and slippage rate are calculated using the time difference of the same tag passing through readers at fixed intervals. This system achieves non-contact, high-precision, and early integrated monitoring and early warning of longitudinal tearing and slippage faults in conveyor belts.

[0007] To achieve the above-mentioned objectives, the present invention employs the following technical solution: a method for early warning of conveyor belt tearing and slippage based on magnetoelectric induction, comprising the following steps:

[0008] S1. Sensor network initialization, installation and calibration: Multiple independently coded passive RFID flexible induction coils are pre-embedded in the conveyor belt to establish the mapping relationship between the tag UID identity information of each induction coil and the physical coordinates of the conveyor belt.

[0009] Multiple coupled readers are installed on the conveyor. During system initialization, the coupled readers continuously emit a high-frequency alternating magnetic field to acquire different tags. Baseline resonant frequency and all baseline resonant frequencies Store in the database.

[0010] S2. Distributed data acquisition and uploading: The coupled reader synchronizes with the clock through the central processing unit and continuously emits a high-frequency alternating magnetic field to read RFID tag information passing through the effective field area in real time, generate data records, and transmit the data records to the central processing unit.

[0011] S3. Data Processing and Tear Detection: After receiving the tag data stream uploaded by the coupled reader, the central processing unit executes the following processing algorithm and makes a judgment:

[0012] (1) If the signal of any tag is completely lost, it is determined that the conveyor belt at the location of the tag has been severely torn and damaged.

[0013] (2) If the real-time resonant frequency of any tag Relative to its baseline resonant frequency If a deviation occurs, it is determined that the conveyor belt in the area where the label is located has experienced abnormal stretching or minor damage.

[0014] S4. Slippage Detection: Based on the data collected in step S2, the same label X1 passes through the coupled reader with a spacing of D sequentially. timestamp , Calculate the time difference Compared with actual speed Then, the slip rate S is calculated. If the slip rate S exceeds the preset threshold, an early warning is triggered.

[0015] S5. Linkage Output: The central processing unit generates graded early warning and control commands based on the judgment results, transmits them to the monitoring terminal, and executes alarm, shutdown, or tension adjustment actions.

[0016] Further, in step S1, the baseline resonant frequency The method for obtaining it is as follows:

[0017] First, the coupling reader reads the initial resonant frequency of the conveyor belt under no-load operation. As the frequency baseline of the resonant frequency.

[0018] The initial resonant frequency The calculation method is as follows:

[0019]

[0020]

[0021] in, The permeability of free space, The number of coil turns. This refers to the cross-sectional area of ​​a single-turn coil. Let be the circumference of a single-turn coil. Let L be the initial resonant frequency, and L be the inductance of the coil. This refers to the capacitance value of the surface mount capacitor.

[0022] Secondly, number and record all induction coils as follows: .

[0023] Finally, by adjusting the capacitance value, the initial resonant frequency of each induction coil is achieved. Within a specific frequency band, obtain all adjusted tags. Baseline resonant frequency All baseline resonant frequencies There are differences between them so that the coupled reader can identify and distinguish them. This differentiated frequency modulation avoids signal conflicts when multiple tags respond simultaneously, ensuring that the reader can accurately distinguish each induction coil and providing a stable and reliable baseline reference for subsequent frequency offset detection.

[0024] Furthermore, in step S1, the installation of the coupler follows the principle of installing two couplers. and The distance D between them serves as the speed measurement reference section.

[0025] The coupled readers are numbered and recorded as follows The coupling reader achieves time synchronization through a central processing unit, continuously emitting a high-frequency alternating magnetic field to excite and read RFID tag information passing through its effective field area; when a tag enters the coupling reader... When the valid field area is successfully read, the read data is modeled as a data tuple:

[0026]

[0027] The UID is a unique identifier for the conveyor belt induction coil tag. For Reader Fixed spatial coordinates; For tags The real-time resonant frequency at the time of this reading; The received signal strength is used to reflect the degree of coupling. For Reader Read the tag The precise timestamps are obtained. With the help of readers with fixed spacing and unified time synchronization, the tags can be converted into belt speed measurements through time difference, while the structured data tuples integrate location, frequency, intensity and time information, providing a complete data foundation for subsequent tear location and slippage calculation.

