Vertical carrier roller, belt conveyor and method for detecting a misalignment of a conveyor belt

Abstract

The application provides a vertical carrier roller, a belt conveyor and a method for detecting deviation of a transmission belt. The vertical carrier roller comprises a lower end cover, an upper end cover, a covering member arranged between the lower end cover and the upper end cover, a closed cavity formed between the covering member, the lower end cover and the upper end cover, a central shaft arranged between the lower end cover and the upper end cover, the central shaft penetrating the cavity, a first end of the central shaft penetrating the lower end cover and extending out of the lower end cover, and a second end of the central shaft penetrating the upper end cover and extending out of the upper end cover, a siren arranged on the upper end cover or the lower end cover, and an air inlet of the siren being in communication with the cavity. When the transmission belt located at the side of the vertical carrier roller deviates and exerts pressure on the covering member of the vertical carrier roller, the cavity is deformed to squeeze the gas in the cavity to be discharged, and the siren emits sound. The application can improve the timeliness and accuracy of the detection of the deviation of the transmission belt of the belt conveyor.

Description

Technical Field

[0001] This invention relates to the field of operational testing technology, and in particular to a method for detecting misalignment of vertical idlers, belt conveyors, and transmission belts. Background Technology

[0002] A belt conveyor is a friction-driven machine that transports materials continuously. It mainly consists of a frame, conveyor belt, idlers, rollers, tensioning devices, and a transmission system. It can transport materials along a defined conveyor line from the initial feeding point to the final unloading point, creating a material transport flow. It can transport both bulk materials and packaged goods. Besides pure material transport, it can also be integrated with the technological requirements of various industrial production processes to form rhythmic assembly line transport operations.

[0003] Among them, idlers are important components of belt conveyor systems, mainly used to support the weight of the belt and materials. At the same time, vertical idlers are also installed on the side of the belt to prevent the belt from running off-track. However, in daily use, because the materials falling on the belt are not in the same position, the offset of the materials causes uneven weight distribution on the belt. As the usage time increases, the belt will run off-track under the action of gravity, which will affect the use of the belt conveyor. Summary of the Invention

[0004] The technical problem to be solved by this invention is to provide a method for detecting belt misalignment in vertical idlers, belt conveyors, and transmission belts. This invention can improve the timeliness and accuracy of detecting belt misalignment in belt conveyors.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows: A vertical idler roller, comprising: Lower end cap; Top cover; A covering component is disposed between the lower end cover and the upper end cover, and a sealed cavity is formed between the covering component, the lower end cover and the upper end cover; A central shaft is disposed between the lower end cover and the upper end cover. The central shaft passes through the cavity. The first end of the central shaft passes through the lower end cover and extends beyond the lower end cover. The second end passes through the upper end cover and extends beyond the upper end cover. A whistle is provided on the upper or lower end cover, and the air inlet of the whistle is connected to the cavity; When the transmission belt located on the side of the vertical idler deviates and exerts pressure on the covering of the vertical idler, it causes the cavity to shrink and deform, squeezing out the gas in the cavity, thereby causing the whistle to sound.

[0006] Optionally, the covering is made of flexible rubber material.

[0007] Optionally, the inner side of the cover is sealed to the outer side of the lower end cap and the outer side of the upper end cap using sealant.

[0008] Optionally, the wall thickness in the middle of the covering is less than the wall thickness at both ends.

[0009] An embodiment of the present invention also provides a belt conveyor, comprising: a frame, a transmission belt placed on the frame, and a plurality of vertical idlers arranged side by side on the side of the transmission belt, wherein the vertical idlers are as described above, the bottom end of the central shaft of the vertical idlers is rotatably connected to the frame of the belt conveyor, and the frequencies and / or volumes of the whistles of the plurality of vertical idlers arranged side by side are different from each other.

[0010] Optionally, the spacing between multiple vertical idlers arranged side by side can be the same or set according to a preset distance step that increases or decreases sequentially.

[0011] An embodiment of the present invention also provides a method for detecting belt misalignment in a belt conveyor, wherein the belt conveyor is as described above, and the method includes: Acquire the sound signal emitted by the whistle of at least one of a plurality of vertical idlers arranged side by side; The position of the vertical roller emitting the sound signal is determined based on the frequency and / or magnitude of the sound signal.

