Belt conveyor fault positioning and maintenance method based on multi-source state monitoring

Abstract

The present application relates to a belt conveyor fault positioning and maintenance method based on multi-source state monitoring, comprising: obtaining the rotating speed of each idler in the idler group arranged continuously along the conveying direction, and the multi-source state parameters of the load pressure, the belt surface height, the temperature and the vibration; selecting any idler as the target idler and determining the adjacent idlers on the upstream side and the downstream side of the target idler; comparing the corresponding state parameters of the target idler and the adjacent idlers, when the rotating speed of the target idler is lower than the preset rotating speed threshold value, and the load pressure or the belt surface height is lower than the corresponding position of the adjacent idler, and the adjacent idler meets the preset abnormal change threshold value, determining the target idler as the fault source idler and determining the associated load idler; generating the maintenance inspection range and the maintenance measures according to the positional relationship of the fault source idler and the associated load idler; the present application can avoid misjudgment caused by load transfer, reduce the investigation range, and improve the accuracy of fault positioning and maintenance processing.

Description

Technical Field

[0001] This invention relates to the field of belt conveyor fault location and maintenance technology, specifically a belt conveyor fault location and maintenance method based on multi-source condition monitoring. Background Technology

[0002] In existing technologies, belt conveyors typically have a large number of idler groups along the conveying direction. As direct support components for the conveyor belt and material load, the idlers' rotational state, support height, load-bearing force, temperature rise, and vibration state directly affect the operational stability of the conveying system. When idlers experience abnormalities such as jamming, wear, installation misalignment, support sinking, or detachment, the changes in the faulty idler's own state may not always manifest as a significant abrupt change in a single parameter. Instead, they may cause related phenomena such as increased load pressure on adjacent idlers, enhanced vibration, temperature changes, or changes in the conveyor belt surface height. If alarms are triggered based solely on a single point of temperature, sound, or vibration signal, it is easy to confuse the faulty idler with adjacent idlers that are exhibiting abnormal responses due to load transfer, leading to inaccurate fault location. Maintenance personnel would then need to expand the scope of their investigation, affecting downtime maintenance efficiency.

[0003] For example, Chinese patent CN113086546A discloses an intelligent idler group for belt conveyors with self-inspection function. It collects status data such as temperature, vibration, and rotational speed of the idlers through sensor modules installed on the idlers, and the data processing roller analyzes the real-time status of the idler group before sending status information to external devices. While this type of solution can improve the automation level of the idler group's own status detection, it mainly focuses on the collection, processing, and transmission of status data within the idler group. It typically judges whether an abnormality is due to the parameters of the monitored idler itself, failing to fully utilize the differences in load-bearing response between adjacent idlers upstream and downstream of the target idler to infer the true source of the fault. Furthermore, it is difficult to provide a clear maintenance and inspection scope and priority targets for situations where the load transfers to adjacent idlers after support failure.

[0004] For example, Chinese patent CN113213101A discloses a method and system for detecting roller anomalies. It collects the sound signal from the roller and processes it through filtering, time-domain feature analysis, frequency-domain analysis, empirical mode decomposition, wavelet packet decomposition, and envelope analysis to determine whether the roller is abnormal and identify the abnormal roller. This solution has good identification significance for sound-based fault characteristics. However, the on-site conditions of belt conveyors are complex. Material impact, environmental noise, conveyor belt joints, changes in roller installation posture, and changes in local support height can all affect the detection results. Especially when the support capacity of the target roller decreases while the passive load of adjacent rollers increases, it is difficult to distinguish between the fault of the adjacent roller itself and the associated anomalies after the failure of the target roller based solely on sound or a single fault characteristic. Therefore, there is an urgent need for a method that can comprehensively consider multiple source state parameters such as roller speed, load pressure, belt surface height, temperature, and vibration, and combine the positional relationship between the target roller and adjacent rollers in the conveying direction to determine the fault source and generate the maintenance range, in order to improve the accuracy of fault location and the pertinence of maintenance measures. Summary of the Invention

[0005] The purpose of this invention is to provide a fault location and maintenance method for belt conveyors based on multi-source condition monitoring, thereby solving some of the drawbacks and shortcomings pointed out in the background art.

[0006] The present invention adopts the following technical solution to solve the above-mentioned technical problems:

[0007] The rotational speed of each idler in a continuously arranged idler group along the conveying direction, as well as one or more state parameters including bearing pressure and conveyor belt surface height, and one or more state parameters including temperature and vibration, are obtained. Any idler is set as the target idler, and the adjacent idlers on the upstream side and the adjacent idlers on the downstream side of the target idler are set as adjacent idlers.

