Conveyor belt damage condition real-time detection light curtain based on optical detection technology

Abstract

The utility model discloses a conveyor belt damage condition real-time detection light curtain based on an optical detection technology, which comprises a light source emitter, a light curtain collector, fault prediction and health management software and a server, and is characterized in that the light source emitter is mounted on a cross beam of a door-shaped bracket, is parallel to the surface of a conveyor belt and is vertical to the movement direction of the conveyor belt; the door-shaped bracket is arranged in an idling area of the conveyor belt; the light curtain collector is arranged on a support base right below the conveying belt and at a position corresponding to the light source emitter, the light source emitter comprises a plurality of infrared emitting tubes and is arranged above an idling area of the detected conveying belt, the width of the light source emitter is larger than that of the conveying belt, the light curtain collector comprises a plurality of infrared receiving tubes and an IO collector, and the IO collector is arranged above the idling area of the conveying belt. The system and the detection method thereof have the advantages that the sensitivity and the accuracy are higher, the cost is lower, the belt surface detection of the conveying belt is realized, and whether the conveying belt is in a damaged state or not and whether the work is normal or not can be conveniently and quickly checked in real time.

Description

Technical Field

[0001] This invention belongs to the field of equipment condition monitoring technology, specifically relating to a light curtain for real-time detection of conveyor belt damage based on optical detection technology. Background Technology

[0002] Belt conveyors are suitable for transporting various types of materials, including granular, lumpy, and powdery materials such as coal, ore, sand, grain, fertilizer, and building materials. Compared to other types of conveying devices, belt conveyors have advantages such as simple structure, stable operation, long conveying distance, and suitability for various complex environments. Therefore, they are widely used in material conveying and logistics in various industries such as mines, ports, power plants, chemical plants, metallurgical plants, construction sites, and grain processing plants. At the same time, belt conveyors require regular cleaning, lubrication, and inspection to ensure the safety and stability of equipment operation and to promptly identify and resolve equipment failures and wear problems.

[0003] In actual production activities, the conveyed materials may contain sharp or serrated particles, or have high hardness. Prolonged friction can cause wear on the belt surface, eventually leading to damage. Simultaneously, if the conveyor belt exceeds its design capacity or becomes clogged with material, it may cause localized overload. Improper installation or tensioning of the conveyor belt may result in additional tension or misalignment. Environmental factors such as high or low temperatures, humidity, and corrosive media can adversely affect the belt material, accelerating belt aging. Lack of maintenance and upkeep can also exacerbate surface wear on the conveyor belt, ultimately leading to damage.

[0004] Currently, the detection mechanisms for conveyor belt damage are usually as follows: visual inspection using cameras and image processing and analysis technology; detecting the temperature distribution on the surface of the conveyor belt using infrared thermometers; flaw detection of the conveyor belt using ultrasonic sensors; and judging the condition of the conveyor belt by monitoring changes in vibration signals. Each of these detection mechanisms has its own advantages and disadvantages in terms of sensitivity, accuracy, and cost. Summary of the Invention

[0005] To achieve the above objectives, the technical solution of the present invention is as follows: a light curtain for real-time detection of conveyor belt damage based on optical detection technology, the light curtain comprising a light source emitter and a light curtain collector, the light source emitter being mounted on the crossbeam of a portal frame, parallel to the surface of the conveyor belt and perpendicular to the direction of conveyor belt movement, the portal frame being positioned in the idle area of ​​the conveyor belt; the light curtain collector being positioned on a bracket base directly below the conveyor belt, corresponding to the position of the light source emitter. An optical path window is provided to protect the light source emitter and the light curtain collector from the influence of the external environment.

[0006] Preferably, the light source emitter includes multiple infrared emitting tubes, which are positioned above the idle area of ​​the conveyor belt being detected.

[0007] Preferably, the width of the light source emitter is greater than the width of the conveyor belt.

[0008] Preferably, the light curtain collector includes multiple infrared receivers and an I / O collector.

[0009] Preferably, the optical path window is made of transparent plexiglass.