[0028] Furthermore, in step S2, the data record includes: tag UID, reader ID, and real-time resonant frequency. Received signal strength and precise timestamp These fields cover the key dimensions required for fault identification: identity, location, deformation-sensitive parameters, coupling quality, and motion timing, ensuring that the central processing unit can fully reconstruct the local state of the conveyor belt at every moment.

[0029] Furthermore, in step S2, the central processing unit serves as the final data aggregation point. Each coupled reader connects to the nearest field data acquisition station via a bus or industrial Ethernet, and the acquisition station is connected to the central processing unit via a fiber optic ring network. This hierarchical network architecture and fiber optic ring network not only meet the requirements of long-distance, multi-node industrial field cabling but also ensure low-latency, high-reliability aggregation of massive amounts of tag data to the central processing unit, adapting to the real-time monitoring needs of harsh environments such as mines and ports.

[0030] Furthermore, in step S3, when the conveyor belt is severely torn, i.e. the induction coil is broken, the coupling reader cannot receive the returned frequency signal, and the central processing unit determines the location of the tear based on the information of the adjacent returned signal tags.

[0031] When abnormal stretching or micro-damage occurs, i.e., the induction coil undergoes geometric deformation due to the stretching of the conveyor belt, the resonant frequency is affected. Resonant frequency with baseline Compared to when a shift occurs, the central processing unit does not issue a tear warning at this time, but records the deformation location. The formula for calculating the frequency shift is:

[0032]

[0033] in, For real-time detected tags The resonant frequency, For tags The baseline resonant frequency. By utilizing two different response mechanisms—signal loss and frequency shift—it can not only accurately locate severe tears that have already occurred, but also capture frequency changes during micro-damage or abnormal stretching stages, enabling early warning and damage location recording, and preventing the fault from worsening.

[0034] Further, in step S4, the time difference and actual speed The calculation formulas are as follows:

[0035]

[0036]

[0037] The formula for calculating the slip rate S is:

[0038] ;

[0039] in, The theoretical operating speed is set for the conveyor belt. The actual belt speed is directly calculated by the time difference of the same label passing through a reader at a fixed interval. The actual speed is then compared with the theoretical speed to obtain a quantified slip rate. This provides a precise and settable threshold evaluation index for the degree of slippage, avoiding false alarms caused by dust and installation deviations in traditional speed measuring rollers.

[0040] Furthermore, in step S5, if the tearing fault is confirmed, the central processing unit outputs a shutdown command to the conveyor main control PLC.

[0041] If the slip warning is triggered, the central processing unit issues an instruction to adjust the belt tension through the tensioning device control cabinet to eliminate the slip, or issues a deceleration instruction. This hierarchical linkage control strategy can immediately stop the machine to prevent the loss from expanding when a tearing accident occurs, and perform soft intervention by adjusting the tension or decelerating at the initial stage of slipping, which not only ensures safety but also avoids the impact of frequent shutdowns on production.

[0042] The present invention also provides a belt conveyor detection system, including:

[0043] Embedded sensing array module: It consists of rectangular induction coils formed by multiple independently encoded passive RFID tags. The induction coils are embedded inside the conveyor belt cover layer in a parallel grid form or pasted at the bottom of the carrying surface. The long side of the induction coil is perpendicular to the running direction of the conveyor belt and covers the entire bandwidth; the coil and the patch capacitor C together form an LC resonant circuit, and its resonant frequency changes with the stress state of the conveyor belt.

[0044] Distributed reader network module: It includes multiple coupled readers. The coupled readers are installed along the conveyor, at the material dropping ports, guiding chutes, and joint areas, and are used to synchronously emit high-frequency alternating magnetic fields and read the RFID tag information passing through their field areas.

[0045] Data processing and fusion warning module: It is the central processing unit of the system, communicatively connected to the distributed reader network module, and is used to receive and process the tag information. The tag information includes tag position, real-time resonant frequency, signal strength, and timestamp; the data processing and fusion warning module performs tearing and slipping state judgments based on algorithms, classifies warnings, locates faults according to the judgment results, and generates control instructions.