[0008] The state parameters of the target idler are compared with the corresponding state parameters of the adjacent idlers. When the rotation speed of the target idler is lower than the preset rotation speed threshold, and the bearing pressure or conveyor belt surface height at the detection position of the target idler is lower than the detection position of the adjacent idler, and the bearing pressure, temperature or vibration of one or two adjacent idlers meets the preset abnormal change threshold, the target idler is identified as the fault source idler, and the adjacent idlers that meet the preset abnormal change threshold are identified as the associated bearing idlers.

[0009] The maintenance and inspection scope is determined based on the positional relationship between the fault source idler and the connected load-bearing idler in the conveying direction, and maintenance measures are generated to prioritize the maintenance of the fault source idler and inspect the connected load-bearing idler.

[0010] Furthermore, before determining the faulty idler, one or more idlers other than the adjacent idlers on the upstream and downstream sides of the target idler are selected as reference idlers. The load pressure, temperature, or vibration change amplitude of the reference idler is compared with the corresponding change amplitude of the adjacent idlers. When the change amplitude of the adjacent idler is higher than the preset difference value of the change amplitude of the reference idler, and the rotation speed of the target idler is lower than the preset rotation speed threshold, it is determined that the abnormality of the adjacent idler is caused by the load transfer after the failure of the target idler.

[0011] Furthermore, when the conveyor belt joint or material concentration section passes through the target idler and the adjacent idler in sequence, the bearing pressure response of the target idler and the adjacent idler are recorded respectively. If the bearing pressure response of the target idler is lower than the preset pressure difference value of the bearing pressure response of the adjacent idler, and the increase in the bearing pressure of the adjacent idler within a preset time window reaches a preset pressure increment threshold, then the target idler is identified as a support failure type fault source idler.

[0012] Furthermore, the failure type of the faulty idler is determined based on the position of the connecting load idler relative to the faulty source idler; when the connecting load idler exists on both the upstream and downstream sides of the faulty source idler, it is determined to be a support sinking type failure or a support detachment type failure; when the connecting load idler exists on the downstream side of the faulty source idler but not on the upstream side, it is initially determined to be a dragging type failure or an installation misalignment type failure, and the connecting load idler on the downstream side is included in the maintenance and inspection scope.

[0013] Furthermore, when the conveyor belt joint or material concentration section passes the target idler, if the load-bearing pressure response of the target idler does not form a corresponding pressure peak, while the adjacent idler forms a pressure peak during the corresponding passage period determined according to the conveyor belt speed and idler spacing, it is determined that the target idler has a lack of support contact, and the target idler is identified as the priority replacement target.

[0014] Furthermore, the duration of the bearing pressure response formed when the conveyor belt joint or material concentration section passes the target idler is compared with the duration of the bearing pressure response formed when it passes the adjacent idler; when the response duration of the target idler is lower than the preset duration difference of the response duration of the adjacent idler, and the response amplitude of the target idler is lower than the preset amplitude difference of the response amplitude of the adjacent idler, it is determined that the target idler has insufficient support height.

[0015] Furthermore, after the conveyor belt joint or material concentration section has passed the target idler and the adjacent idler consecutively, if the load-bearing pressure response of the adjacent idler is higher than the preset pressure difference value of the load-bearing pressure response of the target idler in more than two passes, the possibility of the adjacent idler itself being faulty is ruled out, and the target idler is identified as the fault source idler causing repeated load transfer.

[0016] Furthermore, when there is a connecting support roller on the downstream side of the fault source roller and no connecting support roller on the upstream side, the rotation speed of the fault source roller is lower than the preset rotation speed threshold, the vibration change amplitude of the connecting support roller on the downstream side reaches the preset vibration change threshold, and the temperature change amplitude of the connecting support roller on the downstream side does not reach the preset temperature change threshold, the fault source roller is determined to be a drag-type failure, and the contact position between the fault source roller and the conveyor belt is taken as the wear inspection position.

[0017] Furthermore, when there is a connecting support roller on the downstream side of the fault source roller but no connecting support roller on the upstream side, and the height of the conveyor belt surface at the detection position corresponding to the fault source roller is lower than the preset height difference of the conveyor belt surface at the detection position corresponding to the adjacent roller on the upstream side, the fault source roller is determined to be an installation misalignment type failure, and the mounting base and the height of both ends of the roller shaft of the fault source roller are taken as maintenance and inspection objects.

[0018] Furthermore, when checking the mounting base and the height of both ends of the roller shaft of the fault source idler, the conveyor belt surface height corresponding to both ends of the fault source idler and the bearing pressure at both ends of the downstream connecting bearing idler are compared respectively; when the conveyor belt surface height corresponding to one end of the fault source idler is lower than the preset height difference of the conveyor belt surface height corresponding to the other end, and the bearing pressure on the same side of the downstream connecting bearing idler is higher than the preset pressure difference of the bearing pressure on the other side, the same side end of the fault source idler is determined to be for height adjustment.

