Damage detection device for carrier roller bearing of belt conveyor

Abstract

The utility model relates to the technical field of damage detection of belt conveyors, and discloses a damage detection device for a carrier roller bearing of a belt conveyor. The technical problems that in the prior art, due to the fact that a lower carrier roller bearing is prone to being damaged when a belt conveyor operates, the temperature of a carrier roller rises, a belt of the belt conveyor is prone to being damaged, manual inspection precision is not high, fault positioning precision is poor, and the automation degree is low are solved. The device comprises a plurality of belt conveyors which are linearly arranged and an infrared detection module which is arranged on the outer side of a transport vehicle in a tunnel, the infrared detection module and carrier roller bearings of the belt conveyors are arranged in parallel, and the carrier roller bearings comprise a driving roller, a driven roller and a tensioning roller. According to the utility model, the accuracy and reliability of detection are improved, the maintenance cost is reduced, the operation process is simplified, and effective operation under various environmental conditions is ensured, so that the overall performance and efficiency of the belt conveyor are improved.

Description

Technical Field

[0001] The utility model relates to the technical field of damage detection of belt conveyors, in particular to a damage detection device for a roller bearing of a belt conveyor. Background Art

[0002] As a kind of component widely used in mechanical equipment, rolling bearings have various types and different structures. When a bearing of a device fails, it often causes economic losses and even poses a threat to the personal safety of on-site equipment operators. Therefore, it is very important to monitor the state and diagnose the faults of rolling bearings. The state detection and fault diagnosis technology of rolling bearings has undergone iterative updates and developments over the years. The main technical means include vibration signals, temperature signals, acoustic emission signals, electromagnetic signals, ultrasonic signals, oil sample analysis, etc. Among them, vibration signals are relatively widely developed and applied. With the continuous development of science and technology and the innovative integration of emerging technologies, the state monitoring and fault diagnosis technology of rolling bearings gradually shows the characteristics of automation and intelligence.

[0003] Infrared thermal imaging technology can perform specific imaging according to the external radiation intensity of an object. The obtained thermal image not only includes the object contour but also can visually represent the temperature field distribution on the object surface. When a rolling bearing fails, the spatial temperature field distribution also changes accordingly. Therefore, the bearing monitoring technology based on temperature has been widely applied. Similarly, the bearing state can be judged by the change of the infrared thermal image of the bearing. In recent years, the research on using infrared thermal imaging technology to judge the state of rolling bearings at home and abroad has gradually increased. This technical method has converted the bearing state judgment to a new perspective. By combining the rich thermal image features with the rapidly developing image processing technology, bearing diagnosis and monitoring can be realized, and advantages such as long-distance, non-destructive, high-precision, and intelligent can be achieved. It has gradually become a new research direction in the field of bearing state judgment.

[0004] The Chinese patent document in the prior art: 202011109155.0 discloses a detection device for a belt machine, including a positioning member, a radar detector for detecting the positioning member, and a radar signal processor. However, in the implementation process of the above solution, there are at least the following technical problems: during the TBM construction and the mucking transportation of the belt conveyor, since the roller bearings under the belt conveyor are prone to damage during operation, after the damage, due to increased friction, the temperature of the rollers rises, which easily causes damage to the belt of the belt conveyor. However, due to the long distance of the belt conveyor, manual inspection brings great trouble, and the manual inspection accuracy is not high, the fault location accuracy is poor, and the degree of automation is low. Therefore, there is an urgent need to propose a damage detection device for the roller bearings of a belt conveyor. Summary of the Invention

[0005] In view of the above technical problems, the present disclosure provides a damage detection device for the idler bearings of a belt conveyor, which solves the technical problems in the prior art that the idler bearings below are prone to damage during the operation of the belt conveyor, resulting in an increase in the temperature of the idlers, easy damage to the belt of the belt conveyor, low accuracy in manual inspection, poor fault location accuracy, and low degree of automation. The infrared detection device of the present utility model is installed outside the front of the vehicle transporting materials into the tunnel, and performs infrared scanning on the belt conveyor in real time to detect points with higher temperatures. At the same time, a real-time positioning component is installed on the transport vehicle to locate the place where the bearing is damaged, improving the accuracy and reliability of the detection, reducing the maintenance cost, simplifying the operation process, and ensuring effective operation under various environmental conditions.

