Belt tearing identification system based on sound wave conduction

Abstract

The utility model relates to the field of belt tearing detection, and discloses a belt tearing identification system based on sound wave conduction, which comprises a sound emitter, a sound receiver and a transmission belt, and the sound emitter and the sound receiver are connected with two different ends of the transmission belt through a flowing medium. The utility model has the beneficial effects that the mechanical wear is reduced, the service life of equipment is prolonged, and the maintenance cost is reduced; the stability and adaptability of the detection technology are enhanced, and accurate tearing detection can be provided no matter the belt is static or moves at a high speed; the operation cost is reduced; and the high-performance liquid-liquid composite material has harsh environment adaptability, noise suppression and liquid compatibility, wide medium adaptability and surface compatibility.

Description

Technical Field

[0001] The utility model relates to the field of belt tear detection, in particular to a belt tear identification system based on sound wave conduction. Background Art

[0002] The application of belt tear monitoring technology in industrial production and logistics transportation is of vital importance. As an indispensable transportation equipment in these industries, the integrity and safety of belts are directly related to the production safety, efficiency and cost control of enterprises.

[0003] First, belt tearing may lead to material leakage, equipment damage and production line interruption. In serious cases, it may even cause fire or explosion accidents, posing a serious threat to employees and enterprises. Therefore, real-time monitoring of belt status and timely detection and prevention of tearing are the key to ensuring safe production of enterprises. This monitoring technology can continuously monitor the status of the belt and predict and promptly detect potential tearing risks by detecting abnormal changes in sound waves, thereby avoiding accidents.

[0004] Secondly, belt tearing can cause production lines to stagnate, resulting in huge economic losses. Timely monitoring and early warning can quickly respond to and deal with tearing problems, reduce production interruption time, and improve production efficiency. This means that companies can resume production faster, reduce economic losses caused by tearing, and thus maintain production continuity and stability.

[0005] In addition, belt tears can also lead to expensive repairs, replacement costs, and losses caused by production interruptions. Through monitoring technology, companies can predict and prevent tears, reduce maintenance costs and extend the life of the belt. This predictive maintenance can reduce unnecessary repairs and replacements, reduce the company's operating costs, and increase the overall life of the equipment.

[0006] If belt tearing is not discovered in time, it may lead to a series of serious accidents and losses. Production interruption will directly affect the normal production and operation of the enterprise, causing delays in production plans and defaults on orders. Material leakage will not only lead to waste of resources, but may also pollute the environment, bring environmental responsibilities and image losses to the enterprise. Equipment damage will further increase the cost of repair and replacement, and may even affect the normal operation of the entire production line.

[0007] In summary, the significance of belt tear monitoring technology is to ensure the safe production of enterprises, improve production efficiency, reduce costs, and prevent potential accidents and losses. By real-time monitoring of belt status, timely detection and treatment of tearing problems, enterprises can ensure the stable operation of production lines, reduce economic losses, improve operational efficiency, and ensure the safety of employees and enterprises.

[0008] Therefore, it is of great significance for enterprises to use advanced monitoring technology to monitor the belt status in real time.

[0009] At present, there are 6 mainstream technologies for belt tear monitoring. Their advantages and disadvantages are summarized as follows:

[0010] Solution 1: Monitoring technology based on image processing

[0011] Advantages: Non-contact detection, no need to directly contact the belt, the surface condition of the belt can be intuitively presented through the visual system, and remote monitoring is easy to achieve.

[0012] Disadvantage 1: Factors such as changes in ambient light intensity and dust pollution may affect image quality and reduce the accuracy of tear recognition.

[0013] Disadvantage 2: It has high requirements on camera quality and installation location, and requires continuous maintenance to ensure clarity.

[0014] Solution 2: Line laser projection or single-line laser radar monitoring technology

[0015] Advantages: The belt profile information can be quickly obtained through the camera. The line laser is relatively low-cost and suitable for fast and continuous monitoring. The single-line laser radar is expensive and the belt profile can be directly obtained through calculation.

[0016] Disadvantage 1: It is also susceptible to interference from ambient light and contaminants on the belt surface, resulting in inaccurate projection deformation analysis.