[0019] This invention acquires the rotational speed of each idler in a continuously arranged idler group along the conveying direction, and combines this with various state parameters such as load pressure, conveyor belt height, temperature, and vibration to compare the corresponding state parameters of the target idler with those of its upstream and downstream adjacent idlers. Therefore, when the target idler's rotational speed is lower than a preset speed threshold, and the load pressure or belt height at the target idler's detection position is lower than the corresponding detection position of the adjacent idler, while the adjacent idlers exhibit abnormal changes in load pressure, temperature, or vibration, the target idler can be identified as the fault source idler, and the adjacent idlers with abnormal responses can be identified as associated load-bearing idlers. This avoids misjudging abnormalities in adjacent idlers caused by load transfer as the primary fault.

[0020] This invention further determines the maintenance and inspection scope based on the positional relationship between the faulty idler and the connected load-bearing idler in the conveying direction, and generates maintenance measures to prioritize the maintenance of the faulty idler and inspect the connected load-bearing idler, thus directly translating the fault diagnosis results into on-site maintenance guidelines. This method not only reduces the scope of manual troubleshooting and downtime for inspection, but also establishes a hierarchical processing sequence for conditions such as idler support failure, load transfer, and damage to adjacent idlers, improving the accuracy, timeliness, and safety of belt conveyor operation and maintenance. Attached Figure Description

[0021] Figure 1 This is a flowchart of the multi-source condition monitoring fault location and maintenance process of the present invention.

[0022] Figure 2 This is a comparison diagram of the multi-source state parameters of the idler roller in Embodiment 1 of the present invention.

[0023] Figure 3 This is a diagram showing the time period and pressure peak of the conveyor belt joint in Embodiment 1 of the present invention.

[0024] Figure 4 This is a confirmation diagram of repeated load transfer in Embodiment 1 of the present invention.

[0025] Figure 5 This is a diagram for determining the abnormal state of the downstream connected bearing idler in Embodiment 2 of the present invention.

[0026] Figure 6 This is a diagram for determining the amount of sinking of the idler belt surface in Embodiment 2 of the present invention.

[0027] Figure 7 This is a diagram confirming the deviation between the height adjustment end and the bearing pressure on both sides in Embodiment 2 of the present invention. Detailed Implementation

[0028] As attached Figure 1 As shown, in one specific embodiment, a continuous set of idlers is arranged along the conveying direction of the belt conveyor, and a detection unit for collecting operating status data is configured at each idler. The detection unit is used to acquire the rotational speed of each idler, and to acquire one or more status parameters among the bearing pressure and conveyor belt surface height, as well as one or more status parameters among temperature and vibration. The system selects any idler in the continuously arranged idler set as the target idler, and designates the adjacent idlers upstream and downstream of the target idler as adjacent idlers to establish a status comparison relationship between the target idler and its adjacent idlers.

[0029] During fault localization, the target idler's rotational speed, load-bearing pressure, conveyor belt height, temperature, or vibration parameters are compared with the corresponding parameters of adjacent idlers. When the target idler's rotational speed is lower than a preset speed threshold, and the load-bearing pressure or conveyor belt height at the corresponding detection position of the target idler is lower than that of the adjacent idler at the corresponding detection position, it indicates a decreasing trend in the target idler's support capacity for the conveyor belt or material. Further analysis is then conducted to determine whether the load-bearing pressure, temperature, or vibration of one or two adjacent idlers meets a preset abnormal change threshold. If the adjacent idlers meet this abnormal change threshold, it indicates that the load transfer resulting from the target idler's failure has already acted on the adjacent idlers. In this case, the target idler is identified as the fault source idler, and the adjacent idlers that meet the preset abnormal change threshold are identified as the associated load-bearing idlers.

[0030] After identifying the faulty idler and the associated load-bearing idler, the maintenance and inspection scope is determined based on their relative positions in the conveying direction. If the associated load-bearing idler is located upstream, downstream, or on either side of the faulty idler, the corresponding idler section and related components to be inspected are identified. The system generates maintenance measures based on this scope, including prioritizing the maintenance of the faulty idler and performing condition checks on the associated load-bearing idlers to prevent further load transfer caused by the faulty idler, thereby improving the accuracy of fault location and maintenance of the belt conveyor.

[0031] Based on the above implementation method, a reference judgment process can be further set up before determining the fault source idler to improve the accuracy of fault source judgment. Specifically, in addition to the upstream and downstream adjacent idlers of the target idler, one or more idlers with relatively stable operating conditions are selected as reference idlers, and the load pressure, temperature, or vibration change amplitude of the reference idlers is obtained respectively. Then, the load pressure, temperature, or vibration change amplitude of the reference idler is compared with the corresponding change amplitude of the adjacent idlers to determine whether the abnormal change of the adjacent idlers is caused by local load transfer. If the corresponding change amplitude of the adjacent idlers is significantly higher than that of the reference idlers, and the target idler simultaneously exhibits one or more of the following states: reduced speed, reduced load pressure, or reduced conveyor belt height, then the abnormal change of the adjacent idlers is confirmed to be related to the decline in the support state of the target idler; if the reference idler and the adjacent idlers both show similar changes, then the change is investigated as an overall fluctuation in the operating condition of the conveyor, and the target idler is not directly identified as the fault source idler.