[0012] Optionally, determining the position of the vertical idler roller emitting the sound signal based on the frequency of the sound signal includes: By setting different air inlet diameters and different cavity lengths for the whistle, a different inherent resonant frequency is set for each vertical idler roller; The position of the vertical roller emitting the sound signal is determined by comparing the frequency of the sound signal with the inherent resonant frequency.

[0013] Optionally, determining the position of the vertical idler roller emitting the sound signal based on the magnitude of the sound signal includes: Pickups are placed at intervals along the conveyor belt; The position of the vertical idler roller that emitted the sound signal is determined based on the sound amplitude collected by the microphone.

[0014] Optionally, determining the position of the vertical idler emitting the sound signal based on the frequency and magnitude of the sound signal includes: The sound signal frequency is compared with the different inherent resonant frequencies of each vertical idler roller to obtain the sound-emitting vertical idler roller for primary screening. Based on the sound amplitude collected by the microphones installed on the conveyor belt, the target vertical idler that emits the sound signal is determined by screening in the initial screening vertical idler.

[0015] The above-described technical solution of the present invention has at least the following technical effects: The vertical idler roller of the present invention comprises a lower end cover; an upper end cover; a covering member disposed between the lower and upper end covers, forming a sealed cavity between the covering member, the lower end cover, and the upper end cover; a central shaft disposed between the lower and upper end covers, the central shaft penetrating the cavity, a first end of the central shaft passing through the lower end cover and extending beyond the lower end cover, and a second end passing through the upper end cover and extending beyond the upper end cover; and a whistle disposed on the upper or lower end cover, the air inlet of the whistle communicating with the cavity. When the conveyor belt located on the side of the vertical idler roller deviates and exerts pressure on the covering member of the vertical idler roller, the cavity contracts and deforms, squeezing out the gas in the cavity, thereby causing the whistle to sound. This improves the timeliness and accuracy of conveyor belt deviation detection in belt conveyors. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the vertical idler roller of the present invention; Figure 2 This is a schematic diagram of the belt conveyor of the present invention.

[0017] Explanation of reference numerals in the attached figures: 1-Lower end cover; 2-Upper end cover; 3-Covering component; 4-Central shaft; 5-Whistle; 6-Cavity; 7-Belt conveyor; 71-Vertical idler; 72-Frame. Detailed Implementation

[0018] Exemplary embodiments of the invention will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the invention are shown in the drawings, it should be understood that the invention may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this invention will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[0019] like Figure 1 As shown, an embodiment of the present invention provides a vertical idler roller, comprising: a lower end cover 1; an upper end cover 2; and a covering member 3 disposed between the lower end cover 1 and the upper end cover 2, wherein a sealed cavity 6 is formed between the covering member 3, the lower end cover 1 and the upper end cover 2. A central shaft 4 is disposed between the lower end cover 1 and the upper end cover. The central shaft 4 passes through the cavity 6. The first end of the central shaft 4 passes through the lower end cover 1 and extends outside the lower end cover 1, and the second end passes through the upper end cover 2 and extends outside the upper end cover 2. The whistle 5 is installed on the upper end cover 2 or the lower end cover 1, and the air inlet of the whistle 5 is connected to the cavity 6; When the transmission belt located on the side of the vertical idler deviates and exerts pressure on the covering 3 of the vertical idler, the cavity 6 contracts and deforms, squeezing out the gas in the cavity 6, thereby causing the whistle 5 to make a sound.