[0046] Warning and execution terminal module: It receives the instructions from the data processing and fusion warning module, performs status visual display, hierarchical warning and alarm, and control signal output. The above modules together constitute an integrated closed-loop system from perception, acquisition, analysis to execution: the embedded sensing array realizes passive and maintenance-free stress and integrity detection; the distributed reader network realizes long-distance and multi-node synchronous reading; the data processing module completes multi-parameter fusion and intelligent decision-making; the execution terminal provides visualization and linkage control, thus truly realizing non-contact, early, and collaborative monitoring of tearing and slipping.

[0047] Compared with the prior art, the beneficial effects of the present invention are:

[0048] (1) Compared with traditional contact tear and slip detection devices (such as mechanical switches, speed measuring rollers, strain gauges, etc.), the present invention adopts an embedded passive RFID induction coil array, which does not require additional equipment to be installed on the surface of the conveyor belt, thus avoiding the wear of the conveyor belt caused by contact detection and the damage to the equipment structure during the installation process; the coil is embedded in the inside of the conveyor belt and is not affected by harsh environments such as dust, water stains, and vibration, and has the characteristics of maintenance-free and long service life, and is especially suitable for long-term stable operation in high wear and high pollution conditions such as mines and ports.

[0049] (2) Compared with non-contact detection systems based on vision, laser, or light curtain, this invention uses low-cost passive RFID tags arranged in a grid to form a two-dimensional monitoring network, eliminating the need for complex optical components and image processing algorithms, thus significantly reducing hardware costs. Simultaneously, the system integrates tear detection (based on frequency offset and signal loss) and slippage detection (based on tag passage time difference), achieving multi-parameter fusion early warning with high integration. Furthermore, each tag has an independent code, enabling precise location of faults and providing data support for predictive maintenance of conveyor belts.

[0050] (3) Compared with traditional single-function or post-event alarm detection devices, this invention can achieve real-time online monitoring. By continuously reading the resonant frequency changes of the tag, it can identify early micro-damage and abnormal stretching, and issue an early warning before or in the early stage of tearing. At the same time, by utilizing the time difference of the same tag passing through a fixed-space reader, it can accurately calculate the real-time speed and slippage rate, and quickly respond to slippage faults. The controller can be linked with the conveyor control system to adjust the tension or stop the machine in a timely manner, effectively preventing the accident from escalating and significantly improving the operational safety and intelligence level of the conveyor. Attached Figure Description

[0051] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof.

[0052] Figure 1 This is a schematic diagram of the system's workflow in this invention.

[0053] Figure 2 This is a schematic diagram of the pre-embedded wiring of the conveyor belt in this invention.

[0054] Figure 3 This is a design diagram of the electromagnetic induction coil in this invention.

[0055] Figure 4 This is a schematic diagram of the LC resonant circuit principle of the coupled reader module in this invention.

[0056] Figure 5 This is a diagram illustrating the information interaction between the coupled reader and the induction coil in this invention.

[0057] The attached diagram is labeled as follows: 1. Conveyor belt; 2. Induction coil. Detailed Implementation

[0058] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. Of course, the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0059] Example

[0060] like Figures 1-5 As shown, this embodiment provides a tension detection system for a belt conveyor, including an embedded sensor array module, a distributed reader network module, a data processing and fusion early warning module, and an early warning and execution terminal module.

[0061] The embedded sensor array module consists of rectangular induction coils composed of multiple independently coded passive RFID tags. The induction coils are embedded in the conveyor belt cover layer in the form of parallel grids or pasted on the bottom of the bearing surface. The long side of the induction coil is perpendicular to the running direction of the conveyor belt and covers the entire bandwidth. The coil and the patch capacitor C together form an LC resonant circuit, and its resonant frequency changes with the stress state of the conveyor belt. Figure 2 In the diagram, 1 represents the output band, and 2 represents the induction coil.

[0062] The distributed reader network module includes multiple coupled readers, which are installed along the conveyor line and at the material drop port, guide chute, and joint area. They are used to synchronously transmit high-frequency alternating magnetic fields and read RFID tag information passing through their respective areas.