[0032] Based on the above implementation method, the load changes generated when the conveyor belt joint or material concentration section passes over the idler can be used to further identify the support status of the target idler. Specifically, when the conveyor belt joint or material concentration section passes over the target idler and the adjacent idler in sequence along the conveying direction, the load-bearing pressure response of the target idler and the adjacent idler is recorded respectively, and the amplitude, duration, and pressure peak formation of the load-bearing pressure response are analyzed. If the load-bearing pressure response of the target idler is lower than the preset pressure difference value of the load-bearing pressure response of the adjacent idler, and the increase in the load-bearing pressure of the adjacent idler within a preset time window reaches a preset pressure increment threshold, it indicates that part of the load that should have been borne by the target idler has been transferred to the adjacent idler. At this time, the target idler is identified as a support failure type fault source idler.

[0033] Furthermore, when the conveyor belt joint or material concentration section passes the target idler, if the target idler's load-bearing pressure response does not form a corresponding pressure peak, while the adjacent idler forms a pressure peak during the corresponding passage time determined by the conveyor belt speed and idler spacing, it indicates that effective support contact has not been formed between the target idler and the conveyor belt. In this case, it is determined that the target idler has a lack of support contact, and the target idler is identified as the priority replacement target. The duration of the load-bearing pressure response formed when the conveyor belt joint or material concentration section passes the target idler can also be compared with the duration of the load-bearing pressure response formed when it passes the adjacent idler. When the response duration of the target idler is lower than the preset duration difference of the response duration of the adjacent idler, and the response amplitude of the target idler is lower than the preset amplitude difference of the response amplitude of the adjacent idler, it is determined that the target idler has insufficient support height.

[0034] During continuous monitoring, when the conveyor belt joint or material concentration section passes over the target idler and adjacent idlers multiple times, the system saves the load-bearing pressure response, response duration, and pressure peak formation of the target idler and adjacent idlers for each pass, and performs a consistency judgment on the multiple test results. If the target idler consistently exhibits a low load-bearing pressure response, missing pressure peaks, or short response duration during multiple passes, while adjacent idlers continuously show increased load-bearing pressure or enhanced pressure peaks during the corresponding passes, then the support abnormality of the target idler is confirmed to be persistent, and the target idler is included in the scope of fault source idler confirmation. If the abnormality only occurs during a single pass and does not recur in subsequent passes, the abnormality is reviewed as a temporary material impact or short-term operational disturbance and is not directly used as the basis for confirming the fault source idler.

[0035] Based on the above implementation method, the failure type of the faulty idler can be further identified according to the position of the connecting support idler relative to the faulty idler. Specifically, after identifying the faulty idler and the connecting support idler, it is determined whether the connecting support idler is located upstream, downstream, or both of the faulty idler. When connecting support idlers are present on both the upstream and downstream sides of the faulty idler, it indicates that the supporting capacity of the faulty idler on the conveyor belt is weakened at its location, causing the load to transfer to adjacent idlers on both sides. In this case, the faulty idler is identified as a support sinking type failure or a support detachment type failure. When a connecting support idler is present downstream of the faulty idler but not upstream, it indicates that the abnormal load is mainly transmitted downstream along the conveying direction. In this case, the faulty idler is initially identified as a dragging type failure or an installation misalignment type failure, and the connecting support idler on the downstream side is included in the maintenance and inspection scope.

[0036] Furthermore, when there is a connected load-bearing idler downstream of the faulty idler but no connected load-bearing idler upstream, the rotational speed of the faulty idler is lower than a preset speed threshold, the vibration variation amplitude of the connected load-bearing idler downstream reaches a preset vibration variation threshold, and the temperature variation amplitude of the connected load-bearing idler downstream does not reach a preset temperature variation threshold, it indicates that the faulty idler may be dragging the conveyor belt due to obstructed rotation. This dragging effect causes the connected load-bearing idler downstream to experience periodic impacts or additional vibrations without causing significant abnormal temperature rise. In this case, the faulty idler is determined to be a dragging-type failure, and the contact point between the faulty idler and the conveyor belt is used as a wear inspection point to check for scratches, wear, or localized obstruction marks at this contact point.

