A belt conveyor integrated protection sensor test bench system

Abstract

The application discloses a belt conveyor comprehensive protection sensor test bench system, and the speed generator, the temperature generator and the smoke generator are controlled by programs, so that various working conditions of the conveyor are simulated safely and accurately, and dangerous open flame detection and other backward means are replaced, through a high-precision synchronous acquisition mechanism and an intelligent diagnosis algorithm based on FIR filtering and Leipite criteria, subjective errors of artificial judgment are eliminated, and the objectivity and accuracy of detection are greatly improved, through encryption read-only storage of all operations, data and conclusions, an unalterable detection file is established, traceability of the whole detection process is realized, core requirements of safety and quality management are met, and problems of reliability, efficiency and credibility of sensor integrity verification are fundamentally solved.

Description

Technical Field

[0001] This application relates to the field of belt conveyor protection sensor test bench systems, specifically to a belt conveyor integrated protection sensor test bench system. Background Technology

[0002] Belt conveyors are core equipment for the continuous transport of bulk materials in industrial fields such as mines, ports, and power plants. Their operational safety is directly related to production efficiency and personal safety. Therefore, various sensors for smoke, temperature, speed, belt misalignment, and tear detection are usually installed on conveyors, along with comprehensive protection devices to prevent major accidents such as fires and belt breaks.

[0003] However, some problems still exist in the installation and testing of existing integrated protection devices for belt conveyors. On the one hand, there is a lack of a convenient and reliable automatic signal generation device to simulate key operating parameters such as temperature, smoke, and velocity. For example, the detection of smoke sensors still commonly uses the outdated method of burning the tape to generate smoke, which is inefficient and the concentration and duration of the generated smoke are uncontrollable, making it difficult to ensure the consistency of test conditions. On the other hand, key information such as the original signal data, operator information, and sensor identity generated during the entire detection process cannot be automatically stored and recorded, resulting in scattered test results and process data that are difficult to trace. This brings great inconvenience to subsequent archiving, statistics, retrieval, and analysis. Furthermore, the determination of the sensor's integrity depends entirely on the test personnel's observation and manual judgment of the instrument readings or indication signals, which is easily affected by personnel experience and subjective factors, resulting in misjudgments or omissions, and failing to ensure that the integrated protection system for belt conveyors is always in an effective and reliable state. Summary of the Invention

[0004] The purpose of this application is to provide a comprehensive protection sensor test bench system for belt conveyors, so as to at least solve some of the problems mentioned in the background art.

[0005] According to one aspect of this application, a comprehensive protection sensor test bench system for belt conveyors is provided, comprising: a speed sensor, a temperature sensor, a smoke sensor, a speed generator, a temperature generator, a smoke generator, a signal input module, a signal processing and diagnostic module, and a data management module; Speed ​​generators, temperature generators, and smoke generators are used to generate corresponding physical simulation excitation signals; A speed sensor is installed on the output side of the speed generator to sense the analog speed signal generated by the speed generator and convert it into a speed electrical signal; A temperature sensor is located on the heat output side of the temperature generator to sense the analog temperature signal generated by the temperature generator and convert it into an electrical temperature signal. A smoke sensor is installed on the smoke output side of the smoke generator to sense the analog smoke signal generated by the smoke generator and convert it into a smoke electrical signal; The test signal input module is used to connect to external test speed sensor, test temperature sensor and test smoke sensor, and to receive the test speed electrical signal, test temperature electrical signal and test smoke electrical signal generated by them under the action of physical simulation excitation signal; The signal processing and diagnostic module is connected to the speed sensor, temperature sensor, smoke sensor and the signal under test access module, respectively, and is used to generate diagnostic conclusions based on the received electrical signals and the corresponding electrical signals under test. The data management module is connected to the signal processing and diagnostic module and is used to store diagnostic conclusions and related test data.