[0063] The data processing and fusion early warning module is the central processing unit of the system and is communicatively connected to the distributed reader network module. It is used to receive and process tag information, which includes tag location, real-time resonant frequency, signal strength, and timestamp. The data processing and fusion early warning module performs tearing and slippage state judgment based on the algorithm, performs early warning classification and fault location based on the judgment results, and generates control commands.

[0064] The early warning and execution terminal module is used to receive instructions from the data processing and fusion early warning module, and to perform status visualization display, hierarchical early warning alarm and control signal output.

[0065] This invention also provides a multi-early warning method for tearing and slippage of belt conveyors based on embedded magneto-electric induction, comprising the following steps:

[0066] Step 1: Sensor Network Initialization and Calibration. During the manufacturing or vulcanization of the conveyor belt, multiple independently coded passive RFID flexible induction coils are pre-embedded in the conveyor belt cover layer or pasted to the bottom of the bearing surface in a parallel grid pattern. The long side of the coil is perpendicular to the conveyor belt's running direction to cover the entire belt width. A mapping relationship is established between each tag's UID and its physical coordinates (longitudinal distance, lateral position) on the conveyor belt, i.e., a UID-physical position mapping table is established. The core of the passive RFID flexible induction coil is a rectangular planar induction coil pre-embedded in the lower surface of the conveyor belt, with its long side perpendicular to the conveyor belt's running direction (longitudinal). The coil and a high-precision, low-temperature-coefficient surface-mount capacitor (C) together form an LC resonant circuit.

[0067] Multiple coupling readers are installed along the conveyor frame. These readers continuously emit a high-frequency alternating magnetic field to read the initial resonant frequency of all tags under the stable no-load operation of the conveyor belt. This serves as the baseline for the resonant frequency of each tag, and the different induction coils are numbered sequentially. Then, by finely adjusting the capacitance value, the initial resonant frequency of each coil is achieved. Within a specific frequency band, while maintaining a small difference, the baseline resonant frequency of each coil is obtained. Due to the adjustment of the capacitance value, the resonant frequencies of any two baselines can be adjusted. There are differences between them, making it easy for the coupling reader to identify and distinguish them, and then all baseline resonant frequencies are... Store in the database.

[0068] The initial resonant frequency The calculation method is as follows:

[0069] First, the inductance L of the coil is closely related to the coil's geometry. For a rectangular planar coil, its inductance is:

[0070]

[0071] The inherent resonant frequency of an LC resonant circuit is determined by both the inductance L and the capacitance C, and their calculation relationship is as follows:

[0072]

[0073] in, Where is the permeability of free space, N is the number of turns in the coil, and A is the cross-sectional area of ​​a single turn of the coil. This is the circumference of a single-turn coil; Where L is the initial resonant frequency, L is the inductance of the coil, and C is the capacitance of the surface-mount capacitor.

[0074] Step Two: Distributed Data Synchronization Acquisition. All coupled readers are clock-synchronized through the central processing unit, continuously emitting a scanning magnetic field at a specific frequency, and reading RFID tag information in real time from their effective field area (0.5-1.5 meters in diameter). Each successful read generates a data record, which includes: tag UID, reader ID, and real-time resonant frequency. Received signal strength and precise timestamp (Accuracy down to the millisecond level) and other information.

[0075] The installation of the coupling readers follows these principles: two coupling readers, R1 and R2, are installed in a stable section at a certain distance from the drive roller, with their spacing D precisely measured as a speed measurement reference section; coupling readers are also densely installed in high-risk tearing areas such as the material drop outlet, guide chute, and joints; the installed coupling readers are numbered and recorded. All coupled readers achieve time synchronization through the system's central processing unit or synchronization controller, and continuously emit high-frequency alternating magnetic fields to excite and read RFID tag information passing through their effective field area. When a tag enters a coupled reader... When the effective field region (k=1,2,...) is successfully read, this reading can be modeled as a data tuple:

[0076]

[0077] Among them, UID is the unique identifier of the conveyor belt induction coil tag, which comes from the mapping relationship established in step one; Let k be the fixed spatial coordinates of the reader; For tags The real-time resonant frequency at the time of this reading; The received signal strength reflects the degree of coupling. Reader k reads the precise timestamp of the tag.