[0037] Furthermore, when there is a connected load-bearing idler downstream of the faulty idler but no connected load-bearing idler upstream, and the conveyor belt surface height at the detection position corresponding to the faulty idler is lower than the preset height difference of the conveyor belt surface height at the detection position corresponding to the adjacent idler upstream, it indicates that the faulty idler may be causing localized conveyor belt sagging due to inconsistent installation height or roller misalignment. In this case, the faulty idler is determined to be an installation misalignment type failure, and the height of the mounting base and both ends of the roller shaft of the faulty idler are identified as maintenance and inspection targets. During the inspection, the conveyor belt surface heights corresponding to both ends of the faulty idler are compared, and the bearing pressure at both ends of the downstream connected load-bearing idler is compared. When the conveyor belt surface height corresponding to one end of the faulty idler is lower than the preset height difference of the conveyor belt surface height corresponding to the other end, and the bearing pressure on the same side of the downstream connected load-bearing idler is higher than the preset pressure difference of the bearing pressure on the other side, it indicates that the installation height of that end of the faulty idler needs adjustment. In this case, the same side end of the faulty idler is designated as the height adjustment end to correct the position of the mounting base or roller shaft end.

[0038] Example 1:

[0039] Company A continuously arranges idlers R1 to R8 along the conveying direction on a belt conveyor, and sets up a detection unit at each idler. The detection unit is used to collect parameters such as the rotational speed, load pressure, conveyor belt height, temperature, and vibration state of the corresponding idler. The system sets any idler as the target idler according to the conveying direction, and identifies the adjacent idlers upstream and downstream of the target idler as adjacent idlers to establish a state comparison relationship between the target idler and its adjacent idlers.

[0040] In this embodiment, the system selects R4 as the target idler, R3 as the upstream adjacent idler, and R5 as the downstream adjacent idler. R1 and R7, located outside the target and adjacent idlers and with relatively stable operating states, are selected as reference idlers. Each detection unit collects state parameters according to the same sampling period and transmits the collected results to the control module for comparison and judgment.

[0041] During a test run, the preset speed threshold was 480 r / min, the speed of R4 was 430 r / min, the speed of R3 was 505 r / min, and the speed of R5 was 498 r / min. Since the speed of R4 was lower than the preset speed threshold, and the speeds of R3 and R5 were both within the normal operating range, the system included R4 in the list of suspected faulty idler rollers. Figure 2 The load-bearing pressure of each idler roller is represented by a bar graph, the rotational speed of each idler roller is represented by a broken line graph, and the preset rotational speed threshold is indicated by a horizontal dashed line. Figure 2 It can be directly seen that R4 is lower than the adjacent idler in both speed and load pressure, while R5 has a higher load pressure, which is consistent with the graphical verification relationship for subsequent judgment of the connected load idler.

[0042] Meanwhile, the load-bearing pressure at the detection position corresponding to R4 is 1.85 kN, the load-bearing pressure at the detection position corresponding to R3 is 2.62 kN, and the load-bearing pressure at the detection position corresponding to R5 is 2.70 kN. The system compares the load-bearing pressure of the target idler with that of the adjacent idlers to determine whether the load to be borne by the target idler has been transferred to the adjacent idlers. The load transfer difference is determined according to the following relationship:

[0043]

[0044] in, Indicates the difference in load transfer. This indicates the load-bearing pressure at the corresponding detection position of adjacent idlers. This represents the load-bearing pressure at the detection position corresponding to the target idler. This relationship is obtained by subtracting the target idler's load-bearing pressure from the load-bearing pressure of the adjacent idler, and is used to characterize the increase in load-bearing capacity of the adjacent idler relative to the target idler. When R5 is used as the adjacent idler for calculation, it is substituted into... , ,get:

[0045]

[0046] When the load transfer difference reaches the preset pressure difference, it indicates that part of the load that R4 should have borne has been transferred to R5. Combined with the fact that the speed of R4 is lower than the preset speed threshold, the system initially determines that R4 has a decreasing trend in support capacity and lists R5 as a possible associated load-bearing idler.

[0047] To avoid misjudging overall conveyor fluctuations as localized faults, the system further incorporates a reference idler roller for analysis. The test results show that the load pressure variations for R1 and R7 are 0.09 kN and 0.11 kN, respectively, while those for R3 and R5 are 0.48 kN and 0.55 kN, respectively. Since the load pressure variations of adjacent idlers are significantly higher than those of the reference idler roller, and R4 exhibits both a decrease in rotational speed and a decrease in load pressure, the system determines that the abnormal changes in R3 and R5 are not caused by overall material fluctuations, but rather are related to the load transfer following a decrease in the support condition of R4.