[0017] Disadvantage 2: If the equipment is not accurate enough or is poorly maintained, it may not be able to accurately capture subtle signs of tearing.

[0018] Solution 3: Vibration or pressure, weight analysis monitoring technology

[0019] Advantages: It can monitor the running status of the belt in real time and promptly detect abnormal vibration caused by tearing. Or it can determine belt tearing through pressure testing.

[0020] Disadvantage 1: In a multi-source vibration environment, it is difficult to identify the belt tearing characteristics, and there is a risk of misjudgment.

[0021] Disadvantage 2: The sensor installation and debugging are complicated, and the accurate collection and analysis of vibration signals are required to be high.

[0022] Solution 4: Temperature detection monitoring technology

[0023] Advantages: It can effectively detect the local temperature rise caused by tearing and provide early warning for potential failures.

[0024] Disadvantage 1: Affected by external factors such as ambient temperature fluctuations and solar radiation, the temperature difference may be inaccurate.

[0025] Disadvantage 2: This method has low sensitivity for early tear damage that does not cause significant temperature rise.

[0026] Solution 5: Acoustic Emission Technology Monitoring Technology

[0027] Advantages: Structural damage can be detected by using the acoustic wave signals generated by the expansion of micro-cracks inside the material.

[0028] Disadvantage 1: Difficulty in signal identification and extraction: The sound generated by belt tearing may be short-lived and relatively weak, and can be easily drowned out by background noise (such as the sound of the belt conveyor rollers, environmental noise, etc.). This requires the sound collection equipment to have high sensitivity and efficient signal processing technology to accurately extract and identify these weak signals.

[0029] Disadvantage 2: Environmental adaptability: Conveyors usually operate in complex industrial environments that may contain a variety of noise sources. These noise sources may interfere with the normal operation of the acoustic emission monitoring system, requiring the system to be constantly calibrated and adjusted.

[0030] Disadvantage 3: Spatial coverage problem: The belt may be hundreds of meters or even thousands of meters long. In order to effectively monitor the entire belt, a large number of sound collectors (pickups) need to be deployed. This not only increases the cost of the system, but may also cause signal redundancy and interference.

[0031] Disadvantage 4: Real-time requirement: Belt tearing is a fast process, which requires the monitoring system to respond in real time and accurately identify it. This places high demands on the speed of sound collection, transmission and processing.

[0032] Solution 6: Machine Learning-Based Monitoring Technology

[0033] Advantages: It can automatically learn and identify tearing modes under different working conditions through training models, with high intelligence.

[0034] Disadvantage 1: A large amount of diverse high-quality data is required for training, and the cost of data collection and annotation is high.

[0035] Disadvantage 2: As the belt usage conditions change, the model needs to be regularly updated and optimized to maintain the detection effect. In summary, the existing technology has the following problems:

[0036] 1. Adaptability to harsh environments: Especially in industrial environments full of dust, moisture or oil, the non-contact nature of acoustic wave technology ensures that the sensor is free from pollution interference and maintains stable operation. The monitoring accuracy will not be affected by the accumulation of environmental impurities, such as image recognition technology which may be blocked by visual occlusion.

[0037] 2. Noise suppression and liquid compatibility: The system is designed to effectively resist noise interference in liquid media. Even if the belt is immersed in water, it can transmit sound waves to detect belt tears, solving the problem of many contact sensors degrading their performance after being wet or immersed in water, such as electrochemical corrosion and signal drift displacement.

[0038] 3. Wide media adaptability: Acoustic wave technology is not limited by the type of media. Whether it is gas, liquid, solid or semi-solid, it can effectively transmit sound waves, which means that no matter what material is transmitted inside the belt, the system can work reliably and adapt to various industrial scenarios, such as chemical industry, food processing, mining line, etc.

[0039] 4. Surface compatibility: Belts are made of different materials, from rubber, metal to synthetic materials. Acoustic wave monitoring does not rely on the surface characteristics of the belt, but is conducted internally, reducing dependence on surface materials and improving universal compatibility. There is no need to worry about changes in sensor hardness, friction loss or adhesion. Utility Model Content

[0040] The utility model aims to propose a belt tear identification system based on sound wave conduction to solve the technical problems of insufficient adaptability, low reliability and poor versatility of the existing belt tear detection system under harsh conditions.