[0020] In this embodiment, as Figure 1 As shown, the vertical idler roller includes a lower end cover 1 and an upper end cover 2. A central shaft 4 is disposed between the lower end cover 1 and the upper end cover 2. The two ends of the central shaft 4 pass through the lower end cover 1 and the upper end cover 2 respectively and extend to their outer sides. A covering member 3 is disposed between the lower end cover 1 and the upper end cover 2. The lower end cover 1 and the upper end cover 2 are located at the two ends of the covering member 3 respectively. The outer sides of the lower end cover 1 and the upper end cover 2 are sealed to the inner side of the covering member 3. A cavity 6 is formed between the lower end cover 1, the upper end cover 2 and the covering member 3. A whistle 5 is installed on the lower end cover 1 or the upper end cover 2. The air inlet passes through the lower end cover 1 and is inserted into the cavity 6. When the belt deviates, it will shift to one side. When the belt contacts the vertical idler, it will squeeze the covering 3, causing the covering 3 to deform. This will compress the cavity 6 formed between the lower end cover 1, the upper end cover 2, and the covering 3, causing the gas inside the cavity 6 to be discharged through the whistle 5. This will make the whistle 5 sound, alerting the staff that the belt has deviated, so that the staff can adjust the belt conveyor and ensure the effective use of the belt conveyor.

[0021] In an optional embodiment of the present invention, the covering 3 is made of a flexible rubber material.

[0022] In this embodiment, the covering 3 is made of a highly elastic and tear-resistant flexible rubber material, which takes into account the wear resistance of the roller rotation, repeated compression and rebound, and will not be permanently deformed under long-term compression, and the cavity can automatically reset and store air.

[0023] In an optional embodiment of the present invention, the inner side of the covering 3 is sealed to the outer side of the lower end cover 1 and the outer side of the upper end cover 2 by sealant; preferably, to further increase the sealing performance, the lower end cover 1 and the upper end cover 2 are connected to the covering 3 by an interference fit; the mating surfaces between the lower end cover 1 and the upper end cover 2 and the covering 3 are reinforced by an interference fit, and double sealing is achieved by interference fit on the basis of filling sealant, ensuring that the vertical idler roller does not delaminate or leak air during long-term rotation and vibration, and preventing false alarms or no alarms caused by air leakage in the cavity 6; In an optional embodiment of the present invention, a dustproof oil seal is provided between the lower end cover 1 and the upper end cover 2 and the covering component 3.

[0024] In this embodiment, the mating surfaces between the lower end cover 1 and the upper end cover 2 and the covering 3 are all provided with dustproof oil seals to prevent dust and moisture from entering the cavity 6 and to avoid internal dust accumulation from blocking the air passage of the whistle 5.

[0025] In this embodiment, the mating surfaces between the lower end cap 1 and the upper end cap 2 and the covering 3 are filled with sealant to improve the sealing performance of the cavity 6.

[0026] In an optional embodiment of the present invention, the wall thickness of the middle part of the covering 3 is less than the wall thickness of the two ends.

[0027] In this embodiment, the middle section of the cover 3 has a smaller wall thickness, which makes it more elastic and easier to deform under pressure. As long as the belt slightly rubs against the middle section, the cavity will be compressed, and the whistle will sound immediately, achieving early warning. The two ends of the cover 3 have larger wall thickness, which makes them more rigid and less prone to deformation. On the one hand, this reduces meaningless deformation, and on the other hand, the upper and lower ends and the bonding position of the end cap are thickened to improve the sealing strength and prevent long-term compression from causing the end to delaminate and leak air, thus balancing airtightness and structural strength.

[0028] In an optional embodiment of the present invention, a filter screen is provided at the air inlet of the whistle 5.

[0029] In this embodiment, a metal filter screen is added to the air inlet of the whistle 5 to prevent foreign objects from entering the air passage and avoid clogging the whistle, which would cause it to fail to sound.

[0030] An embodiment of the present invention also provides a belt conveyor, comprising: a frame 72, a transmission belt placed on the frame 72, and a plurality of vertical idlers 71 arranged side by side on the side of the transmission belt. The vertical idlers 71 are vertical idlers as described in the above scheme. The bottom end of the central shaft 4 of the vertical idlers 71 is rotatably connected to the frame 72 of the belt conveyor. The frequencies and / or loudness of the whistles 5 of the plurality of vertical idlers 71 arranged side by side are different from each other.