[0006] Preferably, the diagnostic conclusion includes three states: qualified, signal out of tolerance, and no response; If the comparison result between the electrical signal and the corresponding electrical signal to be tested deviates from the qualified range in the pre-stored threshold rules, it is considered a signal out-of-tolerance state. If the characteristics of the electrical signal to be tested (speed, temperature, or smoke) are missing, it is considered a no-response state.

[0007] Preferably, the physical simulation excitation signals generated by the speed generator, temperature generator, and smoke generator include simulated speed signals, simulated temperature signals, and simulated smoke signals.

[0008] Preferably, the system includes a switch quantity detection submodule, which is connected to the signal input module to be tested. The switch quantity detection submodule is used to input the deviation, tear, coal pile-up or emergency stop sensors and detect their switch state jump events.

[0009] Preferably, the system includes a water spraying test submodule, which is used to control the on / off state of the solenoid valve according to the test command and to detect the fluid on / off state to evaluate the response of the water spraying device.

[0010] Preferably, the signal processing and diagnosis module includes a filtering submodule and an error removal submodule, wherein, The filtering submodule is used to perform FIR digital filtering processing on the synchronously acquired electrical signal and the electrical signal to be detected. The error removal submodule is used to identify and remove gross errors in the filtered signal sequence based on the Leyte criterion.

[0011] Preferably, the data management module includes a permission management sub-module, which is used to perform hierarchical verification of the operator's identity and assign different system operation permissions to administrators and ordinary operators.

[0012] Preferably, the signal processing and diagnosis module further includes a feature extraction and comparison submodule and a diagnosis submodule; The feature extraction and comparison submodule is used to extract feature quantities from the signal processed by the filtering submodule and the error removal submodule and the signal to be detected, and calculate the deviation value between the two as the comparison result; The diagnostic submodule is used to match the comparison results with the pre-stored threshold rules, and output the diagnostic conclusion as qualified, signal out of tolerance, or no response based on the matching results.

[0013] According to another aspect of this application, a detection method performed by a belt conveyor integrated protection sensor test bench system is provided, comprising the following steps: S1, Receive detection type instructions from external input; S2. Based on the detection type instruction, the corresponding physical simulation excitation signal is generated programmatically; S3. Synchronous execution of operation based on physical simulation excitation signal, which includes acquiring physical quantities through sensors and converting them into reference electrical signals, and acquiring and obtaining the electrical signals to be tested generated by external sensors under test. S4. Perform preprocessing on the reference electrical signal and the electrical signal to be tested, including FIR filtering and gross error removal based on the Leyte criterion, to obtain the processed signal and the signal to be tested. S5. Perform feature extraction and comparison between the processed signal and the signal to be detected to generate a set of comparison parameters; S6. Match the comparison parameters with the pre-stored threshold rules, and generate a diagnostic conclusion based on the matching results; S7. Associate the storage detection type instruction, reference electrical signal, electrical signal to be tested, comparison parameters and diagnostic conclusions, and generate an encrypted read-only detection record.

[0014] Preferably, in step S2, the corresponding physical simulation excitation signal is generated programmatically, specifically including at least two of the following operations: It can programmatically adjust and output simulated smoke with controllable concentration; Control the heat source to output simulated heat according to a preset time and temperature curve; The drive motor executes a preset acceleration, constant speed, and deceleration program to output simulated speed.

[0015] This application addresses the technical bottlenecks in existing belt conveyor sensor detection methods, such as outdated methods, low efficiency, high risk of subjective misjudgment, and lack of traceability in the detection process. It constructs an integrated system with programmed excitation, synchronous acquisition, intelligent diagnosis, and full-process data management, centered on a programmed speed generator, temperature generator, and smoke generator. This system achieves a fundamental transformation of sensor detection from manual, decentralized, and qualitative operation to automatic, centralized, and quantitative judgment.