[0048] Based on the initial assessment above, the system uses the load change generated when the conveyor belt joint passes over the idler to reconfirm R4. During conveyor operation, the conveyor belt speed is 2.5 m / s, and the idler spacing is 1.2 m. The system determines the corresponding detection period for the load-bearing pressure response of the adjacent idler based on the time required for the conveyor belt joint to travel from the target idler to the adjacent idler. The corresponding time periods are determined according to the following relationship:

[0049]

[0050] in, This indicates the time required for the conveyor belt joint to travel from the target idler to the adjacent idler. This indicates the distance between the target idler and the adjacent idler. This indicates the conveyor belt running speed. This relationship is derived from the correspondence between running distance and running speed, and is used to determine the detection time range for the conveyor belt splice passing adjacent idlers. Substituting... , ,get:

[0051]

[0052] The system detects whether a pressure peak forms at R5 approximately 0.48 seconds after the conveyor belt joint passes R4. The test results show that when the conveyor belt joint passes R4, the load-bearing pressure response amplitude at R4 is 1.90 kN, the response duration is 0.18 seconds, and no significant pressure peak is formed. When the conveyor belt joint passes R5, the load-bearing pressure response amplitude at R5 is 2.78 kN, the response duration is 0.31 seconds, and a significant pressure peak is formed. Figure 3The load-bearing pressure responses of R4 and R5 after passing the conveyor belt joint are plotted on the same time axis, with the corresponding time interval marked around 0.48s. Figure 3 It is evident that R5 forms a significant peak during this period, while the response curve of R4 is lower and no effective pressure peak appears, further indicating that R4 and the conveyor belt do not form sufficient support contact, and the load generated by the conveyor belt joint is significantly absorbed when passing through R5.

[0053] The system also compares the load-bearing pressure responses generated when the conveyor belt joint or material concentration section passes through R4 and R5 multiple times consecutively. If the load-bearing pressure response of R5 is higher than the preset pressure difference value of the load-bearing pressure response of R4 during multiple passes, and R4 consistently shows a lack of pressure peaks, low response amplitude, or short response duration, then the possibility of R5 itself being faulty and causing abnormal pressure increase is ruled out, and R4 is confirmed as the faulty idler roller causing repeated load transfer. Figure 4 Using the number of consecutive passes as a horizontal comparison benchmark, this paper simultaneously displays the R4 response amplitude, the R5 response amplitude, and the load transfer difference between the two. Figure 4 It is evident that the load transfer difference remained higher than the preset pressure difference during multiple passes, indicating that the anomaly was not caused by a random impact, but rather by a repeatable and stable load transfer phenomenon.

[0054] Based on the above detection and judgment results, the system identified R4 as the support failure source idler, R5 as the associated load-bearing idler, and R3 as a secondary review item. Maintenance measures include prioritizing the inspection or replacement of R4, checking its installation position, rotation status, and contact with the conveyor belt, and reviewing the load-bearing status, temperature, and vibration of R5 to prevent further expansion of load transfer caused by R4 failure.

[0055] Example 2:

[0056] Company A installs idlers R10 to R16 along the conveying direction of its belt conveyor, and equips each idler with a detection unit to collect parameters such as idler speed, load pressure, conveyor belt height, temperature, and vibration. Based on the comparison of the conditions between the continuously arranged idlers, the system identifies the faulty idler and the associated load-bearing idler, and determines the scope of maintenance and inspection based on their positional relationship in the conveying direction.

[0057] In this embodiment, the system has identified R13 as the faulty idler, R12 as the upstream adjacent idler, and R14 as the downstream adjacent idler. The detection results show that R14 meets the criteria for determining a connected load-bearing idler, while R12 does not, indicating that the abnormal load generated after the failure of R13 is mainly transmitted downstream.

[0058] After determining that R14 is located downstream of R13 and that R12 is not in a state of joint load, the system initially includes R13 in the list of failures caused by dragging or misalignment, and incorporates R14 into the maintenance and inspection scope. This judgment is not based on a single parameter, but rather on a combination of factors including the rotational speed of R13, the vibration amplitude of R14, the temperature amplitude of R14, and the height of the conveyor belt surface at the location of R13.

[0059] During a test run, the preset rotational speed threshold was 480 r / min, and the rotational speed of R13 was 422 r / min, indicating that the rotational speed of R13 was below the normal operating requirements. The vibration variation amplitude of R14 was 1.8 mm / s, while the preset vibration variation threshold was 1.2 mm / s. The temperature variation amplitude of R14 was 2.1℃, while the preset temperature variation threshold was 5℃. Since the vibration variation amplitude of R14 reached the preset vibration variation threshold, but the temperature variation amplitude did not reach the preset temperature variation threshold, the system determined that R13 might be dragging the conveyor belt due to obstructed rotation, and designated the contact point between R13 and the conveyor belt as the wear inspection location. Figure 5 As shown, the system converts the R13 rotational speed, R14 vibration, and R14 temperature rise into proportions relative to their respective thresholds. The R13 rotational speed proportion is less than 100%, the R14 vibration proportion reaches 150%, and the R14 temperature rise proportion is only 42%. This graphical relationship intuitively shows that the downstream connecting load-bearing idler roller is mainly characterized by abnormal vibration, without forming obvious abnormal temperature rise, which is consistent with the verification characteristics of drag-type failure.

