Belt conveyor carrier roller fault early warning system

Abstract

The utility model discloses a belt conveyor carrier roller fault early warning system, which is characterized in that a plurality of carrier roller groups which are distributed at equal intervals along the conveying direction of a belt are arranged on a supporting mechanism, each carrier roller group is rotatably supported below the belt, and the belt conveyor carrier roller fault early warning system comprises an acoustic vibration detection optical fiber and a gas detection mechanism; the acoustic vibration detection optical fiber is fixed on the supporting mechanism and extends along the distribution direction of each carrier roller group, the starting end of the acoustic vibration detection optical fiber is provided with a laser for emitting pulse laser to the acoustic vibration detection optical fiber, and the transmission tail end of the acoustic vibration detection optical fiber is provided with an analysis host for collecting acoustic vibration signals; the gas detection mechanism comprises a plurality of collection terminals used for collecting gas concentration, the collection terminals are arranged at equal intervals in the distribution direction of the carrier roller sets and electrically connected with the analysis host, early warning is conducted through voiceprint recognition and gas recognition coupling, fault causes, positions, degrees and scales can be reflected more comprehensively, and the early warning accuracy and sensitivity are further improved.

Description

Technical Field

[0001] The utility model relates to a fault warning device for a belt conveyor idler, in particular to a fault warning system for a belt conveyor idler, belonging to the technical field of safety warning. Background Technique

[0002] Friction ignition caused by the fault of the idler bearing of the belt conveyor is one of the main types of belt conveyor safety accidents. Specifically, when there are safety hazards (bearing defects, gear transmission defects, belt misalignment, belt imbalance, resonance, idler pulley (stuck)) or faults in the belt conveyor idler, abnormal sound signals will be generated, and often abnormal gases such as CO will be generated by the friction between the idler and the belt, which is likely to cause a fire. However, in the prior art, the equipment for belt conveyor fault monitoring and intelligent warning has low accuracy and poor sensitivity, and thus cannot monitor online throughout the process, has many blind times and blind areas, high inspection intensity, high later maintenance cost, etc., and cannot guarantee the safe operation of the belt conveyor. Content of the Utility Model

[0003] The purpose of the utility model is to provide a fault warning system for a belt conveyor idler to solve the problems existing in the prior art. Through the coupling warning of voiceprint recognition and gas recognition, the fault cause, location, degree and scale can be more comprehensively reflected, and the accuracy and sensitivity of the warning can be further improved.

[0004] To achieve the above purpose, the utility model provides the following scheme: The utility model provides a fault warning system for a belt conveyor idler. The belt conveyor includes a support mechanism extending along the belt conveying direction. A plurality of idler groups are arranged at equal intervals along the belt conveying direction on the support mechanism, and each idler group is rotatably supported under the belt. The system includes a sound vibration detection optical fiber and a gas detection mechanism;

[0005] The sound vibration detection optical fiber is fixed on the support mechanism and extends along the distribution direction of each idler group. A laser for emitting pulsed laser to the sound vibration detection optical fiber is provided at the starting end of the sound vibration detection optical fiber, and an analysis host for collecting sound vibration signals is provided at the transmission end of the sound vibration detection optical fiber.

[0006] The gas detection mechanism includes a plurality of collection terminals for collecting gas concentration. Each collection terminal is arranged at equal intervals along the distribution direction of each idler group and is electrically connected to the analysis host.

[0007] Preferably, an optical fiber installation pipe is fixed on the support mechanism. The optical fiber installation pipe extends along the distribution direction of each idler group, and the sound vibration detection optical fiber is arranged in the optical fiber installation pipe.

[0008] Preferably, a plurality of optical fiber bases are fixed on the support mechanism, and the optical fiber bases are equally spaced along the extending direction of the acoustic vibration detection optical fiber. The optical fiber installation tube is detachably connected to each of the optical fiber bases.

[0009] Preferably, the acquisition terminal includes an electrochemical sensor for detecting the CO concentration, and each of the electrochemical sensors is electrically connected to the analysis host.

[0010] Preferably, the acquisition terminal further includes a network node electrically connected to the electrochemical sensor. The network nodes of each acquisition terminal are wirelessly chained for transmission, and each network node is equipped with a wireless gateway for wireless communication therewith. The wireless gateway is electrically connected to the analysis host.