[0016] Specifically, this application uses a programmable speed generator, temperature generator, and smoke generator to safely and accurately simulate various working conditions of the conveyor, replacing outdated methods such as dangerous open flame detection. Through a high-precision synchronous acquisition mechanism and an intelligent diagnostic algorithm based on FIR filtering and the Leyte criterion, it eliminates subjective errors in human judgment, significantly improving the objectivity and accuracy of the detection. By establishing an tamper-proof detection archive through encrypted read-only storage that links all operations, data, and conclusions, it achieves traceability throughout the entire detection process, meeting the core requirements of safety and quality management, and fundamentally solving the problems of reliability, efficiency, and credibility in sensor integrity verification. Attached Figure Description

[0017] Figure 1 This is a block diagram of a comprehensive protection sensor test bench system for a belt conveyor according to an embodiment of this application; Figure 2 This is a front view of the test bench for a comprehensive protection sensor test bench system for a belt conveyor according to an embodiment of this application; Figure 3 This is a schematic diagram of the speed generator structure of a belt conveyor integrated protection sensor test bench system according to an embodiment of this application; Figure 4 This is another view of the test bench of a comprehensive protection sensor test bench system for a belt conveyor according to an embodiment of this application; Figure 5 This is a schematic diagram of the temperature generator structure of a belt conveyor integrated protection sensor test bench system according to an embodiment of this application; Figure 6 This is a schematic diagram of the smoke generator structure of a belt conveyor integrated protection sensor test bench system according to an embodiment of this application; Figure 7 This is a side view of the speed generator of a belt conveyor integrated protection sensor test bench system according to an embodiment of this application; Figure 8 This is a front view of a test bench for a comprehensive protection sensor test bench system for belt conveyors according to an embodiment of this application; Figure 9 This is a rear view of a test bench for a comprehensive protection sensor test bench system for a belt conveyor according to an embodiment of this application. Figure 10 This is a side view of a test bench for a comprehensive protection sensor test bench system for a belt conveyor according to an embodiment of this application. Detailed Implementation

[0018] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0019] Please see Figure 1 and Figure 2 According to one embodiment of this application, a comprehensive protection sensor test bench system and method for belt conveyors are provided. Specifically, the method includes the following steps S1-S7.

[0020] In step S1, the operator logs in via the touchscreen human-machine interface integrated into the test bench. The system calls the role-based permission management submodule to verify identity and operating permissions. After successful verification, the operator selects the item to be tested from a list containing smoke, temperature, speed, deviation, tear, and coal pile sensor types. The operator can manually enter or scan the sensor's unique identification number. The system then retrieves the corresponding model's technical parameters and historical calibration records from a pre-set relational sensor information database based on this number. This database provides complete add, delete, modify, and query operation interfaces. Authorized users can manage all sensor files throughout their entire lifecycle, complete system initialization, and receive external detection type commands. The operator can then access the system through various methods such as... Figure 2 The human-computer interaction interface shown above completes all the above operations.

[0021] In step S2, the system's main controller parses the instructions and, based on the preset signal mapping relationship, drives the corresponding speed generator, temperature generator, and smoke generator to execute precise control logic. For smoke sensor detection, the smoke generator is controlled based on an adjustable power ultrasonic atomization unit, adjusting the duty cycle or amplitude of the drive signal through a closed loop to ensure that the concentration of its output smoke continuously and precisely changes within its full range according to a preset time and concentration reference curve for verifying the sensor's response characteristics. For temperature sensor detection, the temperature generator is controlled by a heat source precisely driven by a solid-state relay or thyristor, ensuring that the temperature of its heating surface strictly follows a time and temperature characteristic curve simulating overheating or frictional heating conditions of the equipment. The shape, slope, and steady-state value of this curve are defined according to the range of the sensor being tested and the testing requirements. For speed sensor detection, the speed generator is controlled by a speed simulation unit composed of a servo driver and an encoder, driving its output shaft to execute a motion program simulating a typical operating cycle of a conveyor. This program includes at least the complete stages of uniform acceleration from zero speed to the target speed, maintaining uniform speed, and uniform deceleration to a stop. The system generates the corresponding physical simulation excitation signal programmatically according to the detection type instruction.