[0041] A belt tearing identification system based on acoustic wave conduction, comprising:

[0042] Sound transmitter, sound receiver and transmission belt;

[0043] The sound transmitter and the sound receiver are connected to different ends of the transmission belt through a flowing medium.

[0044] The beneficial effects provided by the utility model are:

[0045] 1. For the first time, water is introduced as the coupling medium between ultrasound and belt. This innovative method improves the transmission efficiency of ultrasound and solves the problem that traditional dry coupling is easily affected by belt surface conditions. At the same time, the use of water reduces mechanical wear, prolongs equipment life, and reduces maintenance costs;

[0046] 2. It does not rely on direct contact with the belt surface, so that stable ultrasonic transmission can be maintained under various working conditions. This design enhances the stability and adaptability of the detection technology, and can provide accurate tear detection whether the belt is stationary or moving at high speed;

[0047] 3. By fixedly installing the acoustic energy transmitter and receiver and combining it with a narrowband tunable filter, this technology effectively reduces the interference of environmental noise. The directional sound wave transmission and reception method, coupled with the use of narrowband filters, ensures that only sound wave signals of a specific frequency are received, thereby improving the accuracy of detection. In addition, the transmitter and receiver use ultrasonic signals of the same frequency, combined with a bandpass filter, to accurately capture and identify the specific sound wave signals generated by belt tearing;

[0048] 4. The introduction of a circulating water supply system realizes the recycling of water resources, reduces operating costs, improves water resource utilization efficiency, and embodies the green and environmentally friendly design concept.

[0049] 5. Adaptability to harsh environments: Especially in industrial environments full of dust, moisture or oil, the non-contact nature of acoustic wave technology ensures that the sensor is free from pollution interference and maintains stable operation. The monitoring accuracy will not be affected by the accumulation of environmental impurities, such as image recognition technology which may be blocked by visual occlusion.

[0050] 6. Noise suppression and liquid compatibility: The system is designed to effectively resist noise interference in liquid media. Even if the belt is immersed in water, it can transmit sound waves to detect belt tearing, solving the problem of many contact sensors' performance degradation after moisture or immersion in water, such as electrochemical corrosion and signal drift displacement.

[0051] 6. Wide adaptability to media: Acoustic wave technology is not limited by the type of media. Whether it is gas, liquid, solid or semi-solid, it can effectively transmit sound waves, which means that no matter what material is transmitted inside the belt, the system can work reliably and adapt to various industrial scenarios, such as chemical industry, food processing, mining lines, etc.

[0052] 7. Surface compatibility: Belt materials vary from rubber, metal to synthetic materials. Acoustic wave monitoring does not rely on the surface characteristics of the belt, but is conducted internally, reducing dependence on surface materials and improving universal compatibility. There is no need to worry about changes in sensor hardness, friction loss or adhesion. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] Figure 1 It is a schematic diagram of the system structure of the utility model;

[0054] Figure 2 It is a schematic diagram of the structure of the sound transmitter and the sound receiver;

[0055] Figure 3 is a schematic diagram of a belt tear. DETAILED DESCRIPTION

[0056] In order to make the purpose, technical solution and advantages of the utility model clearer, the implementation mode of the utility model will be further described below in conjunction with the accompanying drawings.

[0057] Before formally explaining the present invention, the scheme of the present invention is first generally explained for easy understanding.

[0058] Please refer to Figure 1 , Figure 1 It is a schematic diagram of the system structure of the utility model;

[0059] The utility model provides a belt tear identification system based on sound wave conduction, comprising: a sound transmitter, a sound receiver and a transmission belt;

[0060] The sound transmitter and the sound receiver are connected to different ends of the transmission belt through a flowing medium.

[0061] As an embodiment, the flow medium in the utility model is water. Specifically, the sound transmitter and the sound receiver are installed near the pipe openings of two vertical parallel water pipes;

[0062] The lower end of the sound transmitter is a three-way valve, one end of the valve is connected to the installation water pipe of the sound transmitter, the other end is connected to the installation water pipe of the sound receiver, and the last end is connected to the water pump through the water pipe.