[0011] Preferably, the analysis host is equipped with a management platform electrically connected thereto. The management platform stores a signal of the normal threshold range of the CO concentration and a signal of the normal threshold range of the acoustic vibration.

[0012] Preferably, the management platform is electrically connected to a plurality of alarms. Each of the alarms is installed on the support mechanism and is distributed in one-to-one correspondence with each of the acquisition terminals.

[0013] The utility model has achieved the following technical effects compared with the prior art:

[0014] The utility model uses an acoustic vibration detection optical fiber and its supporting mechanism for voiceprint recognition, uses a gas detection mechanism and its supporting mechanism for gas recognition, and couples and warns voiceprint recognition and gas recognition. Faults in the idler group of the belt conveyor will simultaneously cause abnormal sound and gas concentration. The coupled warning of voiceprint recognition and gas recognition can more comprehensively reflect the cause, location, degree and scale of the fault, and further improve the accuracy and sensitivity of the warning. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to more clearly illustrate the technical solutions in the embodiments of the present utility model or the prior art, the following will briefly introduce the drawings required in the embodiments. Obviously, the drawings in the following description are only some embodiments of the present utility model. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0016] Figure 1 It is a schematic diagram of the distribution of the entire warning system of the present utility model;

[0017] Figure 2 It is a schematic diagram of the communication of each network node of the present utility model;

[0018] Figure 3 It is a schematic diagram of the entire working process of the present utility model;

[0019] Among them, 1 - idler set, 2 - bracket, 3 - support beam, 4 - acoustic vibration detection optical fiber, 5 - alarm, 6 - network node. Specific implementation manner

[0020] Please write the specific implementation manner. The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0021] The purpose of the present invention is to provide a belt conveyor idler fault warning system to solve the problems existing in the prior art. Through the coupling warning of voiceprint recognition and gas recognition, it can more comprehensively reflect the fault cause, location, degree, and scale, and further improve the accuracy and sensitivity of the warning.

[0022] To make the above objects, features, and advantages of the present invention more obvious and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific implementation manners.

[0023] As Figures 1 to 3 shown, this embodiment provides a belt conveyor idler fault warning system. The belt conveyor includes a support mechanism extending along the belt conveying direction. A plurality of idler sets 1 are equally spaced along the belt conveying direction on the support mechanism. The idler sets 1 can be classified into supporting idler sets 1, self-aligning idler sets 1, and buffer idler sets 1 according to their uses. And each idler set 1 is rotatably supported under the belt, including an acoustic vibration detection optical fiber 4 and a gas detection mechanism;

[0024] The acoustic vibration detection optical fiber 4 is used to monitor the bearing friction ignition fault of the idler group 1 and collect the vibration information at each position of the idler group 1 along the belt conveyor. The acoustic vibration detection optical fiber 4 has the following advantages: distributed vibration and temperature; solid and waterproof; high temperature and high pressure resistant; resistant to resistance; insensitive to electromagnetic fields and corrosion; convenient and fast installation. The acoustic vibration detection optical fiber 4 is fixed on the support mechanism and extends along the distribution direction of each idler group 1. A laser for emitting pulsed laser to the acoustic vibration detection optical fiber 4 is provided at the starting end of the acoustic vibration detection optical fiber 4, and an analysis host for collecting acoustic vibration signals is provided at the transmission end of the acoustic vibration detection optical fiber 4; under the action of ambient acoustic vibration, the acoustic vibration detection optical fiber 4 will generate axial strain. Due to the photoelastic effect, the refractive index of the acoustic vibration detection optical fiber 4 will change accordingly, thereby causing a change in the phase information of the Rayleigh scattered light signal in the acoustic vibration detection optical fiber 4. The analysis host analyzes and processes the acoustic vibration signals; the components of the distributed acoustic vibration optical fiber system include but are not limited to: the acoustic vibration detection optical fiber 4, the analysis host, and the management platform. The optical fiber is installed longitudinally along the belt conveyor and arranged in the inner groove of the I-beam under the belt conveyor. Specifically, the support mechanism includes two parallel and spaced support beams 3. A plurality of brackets 2 are equally spaced along the extension direction between the two support beams 3. Roller groups are installed on each bracket 2. The belt is located between the two support beams 3, and each roller group supports under the belt. Preferably, the support beam 3 is made of I-shaped steel beam. The acoustic vibration detection optical fiber 4 is installed along the belt and arranged in the groove inside the I-shaped steel beam. The parts that the acoustic vibration detection optical fiber 4 can monitor include but are not limited to: the idler group 1, the belt, the motor, the gearbox, and the wheel hub.