[0022] Step S3: During the establishment and maintenance of the physical excitation signal, the system's multi-channel synchronous data acquisition unit uses the same high-precision clock source as the trigger reference to acquire two signals in parallel. One signal acquires the high-precision, low-noise speed, temperature, and smoke signals output by the speed sensor, temperature sensor, and smoke sensor directly installed at the output of the speed generator, the heat source of the temperature generator, and inside the smoke diffusion chamber of the smoke generator, all of which have undergone metrological calibration. The other signal acquires the test signal generated by an external test sensor under the same excitation environment through a test signal access module with electrical isolation and signal conditioning functions. This design ensures strict time alignment between the two signals, providing a basis for subsequent accurate comparison, and synchronously acquiring the signal and the test signal based on the physical simulation excitation signal.

[0023] Step S4: Preprocessing first employs a pre-designed finite-length unit impulse response (FIR) digital filter to digitally filter the two synchronously acquired raw electrical signals. The core parameters of this FIR filter, such as its type, order, and cutoff frequency, are designed based on the inherent frequency band characteristics of the target sensor's output signal and the electromagnetic interference noise spectrum commonly found in industrial environments. The aim is to retain effective signal components without distortion while maximally suppressing high-frequency noise and power frequency interference. Subsequently, data cleaning is performed on the filtered discrete signal sequence based on the Leyte criterion: the arithmetic mean and deviation of the sequence are calculated in real time, and sampling points deviating from the mean by more than a preset threshold multiple (e.g., 3 times) are identified as gross errors (outliers) and removed. After these two stages of processing, a stable and reliable processed signal and the processed signal to be tested are finally obtained. The intermediate and final signal waveforms throughout the preprocessing process can be synchronously displayed through a human-machine interface in various visualization formats, such as real-time dynamic curves, bar charts, or numerical text boxes. Preprocessing, including FIR filtering and gross error removal based on the Leyte criterion, is performed on the reference electrical signal and the signal to be tested.

[0024] In step S5, the system automatically invokes the corresponding feature extraction algorithm based on the currently detected sensor type to quantify the key performance indicators from the two processed signals. For speed or slippage signals, the average pulse frequency or period is extracted; for temperature signals, the steady-state temperature value reached or the response time constant required to rise from the initial value to a specific percentage threshold is extracted; for smoke signals, the average slope of the concentration rise curve or the delay experienced by the signal amplitude to reach the alarm set value is extracted. After feature extraction, the system calculates the absolute deviation or relative percentage deviation between the feature quantity of the sensor under test and the corresponding feature quantity of the sensor. This calculation result is the quantitative comparison parameter used to objectively evaluate the sensor performance. The processed signal and the signal under test are then subjected to feature extraction and comparison to generate a set of comparison parameters.

[0025] In step S6, the system accesses the embedded rule database and calls a threshold rule that is completely consistent with the current sensor model and detection item. This rule clarifies the acceptable range of each feature comparison parameter.

[0026] The system execution includes the following steps: If all comparison parameters are within their corresponding acceptable range, a "acceptable" conclusion is generated. If any comparison parameter deviates from its acceptable range, but the signal under test is valid (i.e. the feature quantity can be identified and is non-zero), then the conclusion of "signal out of tolerance" is generated. If the process determines that the characteristics of the electrical signal under test are completely missing (such as no pulse output or signal amplitude continuously below the noise threshold), then a "no response" conclusion is generated.

[0027] Once a diagnostic conclusion is generated, the human-computer interaction unit is immediately activated, illuminating the corresponding color indicator light (green / yellow / red) and triggering the speech synthesis module to broadcast a clear voice prompt. The comparison parameters are then matched with pre-stored threshold rules, and a diagnostic conclusion is generated based on the matching results.