[0063] The whole system is installed in the water tank.

[0064] Please refer to Figure 2 , Figure 2 It is a schematic diagram of the structure of the sound transmitter and the sound receiver.

[0065] The acoustic transmitter comprises: an acoustic emission transducer, an acoustic wave power driving unit, an adjustable frequency source and a first communication interface.

[0066] It should be noted that the adjustable frequency source is electrically connected to the acoustic wave power driving unit; the acoustic wave power driving unit is electrically connected to the acoustic emission transducer; and the adjustable frequency source is also electrically connected to the first communication interface.

[0067] The sound receiver includes: a sound receiving transducer, an adjustable bandpass filter, a sound receiving processor and a second communication interface.

[0068] It should be noted that the sound receiving transducer is electrically connected to the adjustable bandpass filter; and the adjustable bandpass filter is electrically connected to the sound receiving processor.

[0069] The frequency synchronization signal between the sound transmitter and the sound receiver is communicated wirelessly or by wire, specifically, through the first communication port and the second communication port.

[0070] It should be noted that the system also includes a host computer; the sound receiving processor is electrically connected to the host computer.

[0071] As an embodiment, the present invention describes the system in detail as follows.

[0072] 1. Acoustic transmitter: The acoustic transmitter is placed under a directional water column, which comes from a water reservoir and is transported by a water pump. The ultrasonic signal generated by the transducer in the transmitter will be fully coupled and carried by the water flow, contacting the belt surface, and the sound wave is coupled into the belt.

[0073] 2. Sound wave coupling and transmission: Since water is an excellent ultrasonic propagation medium, when the water flow comes into contact with the belt, the ultrasonic wave can be efficiently coupled into the belt material and propagate laterally within the belt cross section.

[0074] 3. Sound receiver: On the other side of the belt, there is also a directional water column and a sound receiving transducer. When there is no tear or other damage in the belt, the ultrasonic signal can continue to pass through the belt and be coupled to the receiving end transducer again with the help of the water column. The transducer converts the received ultrasonic signal into an electrical signal.

[0075] 4. Detection and judgment: please refer to Figure 3 , Figure 3 is a schematic diagram of a belt tear.

[0076] Under normal circumstances, the strength and shape of the electrical signal received by the transducer at the receiving end are relatively stable. However, once the belt is torn or otherwise damaged, the ultrasonic wave will be blocked or attenuated during propagation, resulting in abnormal signals at the receiving end. By monitoring and analyzing the signals at the receiving end, it is possible to accurately determine whether the belt is torn. In the present utility model, the detection and judgment are completed by the acoustic processor transmitting the signal to the host computer through host analysis. It should be noted that the host computer analysis can be a simple comparison and does not require complex improvements or designs.

[0077] 5. Recycling: To save resources and protect the environment, a circulating water supply system is used in the design. The pump draws clean water from the water tank and sends it to the transmitting end and the receiving end. The water coupled by ultrasonic waves returns to the water tank and is reused after filtering. This design scheme fully utilizes the advantages of water as a coupling medium, overcomes the problems of low coupling efficiency and susceptibility to belt surface conditions that dry coupling may face, and reduces equipment wear, with high detection accuracy and long service life.

[0078] In the utility model, the sound transmitter and the sound receiver use the same sound wave transducer, and the working mode can be switched, one for transmission and the other for reception. After the sound transducer at the receiving end converts the sound wave into an electrical signal, it only outputs the same frequency signal as the transmitting end through an adjustable bandpass filter (narrowband filter), which can suppress various environmental noises including belts and rollers. When the belt is in a static state, a pair of sound energy transducers are placed on both sides of the test belt, and the optimal frequency (lowest acoustic impedance) can be determined through a frequency sweep test experiment. At the same time, the size of the transmission power can also be adjusted so that the transducer at the receiving end can receive enough sound wave energy.