[0025] Among them, the gas detection mechanism includes a plurality of collection terminals for collecting gas concentration. Each collection terminal is equally spaced along the distribution direction of each idler group 1 and is electrically connected to the analysis host. The analysis host is used to analyze and process the collected acoustic vibration signals and the electrical signals representing gas concentration, generate the acoustic vibration distribution image of the belt transportation system and restore the on-site audio information by the server software. At the same time, the electrical signals representing gas concentration are demodulated into gas concentration information, so as to realize the whole-process real-time monitoring of the faults of the belt transportation system.

[0026] The utility model uses the acoustic vibration detection optical fiber 4 and its supporting mechanism for voiceprint recognition, uses the gas detection mechanism and its supporting mechanism for gas recognition, and couples and warns voiceprint recognition and gas recognition. Faults in the idler group 1 of the belt conveyor will simultaneously cause abnormal sound and gas concentration. The coupling warning of voiceprint recognition and gas recognition can more comprehensively reflect the cause, location, degree, and scale of the fault, further improve the accuracy and sensitivity of the warning, and reduce the potential safety hazards, economic losses, and casualties caused thereby. The idler group 1 is used to support materials, reduce frictional resistance, support and protect the belt, adjust the tension and alignment, and reduce noise and vibration.

[0027] Furthermore, a fiber optic mounting tube is fixed on the support mechanism, the fiber optic mounting tube is extended along the distribution direction of each roller group 1, and the acoustic vibration detection optical fiber 4 is inserted into the fiber optic mounting tube. A plurality of fiber optic bases are fixed on the support mechanism, each fiber optic base is evenly spaced along the extension direction of the acoustic vibration detection optical fiber 4, and the fiber optic mounting tube is detachably connected to each fiber optic base. The fiber optic mounting tube is provided to protect the acoustic vibration detection optical fiber 4 from being worn, and the fiber optic base is preferably welded to the support mechanism, and the fiber optic mounting tube is detachably connected to the fiber optic base by screws or magnets.

[0028] Preferably, the collection terminal includes an electrochemical sensor for detecting CO concentration, which measures CO concentration by converting CO concentration into a current signal through a chemical reaction, and each electrochemical sensor is electrically connected to the analysis host. The collection terminal is arranged according to the characteristics of the belt conveyor, and a collection terminal is placed every 15 to 20 meters, and installed on the bracket wall at the outer end of the roller, ensuring that the gas collection part on the collection terminal is 10 cm above the outer side of the roller. The electrochemical sensor has the advantages of fast response, high sensitivity and accuracy, and can detect CO in a lower concentration range. The accuracy can reach ppm level, and it also has a long service life and relatively low cost.

[0029] like Figure 2 As shown, the acquisition terminal also includes a network node 6 electrically connected to the electrochemical sensor, and the network nodes 6 of each acquisition terminal are wirelessly chained, and each network node 6 is equipped with a wireless gateway for wireless communication with it, and the wireless gateway is electrically connected to the analysis host. The data collected by each network node 6 is uploaded to the analysis host through the wireless gateway. The wireless chain transmission adopted by the network node 6 has a transmission distance much greater than the arrangement spacing of each network node 6. Preferably, the spacing between the network nodes 6 of each acquisition terminal is 15 to 20m. When a network node 6 fails, the next network node 6 will automatically cross the network node 6 and mark the communication abnormality of the network node 6 in the transmission data. Compared with traditional star, tree, cellular and other communication methods, the advantage of wireless chain transmission is that it can achieve the farthest transmission distance with the smallest data transmission space according to the characteristics of the belt conveyor, while being compatible with some cellular communication advantages.