[0028] In step S7, at the end of the detection, the system automatically performs spatiotemporal correlation and packages all the data of this task, including operator identity, detection timestamp, sensor identity information, original signal segments, processed data, feature comparison parameters, diagnostic conclusions, and system status logs. Then, it calls the built-in encryption engine (using a common symmetric encryption algorithm) to encrypt the entire data packet and generates an archived electronic file with its file attributes forcibly set to read-only. This file is stored in the system's non-volatile memory. Authorized users can quickly retrieve, decrypt, view, and export reports of the encrypted storage records through the historical data management interface based on various combinations of conditions such as detection date, operator number, and sensor number. This enables full-chain, tamper-proof traceability management of the detection process and results, correlates key data storage, and generates encrypted read-only detection records.

[0029] According to one embodiment of this application, a comprehensive protection sensor test bench system for belt conveyors is provided.

[0030] The speed generator, temperature generator, and smoke generator are connected to the system's control core and are used to receive programmed control signals and generate corresponding analog speed signals, analog temperature signals, and analog smoke signals respectively, according to the detection type instructions.

[0031] The speed sensor is located at the output end of the speed generator, the temperature sensor is located at the heat source end of the temperature generator, and the smoke sensor is located inside the smoke diffusion chamber of the smoke generator. These sensors are used to collect the reference speed, reference temperature, and reference smoke concentration and convert them into corresponding speed electrical signals, temperature electrical signals, and smoke electrical signals, respectively.

[0032] The signal input module provides a standardized physical interface for connecting external sensors under test and receiving the electrical signals generated by them under excitation.

[0033] The signal processing and diagnostic module is connected to the speed sensor, temperature sensor, smoke sensor, the signal input module under test, and the system control core. This module is configured to execute the core processing flow: synchronously acquire the reference electrical signal and the signal under test; perform preprocessing on the two signals, including specific filtering and error removal; perform feature extraction and comparison to generate comparison parameters; and finally, match the comparison parameters with pre-stored threshold rules to automatically generate and output a diagnostic conclusion.

[0034] The data management module connects to the system control core and the signal processing and diagnostic module. This module is used to perform operation permission management, maintain the sensor information database, and perform encrypted associated storage and read-only archiving of data such as instructions, signals, parameters, and conclusions throughout the detection process, providing traceable queries.

[0035] The system also includes a switch quantity detection submodule and a sprinkler test submodule. The switch quantity detection submodule is connected to the signal input module under test and is used to input the deviation, tear, coal pile or emergency stop sensors and detect their switch state jump events. The sprinkler test submodule is used to control the solenoid valve on and off according to the test command and detect the fluid on and off status to evaluate the response of the sprinkler device.

[0036] In this system, the modules interact with each other via the internal bus or control core, exchanging commands and data. After external operation commands are input, the system collaboratively completes an automated detection process, from excitation generation, synchronous signal acquisition, intelligent processing and diagnosis to encrypted data traceability. The signal processing and diagnosis module is the hub for automatic comparison, with speed sensors, temperature sensors, smoke sensors, and the signal input module providing input, and the data management module recording the output, thus forming a complete closed-loop system.

[0037] In one embodiment, such as Figure 2 , Figure 8 , Figure 9 , Figure 10 As shown, the test bench consists of a cabinet, a table, and an electrical box. Figure 2 Number 1 is the test bench cabinet, used to install excitation sources such as speed generators, temperature generators, and smoke generators, as well as related sensors; Figure 8 Designation 1 is the table body, used to integrate the electrical box, monitor, work surface and storage accessories; Figure 8 and Figure 10Number 2 is the electrical box, which houses the signal processing and diagnostic module, data management module, signal input module, power supply module, and various signal conditioning circuits. Each module is connected to the system control core through an internal bus, forming a functional closed loop.

[0038] like Figure 2 , Figure 3 , Figure 5 , Figure 7 As shown, the excitation unit includes a velocity generator, a temperature generator, and a smoke generator.