[0078] Step 3: Data Transmission. Each coupled reader connects to the nearest field data acquisition station via bus or industrial Ethernet. The acquisition station is then connected to the central processing unit (located in the control room) via a fiber optic ring network. The communication protocol between the reader and the acquisition station uses Modbus RTU or TCP / IP to ensure real-time and reliable data transmission. The field power supply provides 24V DC power to the reader and is equipped with protection modules.

[0079] The central processing unit, acting as the final data aggregation point, receives real-time data streams forwarded by all acquisition stations from the fiber optic ring network and stores them in a processing queue. This prepares complete and accurate raw data materials for the subsequent multi-parameter fusion risk assessment in step four. Furthermore, the system provides each coupled reader with an independent 24V DC industrial power supply and is equipped with short-circuit and explosion-proof protection modules to ensure stable operation of field equipment in harsh industrial environments.

[0080] Step 4: Data Processing and Multi-Parameter Fusion Early Warning. The central processing unit receives the tag data streams uploaded by each reader and executes the following parallel processing algorithm:

[0081] (1) Tear fault diagnosis:

[0082] When the conveyor belt experiences a severe tear, the induction coil breaks down, and the tag signal is completely lost. However, adjacent upstream, downstream, and lateral tags remain normal. Based on their historical trajectory, it can be determined that a severe tear occurred at the location corresponding to the UID, causing the coil to break down. The fault coordinates are then precisely located using a UID-physical location mapping table.

[0083] When abnormal stretching or micro-damage occurs, the coil undergoes geometric deformation due to the stretching of the conveyor belt, resulting in a change in the real-time resonant frequency. Its baseline resonant frequency In contrast to when a shift occurs, the central processing unit does not issue a tear warning at this time, but records the deformation position. The frequency shift is calculated as follows:

[0084]

[0085] in, Real-time detected tags The resonant frequency, For tags The baseline resonant frequency.

[0086] (2) Slippage detection and calculation: Extract the timestamps of the same tag (e.g., UID=X1) from readers R1 and R2 on the speed measurement reference section. , Calculate its transit time difference Based on the known reader spacing D, the real-time operating speed of the conveyor belt is calculated. ,Will With respect to the preset theoretical belt speed The slip rate S is calculated by comparing the values. The slip rate S is then compared to a preset threshold. If it exceeds the preset threshold, a slip warning is triggered. In this embodiment, the preset threshold is 5%.

[0087] Specifically, two adjacent speed measurement readers are R1 and R2, and their effective fixed distance along the conveyor belt running path is D (unit: meters). D is determined during system installation. Readers R1 and R2 read the same specific tag (let its UID be X1) at timestamps of […]. , The actual speed V of tag X1 moving from reader R1 to reader R2 实 The calculation formula is as follows:

[0088]

[0089] The formula for calculating the slip rate S is as follows:

[0090]

[0091] in, D represents the time difference between the two points; D is the effective fixed distance between the readers R1 and R2. The theoretical operating speed set for the conveyor belt.

[0092] Step 5: Linkage Control and Early Warning Output. Based on the tear and slippage determination results, the central processing unit generates tiered early warning signals and control commands. The early warning signals are transmitted to the monitoring terminal via Ethernet or hardwired for visual display, simultaneously controlling the alarm device (audible and visual alarm). If a tear fault is confirmed, the system outputs a stop command to the conveyor's main control PLC; if a slippage early warning is triggered, the system can link with the tensioning device control cabinet to adjust the tension force to eliminate slippage, or issue a deceleration command.

[0093] Please refer to Figure 4 and Figure 5 . Figure 4 The schematic diagram of a coupled reader circuit shows that the coil inductance and capacitance typically form a matching network or resonant circuit. Its main purpose is to maximize the output efficiency of the power amplifier and to sensitively receive the echo. For example... Figure 5 As shown, when a high-frequency current passes through an inductor coil, it generates a high-frequency alternating magnetic field in the surrounding space. When the induction coil built into the conveyor belt passes by, it generates an induced current and a changing magnetic field. The changing magnetic field generated by the tag coil cuts the reader coil, inducing a weak current (electromagnetic induction) in the coil, thereby enabling signal reception.