[0006] According to one aspect of the present disclosure, there is provided a damage detection device for the idler bearings of a belt conveyor, including a plurality of belt conveyors arranged linearly, and an infrared detection module installed on the outer side of a transport vehicle in a tunnel, the infrared detection module being arranged in parallel with the idler bearings of the belt conveyor, and the idler bearings including a driving drum, a driven drum, and a tensioning drum;

[0007] Rollers adapted to the tracks in the tunnel are installed at the bottom of the transport vehicle, and at least two shock-absorbing springs are arranged at both ends of the rollers; a buckle for hoisting is provided at the top of the transport vehicle;

[0008] The belt conveyor includes a plurality of columns, a belt is installed above the columns, a driving drum is arranged in the middle of the inner side of the belt, driven drums are arranged at both ends, and tensioning drums are arranged on the outer side of the belt and on the left and right sides of the driving drum respectively;

[0009] The infrared detection module includes an infrared camera capable of collecting the infrared radiation of the idler bearings, the optical signal output end of the infrared camera is connected to a detector to convert the infrared radiation wave emitted by the idler bearings into an electrical signal, and the infrared image output end of the detector is electrically connected to an image processing module to upload the image information with defects to a database; the infrared detection module further includes a lidar capable of measuring the distance between the transport vehicle and the idler bearings, and an RTK positioning module for positioning the horizontal and vertical positions of the transport vehicle.

[0010] In some embodiments of the present disclosure, the roller includes an inner wheel and an outer wheel, and the inner wheel and the outer wheel are connected by a plurality of shock-absorbing devices, and the outer wheel is formed by splicing a plurality of arc-shaped shock-absorbing plates.

[0011] In some embodiments of the present disclosure, the shock-absorbing device includes a buffer spring.

[0012] In some embodiments of the present disclosure, one end of the arc-shaped shock-absorbing plate is provided with a groove, and the other end is provided with a protrusion that is in shape fit with the groove to realize splicing of adjacent arc-shaped shock-absorbing plates.

[0013] In some embodiments of the present disclosure, a roller sprocket is installed at the end of the driving roller, and the roller sprocket is connected to a motor sprocket via a transmission belt, and the motor sprocket is installed on the power output shaft of the motor.

[0014] In some embodiments of the present disclosure, a cleaning assembly is installed below the belt, and the cleaning assembly includes a rolling brush, and a dust collection box is sleeved outside the rolling brush via a bearing seat.

[0015] In some embodiments of the present disclosure, a lifting assembly is installed on the transport vehicle, and the lifting assembly includes a fixed outer frame, and a movable inner frame that can be lifted therein is installed inside the fixed outer frame via a lifting hydraulic cylinder, and a bearing bracket is installed on the movable inner frame to fix an infrared detection module.

[0016] In some embodiments of the present disclosure, night navigation lights are installed at both the top and bottom of the infrared detection module.

[0017] The beneficial effects of the present utility model are as follows:

[0018] 1. An infrared camera is used to capture the infrared radiation emitted by the idler bearing, which is converted into an electrical signal by a detector to realize real-time monitoring of the bearing temperature.

[0019] 2. Multi-sensor integration, combined with a lidar and an RTK positioning module, realizes the measurement of the distance between the transport vehicle and the idler bearing, as well as the position positioning of the transport vehicle in space, ensuring the accuracy of detection.

[0020] 3. The infrared image is analyzed by an image processing module to identify the defective area, and the information is uploaded to the database, and the exact position of the abnormal bearing is determined in combination with the position data.

[0021] 4. From installation preparation to result output, the entire detection process is automated, reducing manual intervention and improving detection efficiency and accuracy.

[0022] 5. The detection results can be fed back to the maintenance personnel in real time, and the status of each idler bearing is displayed through a visualization interface, which is convenient for quickly locating problems and taking corresponding maintenance measures.