[0039] Figure 3 Number 3 is the speed generator, installed on the side of the cabinet, which is a speed simulation unit composed of a servo driver and an encoder. Its output shaft is exposed, which facilitates the simultaneous installation of speed sensors (such as magnetoelectric speed sensors) and the connection of speed sensors under test (such as intrinsically safe speed sensors for mining). The speed generator drives the motor to execute preset acceleration, constant speed, and deceleration programs according to the detection command. The speed output range is 0-3000 r / min. The encoder feeds back the speed to the servo driver in real time, forming a closed-loop control to ensure a high degree of repeatability and stability of the output speed.

[0040] Figure 2 No. 2 is the temperature generator, located on the upper part of the cabinet. Its core heating element is precisely driven by a solid-state relay or a silicon controlled rectifier (SCR). A temperature sensor (PT100 platinum resistance thermometer) is embedded in the heat source end of the heating element to collect a reference temperature and convert it into a temperature electrical signal. The temperature sensor under test (such as a mining temperature transmitter) can be placed in the temperature sensor holder on the operating table. The temperature generator outputs heat according to a preset time and temperature curve, with a temperature range of 0-100℃, simulating conditions such as conveyor roller friction heating or bearing overheating.

[0041] like Figure 4 , Figure 6 As shown, the smoke generator uses environmentally friendly e-liquid as the smoke-generating material, and its actuator includes a smoke gun and a smoke gun holder. Figure 6 No. 2 is a smoke gun with a built-in adjustable power ultrasonic atomization unit. By adjusting the duty cycle or amplitude of the drive signal through a closed loop, the output smoke concentration can be continuously and accurately changed according to the preset time and concentration reference curves throughout the entire range. Figure 6 Designation 1 is a smoke gun holder used to secure the smoke gun. A smoke diffusion chamber is located at the front of the smoke gun, and a smoke sensor (such as an ionization or photoelectric smoke sensor) is installed inside to collect a baseline smoke concentration. The smoke sensor to be tested can be fixed to the smoke sensor holder on the work surface, directly facing the smoke diffusion port, ensuring a consistent excitation environment.

[0042] like Figure 8 As shown, the table body ( Figure 8The workbench (No. 1) is the core area for test personnel to connect and operate sensors. The physical interfaces (such as aviation plugs or banana plugs) of the signal input module under test are located on the front of the workbench and are equipped with knobs (…). Figure 8 (No. 16) is used to select the signal type—temperature signals support digital and analog signals (0-20mA, 0-10V, PT100), and speed signals support digital, frequency (200-1000Hz), and analog signals (0-20mA, 0-10V).

[0043] The switch quantity detection submodule connects to mechanical switch quantity sensors for functions such as deviation, tearing, coal piling, and emergency stop via the signal input module, displaying signal transition states in real-time and determining their integrity. The control interface of the sprinkler test submodule is also integrated here, controlling the on / off state of solenoid valves via a program and detecting fluid flow to evaluate the sprinkler system's response.

[0044] monitor( Figure 8 (Item No. 3) is a 21.5-inch industrial touchscreen, installed on the front of the electrical box, serving as the human-machine interface. Operators log in via the touchscreen. The system calls the access control submodule for authentication (hierarchical authorization for administrators / regular operators). After successful authentication, the system retrieves parameters such as the sensor model, range, and historical calibration records from the sensor information management submodule's database, and selects the test item. During the test, the display shows the waveform, deviation value, and diagnostic conclusion of the signal and the signal under test in real time using various controls such as numerical text boxes, dynamic curves, and bar charts. Once the diagnostic conclusion is generated, the indicator light module and voice broadcast module immediately trigger green / yellow / red light prompts and a voice report.

[0045] The control panel is equipped with a smoke sensor placement clip ( Figure 8 (No. 17) and temperature sensor placement box ( Figure 8 (Item No. 18) is used to fix the smoke sensor to be tested and place the temperature sensor to be tested, respectively, to ensure that their positions are stable during the excitation process.