[0031] In this embodiment, the top end of the central shaft 4, which extends outward from the outer side of the lower end cover 1, is rotatably connected to the belt conveyor frame 72. When the belt is working normally and there is no deviation, the vertical idler 71 can rotate normally with the belt at low speed. The belt does not squeeze the covering 3, the volume of the cavity 6 remains unchanged, there is no airflow, and the whistle does not sound. When the belt deviates abnormally, the belt squeezes the covering 3 laterally. Regardless of whether the vertical idler 71 is rotating at this time, the compression and exhaust of the cavity 6 will trigger the whistle 5 to sound, thus completing the belt deviation sound reminder.

[0032] In an optional embodiment of the present invention, the spacing between the multiple vertical idlers arranged side by side is the same or is set according to a preset distance step that increases or decreases sequentially.

[0033] In this embodiment, multiple vertical idlers are spaced apart along the side of the conveyor belt. The spacing between the vertical idlers can be uniform, non-uniform with gradually increasing spacing, or non-uniform with gradually decreasing spacing, so that the vertical idlers can be used to monitor the position of the conveyor belt deviation.

[0034] Embodiments of the present invention also provide a method for detecting belt misalignment in a belt conveyor, wherein the belt conveyor is the belt conveyor described in the above scheme, and the method includes: Acquire the sound signal emitted by the whistle 5 of at least one of the multiple vertical idlers arranged side by side; The position of the vertical roller emitting the sound signal is determined based on the frequency and / or magnitude of the sound signal.

[0035] In an optional embodiment of the present invention, determining the position of the vertical idler roller emitting the sound signal based on the frequency of the sound signal includes: By setting different air inlet diameters for the whistle 5 and different lengths for the cavity 6, a different inherent resonant frequency is set for each vertical idler roller; The position of the vertical roller emitting the sound signal is determined by comparing the frequency of the sound signal with the inherent resonant frequency.

[0036] In this embodiment, frequency differentiation is achieved by setting different diameters for the air inlets of the whistles 5 and different lengths for the cavities 6, so that different whistles have different inherent resonant frequencies without affecting the sensitivity of the squeeze sound generation. The frequency of the collected sound signal is matched with the pre-stored frequency-roller position mapping table. When the frequency matching is successful, the corresponding vertical roller number and frame installation position are directly retrieved to determine the position of the vertical roller that emits the sound signal.

[0037] In an optional embodiment of the present invention, determining the position of the vertical idler roller emitting the sound signal based on the magnitude of the sound signal includes: Pickups are placed at intervals along the conveyor belt; The position of the vertical idler roller that emitted the sound signal is determined based on the sound amplitude collected by the microphone.

[0038] In this embodiment, multiple microphones are arranged at intervals along the belt conveyor, and a table is recorded showing the distance correspondence between each microphone and each vertical idler roller. The microphones collect sound in real time, and the sound amplitude collected by each microphone is compared. The closer the microphone is to the vertical idler roller that emits sound, the louder the detected volume. Using the microphone with the loudest volume as a reference, the position of the corresponding vertical idler roller is determined by looking up the table in conjunction with the distance parameters.

[0039] In an optional embodiment of the present invention, determining the position of the vertical idler roller emitting the sound signal based on the frequency and magnitude of the sound signal includes: The sound signal frequency is compared with the different inherent resonant frequencies of each vertical idler roller to obtain the sound-emitting vertical idler roller for primary screening. Based on the sound amplitude collected by the microphones installed on the conveyor belt, the vertical idler rollers that emit sound are screened in the initial screening to determine the position of the vertical idler roller that emits the sound signal.

[0040] In this embodiment, each vertical idler is equipped with a dedicated fixed-frequency whistle, and a frequency-idler installation position reference table is established. Microphones are deployed in sections along the conveyor belt, synchronously collecting ambient sound. When the sound amplitude exceeds the environmental noise threshold, an idler alarm is detected, and a valid whistle signal is extracted. The signal frequency and loudness amplitude are separated into two sets of features. Spectral analysis is performed on the whistle signal to extract its frequency, which is then matched against a pre-stored frequency table to narrow down the candidate idlers. Irrelevant idlers with mismatched frequencies are eliminated, resulting in the initial screening of sound-emitting vertical idlers. The sound levels detected by each microphone are compared, and loudness differences are matched among the initial screening of sound-emitting vertical idlers to pinpoint the unique sound-emitting idler and determine the location of the vertical idler emitting the sound signal.