[0023] 6. Through regular detection, damaged idler bearings can be discovered and repaired in time, avoiding equipment failures or safety accidents caused by bearing damage, and improving the operation safety and reliability of the entire belt conveyor system.

[0024] 7. Through predictive maintenance, repairs or replacements can be carried out before the bearing is damaged, reducing unexpected downtime and maintenance costs.

[0025] 8. Night navigation lights installed at the top and bottom of the infrared detection module enable it to work properly at night or in low-light environments, improving the environmental adaptability of the detection device.

[0026] 9. The design of the rollers ensures the stable operation of the transport vehicle on the track in the tunnel, reducing the risk of derailment.

[0027] 10. The combination of shock-absorbing springs and arc-shaped shock-absorbing plates provides multi-level shock-absorbing effects, reducing the impact and vibration during transportation and protecting the transported materials and the transport vehicle itself.

[0028] 11. The design of the arc-shaped shock-absorbing plate 28 allows for the quick replacement of worn parts, simplifying the maintenance work.

[0029] 12. The buckle at the top enables the transport vehicle to be easily lifted and moved, improving the operation efficiency.

[0030] 13. Due to the diversity of shock-absorbing devices, the transport vehicle system can adapt to different track conditions and load requirements. Description of the Drawings

[0031] Figure 1 Schematic structural diagram of the damage detection device for the idler bearings of the belt conveyor;

[0032] Figure 2 Schematic structural diagram of the belt conveyor;

[0033] Figure 3 Schematic structural diagram of the belt conveyor from a zero-one perspective;

[0034] Figure 4 Top view of the belt conveyor;

[0035] Figure 5 For Figure 4 Cross-sectional view taken along the A-A plane in

[0036] Figure 6 Schematic structural diagram of the transport vehicle from a zero-one perspective;

[0037] Figure 7 Schematic structural diagram of the infrared detection module;

[0038] Figure 8 Reference diagram of the walking state of the transport vehicle in the tunnel;

[0039] Figure 9 For Figure 8 Enlarged view of the structure of part A in

[0040] Figure 10 For Figure 8 Enlarged view of the structure of part B in

[0041] Figure 11Schematic diagram of the internal structure of the roller;

[0042] Figure 12 Schematic diagram of another perspective of the internal structure of the roller;

[0043] Names of each component in the figure: 1. Belt conveyor; 2. Transport vehicle; 3. Driving roller; 4. Driven roller; 5. Tensioning roller; 6. Column; 7. Belt; 8. Roller sprocket; 9. Transmission belt; 10. Motor sprocket; 11. Motor; 12. Rotating brush; 13. Bearing housing; 14. Ash receiving box; 15. Fixed outer frame; 16. Lifting hydraulic cylinder; 17. Movable inner frame; 18. Bracket; 19. Infrared detection module; 20. Night navigation light; 21. Tunnel; 22. Track; 23. Roller; 24. Shock-absorbing spring; 25. Buckle; 26. Inner wheel; 27. Outer wheel; 28. Arc-shaped shock-absorbing plate; 29. Buffer spring; 30. Groove; 31. Protrusion. Specific embodiments

[0044] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are only used to illustrate and explain the present invention, and are not used to limit the present invention. Embodiment 1

[0045] This example discloses a damage detection device for the idler bearings of a belt conveyor. Refer to Figures 1 to 12 ;

[0046] It includes a plurality of belt conveyors 1 arranged linearly, and an infrared detection module 19 installed outside the transport vehicle 2 in the tunnel. The infrared detection module is arranged in parallel with the idler bearings of the belt conveyor 1. The idler bearings include a driving roller 3, a driven roller 4, and a tensioning roller 5;

[0047] The bottom of the transport vehicle 2 is installed with rollers 23 adapted to the tracks 22 in the tunnel 21, and at least two shock-absorbing springs 24 are arranged at both ends of the rollers 23; A buckle 25 for hoisting is arranged on the top of the transport vehicle 2;

[0048] The roller 23 includes an inner wheel 26 and an outer wheel 27. The inner wheel 26 and the outer wheel 27 are connected by a plurality of shock-absorbing devices. The outer wheel 27 is composed of a plurality of arc-shaped shock-absorbing plates 28 spliced together. The shock-absorbing devices include buffer springs 29. One end of the arc-shaped shock-absorbing plate 28 is provided with a groove 30, and the other end is provided with a protrusion 31 that is in shape-fit with the groove 30 to splice adjacent arc-shaped shock-absorbing plates 28 together.