[0046] Electrical box ( Figure 8 , Figure 10(Item 2) Internally, it houses a signal processing and diagnostic module, a data management module, and a high-precision switching power supply. The power input is 220VAC, and it can output various voltages including 127VAC, 36VAC, 24VDC, and 12VDC to power the sensor under test and external devices. The signal processing and diagnostic module is equipped with a multi-channel synchronous data acquisition unit with a sampling frequency ≥8ksamples / sec and a signal resolution of 12bit. It performs FIR digital filtering and gross error removal based on the Leyte criterion on the electrical signal and the signal under test—real-time calculation of the arithmetic mean and deviation of the sequence, identifying sampling points that deviate from the mean by more than a preset threshold multiple as gross errors and removing them. Subsequently, feature extraction and deviation calculation are performed, generating comparison results and matching them with pre-stored threshold rules, ultimately outputting a diagnostic conclusion of "qualified," "signal out of tolerance," or "no response."

[0047] The data management module has a built-in encryption engine that associates and packages all data elements throughout the entire testing process, including testing instructions, electrical signals, electrical signals under test, feature comparison parameters, diagnostic conclusions, operator information, and timestamps. It then uses encryption algorithms to generate read-only archive files, stored on a 1TB hard drive. Authorized users can quickly retrieve, decrypt, view, and print testing reports through the historical data management interface, based on criteria such as operation date, employee number, and sensor number, achieving full-chain tamper-proof traceability of the testing process.

[0048] like Figure 8 , Figure 9 As shown: Figure 8 Number 5 is the front left cabinet cover, 6 is the front middle cabinet cover, and 7 is the front right cabinet cover, used to enclose the electrical box and storage space; Figure 8 Number 13 is the front middle drawer, and number 14 is the front left and right drawers, used to store sensors, sensors under test, cables and tools; Figure 8 Number 12 is the computer switch cover, which facilitates the operation of the host power switch.

[0049] Figure 9 Number 8 is the rear cover of the electrical cabinet, 9 is the rear left cabinet cover, 10 is the rear middle cabinet cover, and 11 is the rear left cabinet cover. All of these are inspection ports, which facilitate the maintenance of the internal power supply, controller, and signal conditioning boards.

[0050] Figure 10 Number 4 is the front panel, and a power socket is located at the bottom of it. Figure 10 The winning bid number 15) and the main power switch comply with the safety electricity use specifications for coal mine surface and underground laboratories.

[0051] In summary, the belt conveyor integrated protection sensor test bench system provided in this embodiment organically integrates a speed generator, temperature generator, smoke generator, speed sensor, temperature sensor, smoke sensor, signal input module, signal processing and diagnostic module, data management module, as well as switch quantity detection submodule and water spray test submodule into an integrated cabinet and operating table structure, forming a safe, efficient, and traceable sensor testing equipment.

[0052] All parts not covered in this application are the same as or can be implemented using existing technology. Although embodiments of this application have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A belt conveyor integrated protection sensor test bench system, characterized in that, include: Speed ​​sensor, temperature sensor, smoke sensor, speed generator, temperature generator, smoke generator, signal input module, signal processing and diagnostic module, and data management module; The velocity generator, temperature generator, and smoke generator are used to generate corresponding physical simulation excitation signals; The speed sensor is located on the output side of the speed generator and is used to sense the analog speed signal generated by the speed generator and convert it into a speed electrical signal. The temperature sensor is located on the heat output side of the temperature generator and is used to sense the analog temperature signal generated by the temperature generator and convert it into a temperature electrical signal. The smoke sensor is located on the smoke output side of the smoke generator and is used to sense the simulated smoke signal generated by the smoke generator and convert it into a smoke electrical signal. The signal input module is used to connect to an external speed sensor, temperature sensor, and smoke sensor, and to receive the electrical signals of speed, temperature, and smoke generated by them under the action of the physical simulation excitation signal. The signal processing and diagnostic module is connected to the speed sensor, temperature sensor, smoke sensor and the signal to be tested access module, respectively, and is used to generate diagnostic conclusions based on the received electrical signals and the corresponding electrical signals to be tested. The data management module is connected to the signal processing and diagnosis module and is used to store the diagnostic conclusions and associated detection data.