[0010] Preferably, an air purging device is also provided on one side of the infrared receiver tube. The air purging device includes a compressed air nozzle and an air filter. The compressed air nozzle is connected to the housing of the light curtain collector. The air filter is installed on the compressed air nozzle. The air filter can be a traditional air filter element or an air filter screen, used to filter impurities from the air and prevent secondary pollution. The compressed air nozzle is directly facing the infrared receiver tube. The air purging device is connected to a solenoid valve for controlling the start and stop of the air purging. The surface of the infrared receiver element is periodically purged with compressed air to remove dust and particulate matter.

[0011] Preferably, the compressed air nozzle is provided with several spherical connectors, and nozzles are connected to the spherical connectors. The nozzles are set at a suitable angle to the infrared tube, and the angle of the nozzles is adjusted by the spherical connectors. Preferably, the spherical connectors on the compressed air nozzle are spaced apart, and the nozzles without spherical connectors are connected with sealing plugs, achieving low cost and maintainability.

[0012] Preferably, a carbon nanotube film or a metal film is disposed on the outer side of the infrared receiving element, which helps to improve the infrared light absorption capability.

[0013] Preferably, the specific implementation steps of this utility model can be as follows:

[0014] 1) The light source emitter emits a row of infrared beams in a direction perpendicular to the surface of the conveyor belt. Under normal conditions and without damage to the conveyor belt, the beams should be blocked.

[0015] 2) The infrared receiver tube of the light curtain collector located directly below the conveyor belt should be unable to detect infrared light signals and output 0; otherwise, it should output 1, which means that an infrared light signal has been received at that point and the conveyor belt at that point is damaged.

[0016] 3) The infrared receiver tube of the light curtain collector located outside the conveyor belt should be able to detect the infrared light signal without obstruction and output 1; otherwise, it outputs 0, which means that there is an abnormality at the outer edge of the conveyor belt at that location.

[0017] 4) The back-end multi-channel IO collector sends the detection status to the fault prediction and health management software deployed on the server. This step is a conventional technology in this field, which realizes the display of the status of each channel and the monitoring of real-time data. That is, alarm thresholds are set according to standards, and when the measured value exceeds the threshold, the corresponding alarm is issued.

[0018] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention proposes a conveyor belt surface detection system with high sensitivity and accuracy, and low cost. It can check whether the conveyor belt is damaged or working properly in real time, conveniently and quickly, without the need for manual inspection. The system has a simple structure, high sensitivity and accuracy, and high reliability and stability, and is suitable for monitoring equipment operating conditions in complex coal mine environments. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of the detection light curtain of the present invention;

[0020] Figure 2 This is a system block diagram of the light curtain detection of the present invention.

[0021] List of identifiers in the attached diagram: 1-Light source emitter, 2-Light curtain collector, 3-Support, 4-Conveyor belt idle area. Detailed Implementation

[0022] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are for illustrative purposes only and are not intended to limit the scope of the invention.

[0023] Example: Figure 1-2 As shown, this system comprises three parts: a light source transmitter, which begins emitting infrared pulse waves at a certain angle towards the light curtain receiver window upon power-up; a light curtain collector, containing multiple photosensitive receivers, which consider a square wave pulse detected by each receiver to be valid; and a backend multi-channel IO collector that sends the detection status to the fault prediction and health management software; and the fault prediction and health management software that displays the status of each channel and determines the alarm based on the set alarm rules. In this embodiment, the software management of the detection results is a refinement of the solution and not a core improvement of the solution.

[0024] This embodiment describes a real-time detection light curtain for conveyor belt damage based on optical detection technology. Specifically, the light curtain includes a light source emitter, a light curtain collector, fault prediction and health management software, and a server. The light source emitter is installed on the crossbeam of a portal frame, parallel to the surface of the conveyor belt and perpendicular to the direction of the conveyor belt's movement. The portal frame is located in the idle area of ​​the conveyor belt. The light curtain collector is located on a support base directly below the conveyor belt, corresponding to the position of the light source emitter.

[0025] Furthermore, the light source emitter includes multiple infrared emitting tubes, which are positioned above the idle area of ​​the conveyor belt being detected.

[0026] Furthermore, the width of the light source emitter should be greater than the width of the conveyor belt, depending on the width of the conveyor belt.