[0049] Working process: First, the buckle 25 on the top of the transport vehicle 2 allows the vehicle to be hoisted and moved when needed, increasing the flexibility of operation; the transport vehicle 2 is placed on the inner track 22 of the tunnel 21. The rollers 23 at the bottom of the transport vehicle 2 are adapted to the track to ensure the stable operation of the vehicle on the track. The shock-absorbing springs 24 at both ends of the rollers 23 absorb the vibration from the track and reduce the impact on the transport vehicle. The shock-absorbing devices are connected to further enhance the shock-absorbing effect. The outer wheel 27 is spliced ​​by a plurality of arc-shaped shock-absorbing plates 28, and each arc-shaped shock-absorbing plate 28 is interconnected by a groove 30 and a protrusion 31 to form a continuous outer wheel structure.

[0050] The belt conveyor 1 comprises a plurality of columns 6, a belt 7 is mounted on the columns 6, a driving roller 3 is arranged in the middle of the inner side of the belt 7, driven rollers 4 are arranged at both ends, and tensioning rollers 5 are arranged on the outer side of the belt 7 and on the left and right sides of the driving roller 3 respectively;

[0051] The infrared detection module 19 includes an infrared camera capable of collecting infrared radiation from roller bearings. The optical signal output end of the infrared camera is connected to a detector to convert the infrared radiation waves emitted by the roller bearings into electrical signals. The infrared image output end of the detector is electrically connected to an image processing module to upload defective image information to a database. The infrared detection module 19 also includes a laser radar capable of measuring the distance between the transport vehicle and the roller bearings, and an RTK positioning module for locating the horizontal and vertical positions of the transport vehicle.

[0052] LiDAR: Avia LiDAR is selected, which has the characteristics of long range, high precision, light weight and good stability.

[0053] RTK high-precision positioning equipment: IFS-2000 vehicle-use inertial measurement and satellite positioning fusion sensor is selected to support major global satellite navigation systems such as Beidou, GPS, GALILEO and GLONASS. It integrates an IMU module, which fuses IMU data with GNSS data based on a built-in filtering algorithm to provide accurate three-axis attitude angle and position information, and supports a maximum update rate of 100Hz.

[0054] The infrared camera uses the DM60 uncooled focal plane online infrared thermal imager, which is small in size, light in weight, compact, solid and durable, with high sensitivity, clear image, accurate temperature measurement and flexible control. It can effectively perform non-contact temperature measurement and rapid fault detection in the field of predictive status detection.

[0055] A drum sprocket 8 is installed at the end of the active drum 3 , and the drum sprocket 8 is connected to a motor sprocket 10 via a transmission belt 9 , and the motor sprocket 10 is installed on a power output shaft of a motor 11 .

[0056] A cleaning assembly is installed below the belt 7, and the cleaning assembly includes a rolling brush 12, and an ash box 14 is sleeved on the outer side of the rolling brush 12 through a bearing seat 13.

[0057] A lifting component is installed on the transport vehicle 2. The lifting component includes a fixed outer frame 15. Inside the fixed outer frame 15, a moving inner frame 17 that can be lifted therein is installed through a lifting hydraulic cylinder 16. A bearing bracket 18 is installed on the moving inner frame 17 to fix the infrared detection module.

[0058] Navigation lights 20 are installed at both the top and bottom of the infrared detection module 19.