2. The system according to claim 1, characterized in that, The diagnostic conclusion includes three states: qualified, signal out of tolerance, and no response. If the comparison result between the electrical signal and the corresponding electrical signal to be tested deviates from the qualified range in the pre-stored threshold rules, it is a signal out-of-tolerance state. If the characteristics of the electrical signal to be tested speed, electrical signal to be tested temperature, or electrical signal to be tested smoke are missing, it is a no-response state.

3. The system according to claim 2, characterized in that, The physical simulation excitation signals generated by the speed generator, temperature generator, and smoke generator include simulated speed signals, simulated temperature signals, and simulated smoke signals.

4. The system according to claim 1, characterized in that, The system includes a switch quantity detection submodule, which is connected to the signal access module under test. It is used to access the deviation, tear, coal pile-up or emergency stop sensors and detect their switch state jump events.

5. The system according to claim 1, characterized in that, The system includes a water spraying test submodule, which is used to control the on / off state of the solenoid valve according to the test command and to detect the fluid on / off state to evaluate the response of the water spraying device.

6. The system according to claim 1, characterized in that, The signal processing and diagnosis module includes a filtering submodule and an error removal submodule, wherein, The filtering submodule is used to perform FIR digital filtering processing on the synchronously acquired electrical signal and the electrical signal to be detected. The error removal submodule is used to identify and remove gross errors in the filtered signal sequence based on the Leyte criterion.

7. The system according to claim 1, characterized in that, The data management module includes a permission management submodule, which is used to perform hierarchical verification of the operator's identity and assign different system operation permissions to administrators and ordinary operators.

8. The system according to claim 6, characterized in that, The signal processing and diagnosis module further includes a feature extraction and comparison submodule and a diagnosis submodule; The feature extraction and comparison submodule is used to extract feature quantities from the signal processed by the filtering submodule and the error elimination submodule and the signal to be detected, and calculate the deviation value between the two as the comparison result; The diagnostic submodule is used to match the comparison results with pre-stored threshold rules, and output diagnostic conclusions such as qualified, signal out of tolerance, or no response based on the matching results.

9. A detection method performed by a comprehensive protection sensor test bench system for belt conveyors, characterized in that, Includes the following steps: S1, Receive detection type instructions from external input; S2. Based on the detection type instruction, the corresponding physical simulation excitation signal is generated programmatically; S3. Synchronous execution of operation based on physical simulation excitation signal, which includes acquiring physical quantities through sensors and converting them into reference electrical signals, and acquiring and obtaining the electrical signals to be tested generated by external sensors under test. S4. Perform preprocessing on the reference electrical signal and the electrical signal to be tested, including FIR filtering and gross error removal based on the Leyte criterion, to obtain the processed signal and the signal to be tested. S5. Perform feature extraction and comparison between the processed signal and the signal to be detected to generate a set of comparison parameters; S6. Match the comparison parameters with the pre-stored threshold rules, and generate a diagnostic conclusion based on the matching results; S7. Associate the storage detection type instruction, reference electrical signal, electrical signal to be tested, comparison parameters and diagnostic conclusions, and generate an encrypted read-only detection record.

10. The detection method according to claim 9, characterized in that, In step S2, the corresponding physical simulation excitation signal is generated programmatically, specifically including at least two of the following operations: It can programmatically adjust and output simulated smoke with controllable concentration; Control the heat source to output simulated heat according to a preset time and temperature curve; The drive motor executes a preset acceleration, constant speed, and deceleration program to output simulated speed.

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