[0060] To further distinguish whether installation misalignment still exists at R13, the system compares the conveyor belt surface height at the detection position corresponding to R13 with that at the detection position corresponding to R12. The conveyor belt surface height at the detection position corresponding to R13 is 796mm, and the conveyor belt surface height at the detection position corresponding to R12 is 803mm, with a preset height difference of 5mm. The belt surface height difference is determined according to the following relationship:

[0061]

[0062] Where ΔH represents the amount of belt surface subsidence of the fault source idler relative to the adjacent idler on the upstream side. This indicates the conveyor belt surface height at the corresponding detection position of the adjacent idler roller on the upstream side. This represents the conveyor belt surface height at the detection location corresponding to the faulty idler. This relationship is obtained by subtracting the belt surface height at the faulty idler from the belt surface height at the adjacent idler on the upstream side, and is used to characterize the degree of localized conveyor belt subsidence at the location of the faulty idler. Substituting... It is 803mm. Given 796mm, we get:

[0063]

[0064] Since the calculated belt surface height difference is 7mm, which is greater than the preset height difference of 5mm, the system determines that there is significant belt surface sagging at the location of R13. In addition to exhibiting dragging and resistance characteristics, R13 also exhibits installation misalignment failure characteristics. Therefore, the system will focus on the height of the mounting base of R13 and the two ends of the roller shaft as maintenance and inspection targets. Figure 6 As shown, the belt height at the detection positions corresponding to R12, R13, and R14 exhibits a trend of first decreasing and then increasing along the conveying direction, with the lowest belt height at R13; simultaneously, Figure 6 The belt surface subsidence of R13 relative to R12 is displayed side by side with the height difference threshold, so that the judgment process of 7mm subsidence exceeding the 5mm threshold can correspond to the position relationship of the idler roller.

[0065] During the inspection of the installation status at both ends of R13, the test results showed that the conveyor belt surface height corresponding to the left end of R13 was 794mm, and the corresponding conveyor belt surface height corresponding to the right end was 801mm, indicating that the left end of R13 was lower than the right end. The downstream connecting idler roller R14 has a bearing pressure of 2.95kN on the left and 2.22kN on the right, with a preset pressure difference of 0.50kN. The pressure deviation at both ends is determined according to the following relationship:

[0066]

[0067] Wherein, ΔF represents the bearing pressure difference between the two sides of the downstream connecting bearing idler. This indicates the bearing pressure on the same side as the lower end of the downstream connecting idler and the fault source idler. This represents the bearing pressure on the other side of the downstream connecting idler. This relationship is used to determine whether the lower end of the faulty idler causes an increase in the bearing pressure on the same side downstream. Since the left end of R13 is the lower end, substitute... It is 2.95kN. The value is 2.22 kN, therefore:

[0068]

[0069] Since the calculated pressure deviation at both ends is 0.73kN, which is greater than the preset pressure difference of 0.50kN, the system designates the left end of R13 as the height adjustment end. During maintenance, prioritize checking the mounting base at the left end of R13, the support position and tightness of the roller end, and simultaneously check for scratches, wear, or localized obstructions in the contact area between R13 and the conveyor belt. Figure 7 As shown, the height of the left end of R13 is lower than that of the right end, while the bearing pressure on the left side of R14 is higher than that on the right side. The two form a correspondence between low height and high bearing on the same side. Figure 7 The pressure deviation ΔF is also indicated as 0.73kN, which helps confirm that the left end of R13 is the height adjustment end that needs to be calibrated.

[0070] For the downstream connecting load-bearing idler R14, the system verifies its load-bearing pressure, vibration, and temperature, and focuses on inspecting the area with higher load-bearing pressure on the left side of R14. If adjusting the height of the left end of R13 and restoring the rotation state of R13 reduces the vibration amplitude of R14 and the deviation of load-bearing pressure on both sides to below the corresponding threshold, then R13 is confirmed as the main fault source idler causing the load transfer on the downstream side.

[0071] In this way, the system can combine the dragging characteristics, belt surface sinking characteristics, and pressure deviation at both ends to determine the failure type and height adjustment end of R13 when the downstream connecting load-bearing idler has already experienced abnormal load. It can then generate maintenance measures for the R13 mounting seat, the height of the left end of the roller shaft, the contact wear position of the conveyor belt, and the load condition of R14.

Claims

1. A method for fault location and maintenance of belt conveyors based on multi-source condition monitoring, characterized in that: The rotational speed of each idler in a continuously arranged idler group along the conveying direction, as well as one or more state parameters including bearing pressure and conveyor belt surface height, and one or more state parameters including temperature and vibration, are obtained. Any idler is set as the target idler, and the adjacent idlers on the upstream side and the adjacent idlers on the downstream side of the target idler are set as adjacent idlers. The state parameters of the target idler are compared with the corresponding state parameters of the adjacent idlers. When the rotation speed of the target idler is lower than the preset rotation speed threshold, and the bearing pressure or conveyor belt surface height at the detection position of the target idler is lower than the detection position of the adjacent idler, and the bearing pressure, temperature or vibration of one or two adjacent idlers meets the preset abnormal change threshold, the target idler is identified as the fault source idler, and the adjacent idlers that meet the preset abnormal change threshold are identified as the associated bearing idlers. The maintenance and inspection scope is determined based on the positional relationship between the fault source idler and the connected load-bearing idler in the conveying direction, and maintenance measures are generated to prioritize the maintenance of the fault source idler and inspect the connected load-bearing idler.