[0059] During the working process, the transport vehicle moves along the extension direction of the belt conveyor. The infrared detection module keeps a certain distance from the idler bearing. The infrared camera captures the infrared radiation emitted by the idler bearing. The detector converts the infrared radiation into an electrical signal. The image processing module analyzes the electrical signal, identifies the possibly existing high-temperature abnormal area, indicates the possible damage of the bearing, and the image information with defects is uploaded to the database for subsequent analysis and maintenance. The lidar continuously measures the distance between the transport vehicle and the idler bearing, and the RTK positioning module provides accurate position information. The cleaning component runs with the belt to clean the residual materials on the belt. The motor drives the driving roller to rotate through the transmission belt to make the belt run. As needed, the height of the infrared detection module is adjusted through the lifting component to ensure an appropriate distance between the detection module and the idler bearing. It is applicable to conveyor belts that need to run for a long time and are difficult to manually check regularly, can effectively monitor the state of the idler bearing, timely detect potential faults, and reduce downtime and maintenance costs.

[0060] A method for detecting the damage of the idler bearing of a belt conveyor includes the following steps:

[0061] a. Installation preparation: Install the infrared detection module on the transport vehicle, and adjust the height of the infrared detection module by adjusting the lifting component so that the infrared camera is arranged parallel to the idler bearing.

[0062] b. Start detection: Start the transport vehicle and make it move along the extension direction of the belt conveyor. During the process, the infrared camera takes pictures of the idler bearing and captures the infrared radiation emitted by the idler bearing.

[0063] c. Data acquisition: The detector converts the infrared radiation into an electrical signal. The image processing module determines the temperature value of each single-pixel area in the image through the comparison of the gray values of the thermal images, and then realizes the real-time overall temperature measurement analysis of multiple points to identify the defective areas. The lidar measures the distance between the transport vehicle and the idler bearing. The RTK positioning module provides the position of the transport vehicle in the horizontal and vertical directions.

[0064] d. Data analysis: The image processing module uploads the image information with defects to the database, confirms the area where the idler bearing has overheating phenomenon, and combines the data provided by the lidar and the RTK positioning module to determine the position of the abnormal idler bearing.

[0065] e. Result output: According to the analysis results, generate reports or warning messages, and display the status of each idler bearing through a visualization interface to facilitate maintenance personnel to locate problems;

[0066] f. Maintenance actions: According to the detection results, take maintenance measures for damaged idler bearings.

[0067] When the surface temperature of an object exceeds absolute zero, it will radiate electromagnetic waves to the outside world. All objects in nature can emit infrared radiation to the outside world. According to different temperatures, there are also differences in the radiation intensity and wavelength distribution characteristics of electromagnetic waves. Electromagnetic waves can be divided into invisible light and visible light according to wavelength. The wavelength range of visible light is 0.4~0.76 μm, and the rest of the wavelength range is invisible light. The infrared radiation emitted by an object belongs to the 0.76~1000 μm band of invisible light; it can be divided into near-infrared of 0.76~3 μm, mid-infrared of 3~6 μm, and far-infrared of 6~1000 μm according to wavelength.

[0068] The collected light is filtered through an optical system to achieve infrared radiation focusing. The infrared detector converts the optical signal into an electrical signal and then generates a corresponding infrared image. The infrared detector detects the infrared radiation interpolation between the target itself and the background and displays the surface temperature distribution of the object. In addition, although the infrared radiation has poor penetration and propagation ability, the far-infrared radiation has less loss than the near-infrared and mid-infrared during propagation, and is more suitable for all-weather and long-distance propagation. Infrared thermal imaging detection mainly measures the infrared radiation energy on the surface of an object;

[0069] Rolling bearings belong to rotating machinery. Therefore, the infrared thermal imaging fault diagnosis and condition monitoring of rolling bearings can be divided into the infrared intelligent condition monitoring and fault diagnosis of rotating machinery. The technical process of infrared intelligent condition monitoring and fault diagnosis of rotating machinery mainly includes: image acquisition, image preprocessing and enhancement, image feature parameter extraction, and fault feature classification. After the original thermal image of the rolling bearing is collected by an infrared thermal imager, preprocessing and enhancement are required to reduce the signal-to-noise ratio of the image and make the fault features more obvious. The preprocessed and enhanced image contains the state characteristics of the rolling bearing. Extracting more representative image feature parameters can train a classifier with better performance parameters and achieve higher classification and diagnosis accuracy. Corresponding to different image features, accurate classification can be performed to judge the current working state of the rolling bearing. First, the infrared thermal imager collects the infrared thermal image of the rolling bearing and makes an image dataset, then uses two-dimensional discrete wavelet transform for preprocessing and enhancement, followed by feature extraction and dimensionality reduction, and finally performs fault classification and result verification.