[0041] The present invention can, when the belt deviates to one side, squeeze the covering 3, thereby deforming the covering 3 and compressing the cavity 6 formed between the lower end cover 1, the upper end cover 2 and the covering 3. This causes the gas inside the cavity 6 to be discharged through the whistle 5, which then sounds to alert the staff that the belt has deviated, so that the staff can adjust the belt conveyor in time and ensure the effective use of the belt conveyor.

[0042] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A vertical idler roller, characterized in that, include: Lower end cap (1); Top cover (2); The cover (3) is disposed between the lower end cover (1) and the upper end cover (2), and a sealed cavity (6) is formed between the cover (3), the lower end cover (1) and the upper end cover (2). A central shaft (4) is disposed between the lower end cover (1) and the upper end cover. The central shaft (4) passes through the cavity (6). The first end of the central shaft (4) passes through the lower end cover (1) and extends beyond the lower end cover (1). The second end passes through the upper end cover (2) and extends beyond the upper end cover (2). The whistle (5) is installed on the upper end cover (2) or the lower end cover (1), and the air inlet of the whistle (5) is connected to the cavity (6); When the transmission belt located on the side of the vertical idler deviates and exerts pressure on the cover (3) of the vertical idler, the cavity (6) contracts and deforms, squeezing out the gas in the cavity (6), thereby causing the whistle (5) to make a sound.

2. The vertical idler roller according to claim 1, characterized in that, The covering (3) is made of flexible rubber material.

3. The vertical idler roller according to claim 1, characterized in that, The inner side of the cover (3) is sealed to the outer side of the lower end cap (1) and the outer side of the upper end cap (2) by sealant.

4. The vertical idler roller according to claim 1, characterized in that, The wall thickness of the middle part of the covering (3) is less than that of the two ends.

5. A belt conveyor, characterized in that, include: The frame (72), the conveyor belt placed on the frame (72), and a plurality of vertical idlers (71) arranged side by side on the side of the conveyor belt, wherein the vertical idlers (71) are vertical idlers as described in any one of claims 1 to 4, the bottom end of the central shaft (4) of the vertical idlers (71) is rotatably connected to the belt conveyor frame (72), and the frequencies and / or volumes of the whistles (5) of the plurality of vertical idlers (71) arranged side by side are different from each other.

6. The belt conveyor according to claim 5, characterized in that, The spacing between multiple vertical idlers arranged side by side is the same or is set according to a preset distance step that increases or decreases sequentially.

7. A method for detecting belt misalignment in a belt conveyor, characterized in that, The belt conveyor is the belt conveyor as described in claim 5 or 6, and the method includes: Acquire the sound signal emitted by the whistle (5) of at least one of the multiple vertical idlers arranged side by side; The position of the vertical roller emitting the sound signal is determined based on the frequency and / or magnitude of the sound signal.

8. The method for detecting belt misalignment in a belt conveyor according to claim 7, characterized in that, Determining the position of the vertical idler roller emitting the sound signal based on the frequency of the sound signal includes: By setting different air inlet diameters of the whistle (5) and different lengths of the cavity (6), different inherent resonant frequencies are set for each vertical idler roller; The position of the vertical roller emitting the sound signal is determined by comparing the frequency of the sound signal with the inherent resonant frequency.

9. The method for detecting belt misalignment in a belt conveyor according to claim 7, characterized in that, Determining the position of the vertical idler roller emitting the sound signal based on the magnitude of the sound signal includes: Pickups are placed at intervals along the conveyor belt; The position of the vertical idler roller that emitted the sound signal is determined based on the sound amplitude collected by the microphone.

10. The method for detecting belt misalignment in a belt conveyor according to claim 7, characterized in that, Determining the position of the vertical idler roller emitting the sound signal based on its frequency and intensity includes: The sound signal frequency is compared with the different inherent resonant frequencies of each vertical idler roller to obtain the sound-emitting vertical idler roller for primary screening. Based on the sound amplitude collected by the microphones installed on the conveyor belt, the target vertical idler that emits the sound signal is determined by screening in the initial screening vertical idler.

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