[0030] The preferred network node 6 uses CC2530 as the main chip, which is a chip specially designed for the Internet of Things, with integrated RF transceiver, flash memory and other components; built-in ZigBee protocol stack, with the advantages of low cost, low power consumption, small size, good penetration and strong anti-interference ability; each network node 6 realizes point-to-point communication and relay transmission through ZigBee wireless network technology, so that each collection terminal not only collects gas concentration information, but also serves as a wireless communication route, thereby realizing long-distance transmission.

[0031] Further, it should be noted that the gas detection mechanism also includes a power supply, etc. The power supply inputs AC 110v - 300v and outputs DC 36v. A step-down module is also provided on the acquisition terminal to supply power to the electrochemical sensor and the network node 6 through the step-down module.

[0032] Preferably, the analysis host is equipped with a management platform electrically connected to it. The management platform stores the signal of the normal threshold range of CO concentration and the signal of the normal threshold range of acoustic vibration. The management platform performs AI self-learning to determine the specific location of the abnormality of the belt conveyor. The management platform is electrically connected to a plurality of alarms 5. Each alarm 5 is installed on the support mechanism and is distributed in one-to-one correspondence with each acquisition terminal. Preferably, the alarm 5 adopts an audible and visual alarm, etc., including an indicator light matching each network node 6, and a blue display through the indicator light indicates normal communication.

[0033] Among them, the management platform adopts a feature extraction method based on AI and combines the accumulation of tens of thousands of test samples. It can automatically extract weak fault vibration signals from the background noise of equipment operation. At the same time, it sensitively identifies and analyzes CO concentration information, realizes machine recognition and accurate positioning, and controls the alarm 5 to perform combined audible and visual alarms. It has the advantages of being independently controllable, low false alarm rate, integrated transmission and sensing, and easy integration of interfaces with upper-layer systems. The steps of massive data modeling are: S1, obtaining original signal data; S2, performing filtering and denoising processing on the original signal; S3, extracting multi-dimensional features of time, space, and frequency; S4, establishing a traditional model; S5, AI self-learning. Massive data modeling and machine learning jointly achieve the function of low false alarm rate.

[0034] As Figure 3 shown, further, based on a belt conveyor idler fault warning system, its specific working process is as follows:

[0035] When a fault such as friction and ignition occurs in the belt conveyor idler group 1, abnormal sounds will be generated. Belt friction will generate abnormal gases such as CO and heat. The higher the temperature, the greater the gas concentration, and its main component is CO.

[0036] The operation of the acoustic and vibration detection optical fiber 4: S1, the laser emits pulsed laser to the acoustic and vibration detection optical fiber 4, and the system regards each point on the acoustic and vibration detection optical fiber 4 as an acoustic and vibration sensor unit; S2, under the action of ambient acoustic vibration, the acoustic and vibration detection optical fiber 4 will generate axial strain. Due to the photoelastic effect, the refractive index of the optical fiber will change accordingly, thereby causing a change in the phase information of the Rayleigh scattering light signal in the acoustic and vibration detection optical fiber 4; S3, the analysis host detects the signal and demodulates the signal.

[0037] While the acoustic vibration detection optical fiber 4 is working, abnormal gas is detected by the acquisition terminal. The acquisition terminal uses an electrochemical sensor to detect the CO concentration. It measures the CO concentration by converting the CO concentration into an electrical signal through a chemical reaction. The analysis host can draw the CO concentration content line and trend curve of the entire network based on the CO concentration content and trend of a single node and the conveyor belt direction, and can predict faults such as idler friction ignition in advance. Compared with traditional communication methods such as star, tree, and honeycomb, the advantage of chain transmission is that it can achieve the farthest transmission distance with the smallest data transmission space according to the characteristics of the conveyor belt, and at the same time is compatible with some advantages of honeycomb communication.

[0038] The analysis host detects and demodulates the acoustic vibration signal and the electrical signal of the pointer gas concentration, and transmits the data to the management platform. The management platform compares the real-time optical fiber acoustic vibration signal with the background signal to achieve the detection, positioning, and early warning of vibration or sound waves. When the CO concentration exceeds the normal threshold range, it realizes the positioning and early warning of the abnormal CO concentration position, and controls the alarm 5 to perform combined sound and light alarm.