[0094] In summary, this invention provides a method and system for early warning of conveyor belt tearing and slippage based on magnetoelectric induction. Its core lies in constructing a two-dimensional gridded sensor network composed of passive RFID flexible induction coils, combined with a distributed coupled reader to achieve all-weather, non-contact monitoring of conveyor belt operation. By reading the resonant frequency changes and signal loss of the tags, the system can accurately identify the location of severe tears in the conveyor belt and capture early micro-damage. Simultaneously, by utilizing the time difference of the same tag passing through a fixed-gap reader, the system calculates the conveyor belt speed and slippage rate in real time, achieving quantitative early warning of slippage faults. The modular design of this system encompasses an embedded sensor array, a distributed reader network, a data processing and fusion early warning module, and an early warning and execution terminal. All components work collaboratively to form a complete closed loop from signal perception, data acquisition, intelligent judgment to coordinated control. In practical applications, this invention not only overcomes the limitations of traditional detection methods, such as reliance on manual inspection, response lag, and susceptibility to environmental interference, but also achieves integrated monitoring of tearing and slippage through a dual mechanism of frequency offset and time difference, significantly improving the timeliness and accuracy of fault identification. In addition, the system has good scalability and industrial adaptability, and can optimize algorithms and iterate functions according to working conditions, providing intelligent and highly reliable technical support for the safe operation of the conveyor belt.

[0095] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for early warning of conveyor belt tearing and slippage based on magnetoelectric induction, characterized in that, Includes the following steps: S1. Sensor network initialization, installation and calibration: Set multiple independently coded induction coils in the conveyor belt and establish the mapping relationship between the tag UID identity information of each induction coil and the physical coordinates of the conveyor belt. Multiple coupled readers are installed on the conveyor. During system initialization, the coupled readers continuously emit a high-frequency alternating magnetic field to acquire all tags. Baseline resonant frequency and all baseline resonant frequencies Store in the database; S2. Distributed data acquisition and uploading: The coupled reader synchronizes with the clock through the central processing unit and continuously emits a high-frequency alternating magnetic field to read RFID tag information passing through the effective field area in real time, generate data records, and transmit the data records to the central processing unit. S3. Data Processing and Tear Detection: After receiving the tag data stream uploaded by the coupled reader, the central processing unit performs the following processing steps and makes a judgment: (1) If the signal of any tag is completely lost, it is determined that the conveyor belt at the location of the tag has been severely torn and damaged; (2) If the real-time resonant frequency of any tag Relative to its baseline resonant frequency If a deviation occurs, it is determined that the conveyor belt in the area where the label is located has experienced abnormal stretching or minor damage; S4. Slippage Detection: Based on the data collected in step S2, and according to the same label... The timestamps of the coupled readers R1 and R2 with a spacing of D passed successively. , Calculate the time difference Compared with actual speed Then, the slip rate S is calculated. If the slip rate S exceeds the preset threshold, an alarm is triggered. S5. Linkage Output: The central processing unit generates graded early warning and control commands based on the judgment results, transmits them to the monitoring terminal, and executes alarm, shutdown, or tension adjustment actions. In step S1, the baseline resonant frequency The method for obtaining it is as follows: First, the coupling reader reads the initial resonant frequency of the conveyor belt under no-load operation. As the frequency baseline for the resonant frequency; The initial resonant frequency The calculation method is as follows: ； ； in, The permeability of free space, The number of coil turns. This refers to the cross-sectional area of ​​a single-turn coil. Let be the circumference of a single-turn coil. Let L be the initial resonant frequency, and L be the inductance of the coil. This refers to the capacitance value of the surface mount capacitor; Secondly, number and record all induction coils as follows: ; Finally, by adjusting the capacitance value, all the adjusted labels were obtained. Baseline resonant frequency During the adjustment process, all baseline resonant frequencies are adjusted. There are differences between them so that the coupled reader can identify and distinguish them.