[0079] The beneficial effects of the utility model are:

[0080] 1. For the first time, water is introduced as the coupling medium between ultrasound and belt. This innovative method improves the transmission efficiency of ultrasound and solves the problem that traditional dry coupling is easily affected by belt surface conditions. At the same time, the use of water reduces mechanical wear, prolongs equipment life, and reduces maintenance costs;

[0081] 2. It does not rely on direct contact with the belt surface, so that stable ultrasonic transmission can be maintained under various working conditions. This design enhances the stability and adaptability of the detection technology, and can provide accurate tear detection whether the belt is stationary or moving at high speed;

[0082] 3. By fixedly installing the acoustic energy transmitter and receiver and combining it with a narrowband tunable filter, this technology effectively reduces the interference of environmental noise. The directional sound wave transmission and reception method, coupled with the use of narrowband filters, ensures that only sound wave signals of a specific frequency are received, thereby improving the accuracy of detection. In addition, the transmitter and receiver use ultrasonic signals of the same frequency, combined with a bandpass filter, to accurately capture and identify the specific sound wave signals generated by belt tearing;

[0083] 4. The introduction of a circulating water supply system realizes the recycling of water resources, reduces operating costs, improves water resource utilization efficiency, and embodies the green and environmentally friendly design concept.

[0084] 5. Adaptability to harsh environments: Especially in industrial environments full of dust, moisture or oil, the non-contact nature of acoustic wave technology ensures that the sensor is free from pollution interference and maintains stable operation. The monitoring accuracy will not be affected by the accumulation of environmental impurities, such as image recognition technology which may be blocked by visual occlusion.

[0085] 6. Noise suppression and liquid compatibility: The system is designed to effectively resist noise interference in liquid media. Even if the belt is immersed in water, it can transmit sound waves to detect belt tearing, solving the problem of many contact sensors' performance degradation after moisture or immersion in water, such as electrochemical corrosion and signal drift displacement.

[0086] 6. Wide adaptability to media: Acoustic wave technology is not limited by the type of media. Whether it is gas, liquid, solid or semi-solid, it can effectively transmit sound waves, which means that no matter what material is transmitted inside the belt, the system can work reliably and adapt to various industrial scenarios, such as chemical industry, food processing, mining lines, etc.

[0087] 7. Surface compatibility: Belt materials vary from rubber, metal to synthetic materials. Acoustic wave monitoring does not rely on the surface characteristics of the belt, but is conducted internally, reducing dependence on surface materials and improving universal compatibility. There is no need to worry about changes in sensor hardness, friction loss or adhesion.

[0088] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A belt tear identification system based on acoustic wave conduction, characterized in that: include: Sound transmitter, sound receiver and transmission belt; The sound transmitter and the sound receiver are connected to different ends of the transmission belt through a flowing medium.

2. A belt tear identification system based on acoustic wave conduction as claimed in claim 1, characterized in that: The acoustic transmitter comprises: an acoustic emission transducer, an acoustic wave power driving unit, an adjustable frequency source and a first communication interface.

3. A belt tear identification system based on acoustic wave conduction as claimed in claim 2, characterized in that: The adjustable frequency source is electrically connected to the acoustic wave power driving unit; the acoustic wave power driving unit is electrically connected to the acoustic emission transducer; and the adjustable frequency source is also electrically connected to the first communication interface.

4. The belt tear identification system based on acoustic wave conduction according to claim 1, characterized in that: The sound receiver includes: a sound receiving transducer, an adjustable bandpass filter, a sound receiving processor and a second communication interface.

5. A belt tear identification system based on acoustic wave conduction as claimed in claim 4, characterized in that: The sound receiving transducer is electrically connected to the adjustable bandpass filter; the adjustable bandpass filter is electrically connected to the sound receiving processor.

6. The belt tear identification system based on acoustic wave conduction according to claim 1, characterized in that: The frequency synchronization signal between the sound transmitter and the sound receiver is communicated wirelessly or by wire.

7. The belt tear identification system based on acoustic wave conduction according to claim 1, characterized in that: The flowing medium is water.

8. The belt tear identification system based on acoustic wave conduction as claimed in claim 4, characterized in that: It also includes a host computer; the sound receiving processor is electrically connected to the host computer.

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