[0039] The whole system has the following advantages: high accuracy, high sensitivity, intelligent early warning, good real-time performance, high positioning accuracy, strong environmental adaptability, and low maintenance cost. As a new monitoring technology means, combined with artificial intelligence algorithms, big data analysis and other technologies, using a management platform based on digital twin technology, it realizes the 3D display of the conveyor belt operation status, digital roaming inspection, big data storage and visual early warning, and realizes the whole-process monitoring, intelligent identification, accurate positioning and timely early warning (faults and fires) of the conveyor belt operation faults. It can solve the problems of traditional monitoring means such as inability to monitor online throughout the process, many blind times and blind areas, high inspection intensity, and high later maintenance cost, and has important application value for ensuring the safe operation of the raw material conveyor belt, avoiding production accidents, reducing unplanned shutdowns and improving production efficiency.

[0040] Adaptations made according to actual needs are all within the protection scope of the present utility model.

[0041] It should be noted that for those skilled in the art, it is obvious that the present utility model is not limited to the details of the above exemplary embodiments, and can be implemented in other specific forms without departing from the spirit or basic characteristics of the present utility model. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of the present utility model is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be included in the present utility model. Any reference signs in the claims should not be regarded as limiting the claimed rights.

[0042] In the present utility model, specific examples are used to elaborate on the principle and implementation manner of the present utility model. The description of the above embodiments is only used to help understand the method and its core idea of the present utility model; at the same time, for those of ordinary skill in the art, according to the idea of the present utility model, there will be changes in the specific implementation manner and application scope. In summary, the content of this specification should not be construed as a limitation to the present utility model.

Claims

1. A belt conveyor idler fault warning system. The belt conveyor includes a support mechanism extending along the belt conveying direction. A plurality of idler groups are arranged on the support mechanism at equal intervals along the belt conveying direction, and each idler group is rotatably supported under the belt. It is characterized in that, It includes a vibration and sound detection optical fiber and a gas detection mechanism; The vibration and sound detection optical fiber is fixed on the support mechanism and extends along the distribution direction of each roller group. A laser for emitting pulsed laser to the vibration and sound detection optical fiber is provided at the starting end of the vibration and sound detection optical fiber, and an analysis host for collecting vibration and sound signals is provided at the transmission end of the vibration and sound detection optical fiber; The gas detection mechanism includes a plurality of collection terminals for collecting gas concentration. Each collection terminal is arranged at equal intervals along the distribution direction of each roller group and is electrically connected to the analysis host.

2. The belt conveyor idler fault warning system according to claim 1, characterized in that, An optical fiber installation tube is fixed on the support mechanism. The optical fiber installation tube extends along the distribution direction of each roller group, and the vibration and sound detection optical fiber is arranged inside the optical fiber installation tube.

3. The belt conveyor idler fault warning system according to claim 2, characterized in that, A plurality of optical fiber bases are fixed on the support mechanism. Each optical fiber base is distributed at equal intervals along the extending direction of the vibration and sound detection optical fiber, and the optical fiber installation tube is detachably connected to each optical fiber base.

4. The belt conveyor idler fault warning system according to claim 2 or 3, characterized in that, The collection terminal includes an electrochemical sensor for detecting CO concentration. Each electrochemical sensor is electrically connected to the analysis host.

5. The belt conveyor idler fault warning system according to claim 4, characterized in that, The collection terminal further includes a network node electrically connected to the electrochemical sensor. The network nodes of each collection terminal are wirelessly chained for transmission, and each network node is equipped with a wireless gateway for wireless communication therewith. The wireless gateway is electrically connected to the analysis host.

6. The belt conveyor idler fault warning system according to claim 5, wherein, The analysis host is equipped with a management platform electrically connected thereto. The management platform stores a CO concentration normal threshold range signal and a vibration and sound normal threshold range signal.

7. The belt conveyor idler fault warning system according to claim 6, wherein The management platform is electrically connected to a plurality of alarms. Each alarm is installed on the support mechanism and is distributed in one-to-one correspondence with each collection terminal.

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