2. The method for early warning of conveyor belt tearing and slippage based on magnetoelectric induction according to claim 1, characterized in that, In step S1, the installation of the coupler follows the principle of installing two couplers. and their spacing As a reference section for speed measurement; The coupled readers are numbered and recorded as follows The coupling reader achieves time synchronization through a central processing unit, continuously emitting a high-frequency alternating magnetic field to excite and read RFID tag information passing through its effective field area; when a tag enters the coupling reader... When the valid field area is successfully read, the read data is modeled as a data tuple: The UID is a unique identifier for the conveyor belt induction coil tag. For Reader Fixed spatial coordinates; For tags The real-time resonant frequency at the time of this reading; The received signal strength is used to reflect the degree of coupling. i For Reader Read the tag The precise timestamp.

3. The method for early warning of conveyor belt tearing and slippage based on magnetoelectric induction according to claim 2, characterized in that, In step S2, the data record includes: tag UID, reader ID, and real-time resonant frequency. Received signal strength and precise timestamp i .

4. The method for early warning of conveyor belt tearing and slippage based on magnetoelectric induction according to claim 3, characterized in that, In step S2, the central processing unit serves as the final data aggregation point. Each coupled reader connects to the nearest field data acquisition station via a bus or industrial Ethernet. The acquisition station is then connected to the central processing unit via a fiber optic ring network.

5. The method for early warning of conveyor belt tearing and slippage based on magnetoelectric induction according to claim 4, characterized in that, In step S3, when the conveyor belt is severely torn, i.e. the induction coil is broken, the coupling reader cannot receive the returned frequency signal, and the central processing unit determines the location of the tear based on the information of the adjacent returned signal tags. When abnormal stretching or micro-damage occurs, i.e., the induction coil undergoes geometric deformation due to the stretching of the conveyor belt, the resonant frequency is affected. Resonant frequency with baseline Compared to when a shift occurs, the central processing unit does not issue a tear warning at this time, but records the deformation location. The formula for calculating the frequency shift is: ,in, To detect the tag The real-time resonant frequency, For tags The baseline resonant frequency.

6. The method for early warning of conveyor belt tearing and slippage based on magnetoelectric induction according to claim 5, characterized in that, In step S4, the time difference and actual speed The calculation formulas are as follows: ， ， The formula for calculating the slip rate S is: ； in, The theoretical operating speed set for the conveyor belt.

7. The method for early warning of conveyor belt tearing and slippage based on magnetoelectric induction according to claim 1, characterized in that, In step S5, if the tearing fault is confirmed, the central processing unit outputs a stop command to the conveyor main control PLC. If a slippage warning is triggered, the central processing unit issues an instruction to adjust the conveyor belt tension through the tensioning device control cabinet to eliminate slippage, or issues a deceleration instruction.

8. A detection system for implementing the conveyor belt tearing and slippage early warning method based on magnetoelectric induction as described in any one of claims 1-7, characterized in that: include: Embedded sensor array module: It consists of rectangular induction coils composed of multiple independently coded passive RFID tags. The induction coils are pre-embedded in the conveyor belt cover layer in the form of parallel grids or pasted on the bottom of the bearing surface. The long side of the induction coil is perpendicular to the running direction of the conveyor belt and covers the entire width. The coil and the chip capacitor C together form an LC resonant circuit, and its resonant frequency changes with the stress state of the conveyor belt. Distributed reader network module: includes multiple coupled readers, which are installed along the conveyor line and at the material drop port, guide chute, and joint area, for synchronously transmitting high-frequency alternating magnetic fields and reading RFID tag information passing through their area; The data processing and fusion early warning module is the central processing unit of the system. It is communicatively connected to the distributed reader network module and is used to receive and process tag information, including tag UID identity information, real-time resonant frequency, signal strength, and timestamp. The data processing and fusion early warning module performs tearing and slippage state judgment based on the algorithm, performs early warning classification and fault location based on the judgment results, and generates control commands. Early warning and execution terminal module: Receives instructions from the data processing and fusion early warning module, performs status visualization display, hierarchical early warning alarm and control signal output.

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