2. The method according to claim 1, characterized in that: Before identifying the faulty idler, one or more idlers other than the adjacent idlers on the upstream and downstream sides of the target idler are selected as reference idlers. The load pressure, temperature, or vibration change amplitude of the reference idler is compared with the corresponding change amplitude of the adjacent idlers. When the change amplitude of the adjacent idler is higher than the preset difference value of the change amplitude of the reference idler, and the rotation speed of the target idler is lower than the preset rotation speed threshold, it is determined that the abnormality of the adjacent idler is caused by the load transfer after the failure of the target idler.

3. The method according to claim 1, characterized in that: When the conveyor belt joint or material concentration section passes through the target idler and the adjacent idler in sequence, the bearing pressure response of the target idler and the adjacent idler are recorded respectively. If the bearing pressure response of the target idler is lower than the preset pressure difference value of the bearing pressure response of the adjacent idler, and the increase in the bearing pressure of the adjacent idler within the preset time window reaches the preset pressure increment threshold, then the target idler is identified as a support failure type fault source idler.

4. The method according to claim 1, characterized in that: The failure type of the faulty idler is determined based on the position of the connecting load idler relative to the faulty idler. When the connecting load idler exists on both the upstream and downstream sides of the faulty idler, it is determined to be a support sinking failure or a support detachment failure. When the connecting load idler exists on the downstream side of the faulty idler but not on the upstream side, it is initially determined to be a dragging failure or an installation misalignment failure, and the connecting load idler on the downstream side is included in the maintenance and inspection scope.

5. The method according to claim 3, characterized in that: When the conveyor belt joint or material concentration section passes the target idler, if the load-bearing pressure response of the target idler does not form a corresponding pressure peak, while the adjacent idler forms a pressure peak during the corresponding passage period determined according to the conveyor belt speed and idler spacing, it is determined that the target idler has a lack of support contact, and the target idler is identified as a replacement object.

6. The method according to claim 3, characterized in that: The duration of the bearing pressure response formed when the conveyor belt joint or material concentration section passes the target idler is compared with the duration of the bearing pressure response formed when it passes the adjacent idler. When the response duration of the target idler is lower than the preset duration difference of the response duration of the adjacent idler, and the response amplitude of the target idler is lower than the preset amplitude difference of the response amplitude of the adjacent idler, it is determined that the target idler has insufficient support height.

7. The method according to claim 3, characterized in that: When the conveyor belt joint or material concentration section passes through the target idler and the adjacent idler consecutively, if the load-bearing pressure response of the adjacent idler is higher than the preset pressure difference value of the load-bearing pressure response of the target idler in more than two passes, the possibility of the adjacent idler itself being faulty is ruled out, and the target idler is identified as the fault source idler causing repeated load transfer.

8. The method according to claim 4, characterized in that: When the connecting support roller exists downstream of the fault source roller but not upstream, the rotational speed of the fault source roller is lower than the preset rotational speed threshold, the vibration change amplitude of the connecting support roller downstream reaches the preset vibration change threshold, and the temperature change amplitude of the connecting support roller downstream does not reach the preset temperature change threshold, the fault source roller is determined to be a dragging failure, and the contact position between the fault source roller and the conveyor belt is taken as the wear inspection position.

9. The method according to claim 4, characterized in that: When there is a connecting support roller downstream of the fault source roller but no connecting support roller upstream, and the height of the conveyor belt surface at the detection position corresponding to the fault source roller is lower than the preset height difference of the conveyor belt surface at the detection position corresponding to the adjacent roller upstream, the fault source roller is determined to be an installation misalignment type failure, and the mounting base and the height of both ends of the roller shaft of the fault source roller are taken as maintenance and inspection objects.

10. The method according to claim 9, characterized in that: When checking the mounting base and the height of both ends of the roller shaft of the fault source idler, the conveyor belt surface height corresponding to both ends of the fault source idler and the bearing pressure at both ends of the downstream connecting bearing idler are compared respectively. When the conveyor belt surface height corresponding to one end of the fault source idler is lower than the preset height difference of the conveyor belt surface height corresponding to the other end, and the bearing pressure on the same side of the downstream connecting bearing idler is higher than the preset pressure difference of the bearing pressure on the other side, the same side end of the fault source idler is determined to be for height adjustment.

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