[0070] Although some preferred embodiments of the present utility model have been described, those skilled in the art can make additional changes and modifications once they learn the basic creative concept. Therefore, the appended claims are intended to be construed as including the preferred embodiments as well as all changes and modifications falling within the scope of the present utility model.

[0071] Obviously, those skilled in the art can make various changes and modifications to the present utility model without departing from the spirit and scope of the present utility model. Thus, if these modifications and variations of the present utility model fall within the scope of the claims of this application and their equivalent technologies, the present utility model is also intended to include these modifications and variations.

Claims

1. A damage detection device for a roller bearing of a belt conveyor, characterized in that: It includes a plurality of belt conveyors arranged linearly, and an infrared detection module installed on the outside of a transport vehicle in a tunnel, wherein the infrared detection module is arranged in parallel with a roller bearing of the belt conveyor, and the roller bearing includes a driving roller, a driven roller, and a tensioning roller; The bottom of the transport vehicle is equipped with rollers that match the tracks in the tunnel, and at least two shock-absorbing springs are arranged at both ends of the rollers; the top of the transport vehicle is equipped with buckles for hoisting; The belt conveyor comprises a plurality of columns, a belt is installed on the columns, a driving roller is arranged in the middle of the inner side of the belt, driven rollers are arranged at both ends, and tensioning rollers are arranged on the outer side of the belt and on the left and right sides of the driving roller respectively; The infrared detection module includes an infrared camera capable of collecting infrared radiation from roller bearings. The optical signal output end of the infrared camera is connected to a detector to convert infrared radiation waves emitted by the roller bearings into electrical signals. The infrared image output end of the detector is electrically connected to an image processing module to upload defective image information to a database. The infrared detection module also includes a laser radar capable of measuring the distance between the transport vehicle and the roller bearings, and an RTK positioning module for locating the horizontal and vertical positions of the transport vehicle.

2. The damage detection device for the roller bearing of the belt conveyor according to claim 1, characterized in that: The roller comprises an inner wheel and an outer wheel, the inner wheel and the outer wheel are connected via a plurality of shock absorbing devices, and the outer wheel is formed by splicing a plurality of arc-shaped shock absorbing plates.

3. The damage detection device for the roller bearing of the belt conveyor according to claim 2, characterized in that: The shock absorbing device comprises a buffer spring.

4. The damage detection device for the roller bearing of the belt conveyor according to claim 2, characterized in that: A groove is arranged at one end of the arc-shaped shock-absorbing plate, and a protrusion which matches the groove in shape and position is arranged at the other end, so that adjacent arc-shaped shock-absorbing plates can be spliced ​​together.

5. The damage detection device for the roller bearing of the belt conveyor according to claim 1, characterized in that: A roller sprocket is installed at the end of the active roller, the roller sprocket is connected to the motor sprocket via a transmission belt, and the motor sprocket is installed on the power output shaft of the motor.

6. The damage detection device for the roller bearing of the belt conveyor according to claim 1, characterized in that: A cleaning component is installed below the belt, and the cleaning component comprises a rolling brush. An ash box is arranged on the outer side of the rolling brush through a bearing seat sleeve.

7. The damage detection device for the roller bearing of the belt conveyor according to claim 1, characterized in that: The transport vehicle is provided with a lifting assembly, which comprises a fixed outer frame, an inner side of the fixed outer frame is provided with a movable inner frame which can be lifted and lowered therein via a lifting hydraulic cylinder, and a supporting frame is provided on the movable inner frame to fix the infrared detection module.

8. The damage detection device for the roller bearing of the belt conveyor according to claim 1, characterized in that: Night navigation lights are installed on the top and bottom of the infrared detection module.

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