[0027] Furthermore, the light curtain collector includes multiple infrared receivers and an I / O collector.

[0028] Furthermore, the optical path window is made of transparent plexiglass.

[0029] Furthermore, this embodiment also includes a configuration specifically comprising: an air purging device on one side of the infrared receiver tube, the air purging device comprising a compressed air nozzle and an air filter, the compressed air nozzle being connected to the housing of the light curtain collector, specifically, the compressed air nozzle being fixed to the housing of the light curtain collector by clamps, and the air filter being mounted on the compressed air nozzle. Specifically, the air filter is horizontally mounted inside the compressed air nozzle, sealingly connected to the inner wall of the compressed air nozzle. The air filter can be a traditional air filter element or air filter screen, used to filter impurities from the air and prevent secondary pollution. The nozzle of the compressed air nozzle faces the infrared receiver tube, and the air purging device is connected to a solenoid valve for controlling the start and stop of the air purging, periodically purging the surface of the infrared receiver element with compressed air to remove dust and particulate matter. The compressed air nozzle is provided with several spherical connectors, which can be directly screwed into a fixed joint, which is then fixed to the compressed air nozzle by welding or threaded connection. Nozzles are connected to the spherical connectors, and the nozzles are set at a suitable angle to the infrared tube, the angle of the nozzles being adjusted by the spherical connectors. Furthermore, the ball joints on the compressed air nozzle are spaced apart, and the nozzles that do not use ball joints are connected with sealing plugs, achieving low cost and maintainability.

[0030] Furthermore, a detection method for a real-time detection light curtain for conveyor belt damage based on optical detection technology includes the following steps:

[0031] 1) The light source emitter emits a row of infrared beams in a direction perpendicular to the surface of the conveyor belt. Under normal conditions and without damage to the conveyor belt, the beams should be blocked.

[0032] 2) The infrared receiver tube of the light curtain collector located directly below the conveyor belt should be unable to detect infrared light signals and output 0; otherwise, it should output 1, which means that an infrared light signal has been received at that point and the conveyor belt at that point is damaged.

[0033] 3) The infrared receiver tube of the light curtain collector located outside the conveyor belt should be able to detect the infrared light signal without obstruction and output 1; otherwise, it outputs 0, which means that there is an abnormality at the outer edge of the conveyor belt at that location.

[0034] 4) The backend multi-channel IO collector sends the detection status to the fault prediction and health management software deployed on the server. The software displays the status of each channel and determines the alarm according to the set alarm rules.

[0035] It should be noted that the above content merely illustrates the technical concept of the present invention and should not be construed as limiting the scope of protection of the present invention. For those skilled in the art, various improvements and modifications can be made without departing from the principle of the present invention, and all such improvements and modifications fall within the scope of protection of the claims of the present invention.

Claims

1. A light curtain for real-time detection of conveyor belt damage based on optical detection technology, characterized in that, The light curtain includes a light source emitter (1) and a light curtain collector (2). The light source emitter (1) is installed on the crossbeam of the portal frame (3). The light source emitter (1) is parallel to the surface of the conveyor belt and perpendicular to the direction of movement of the conveyor belt. The portal frame (3) is set in the idle area (4) of the conveyor belt. The light curtain collector (2) is set on the base of the bracket (3) directly below the conveyor belt, corresponding to the position of the light source emitter (1).

2. The real-time detection light curtain for conveyor belt damage based on optical detection technology according to claim 1, characterized in that, The light source emitter (1) contains multiple infrared emitting tubes, which are set above the idle area of ​​the conveyor belt being detected.

3. The real-time detection light curtain for conveyor belt damage based on optical detection technology according to claim 1, characterized in that, The width of the light source emitter (1) is greater than the width of the conveyor belt, depending on the width of the conveyor belt.

4. The real-time detection light curtain for conveyor belt damage based on optical detection technology according to claim 1, characterized in that, The light curtain collector (2) includes a multi-channel infrared receiver and an I / O collector.

5. The real-time detection light curtain for conveyor belt damage based on optical detection technology according to claim 1, characterized in that, The optical path window is made of transparent acrylic glass.

6. The real-time detection light curtain for conveyor belt damage based on optical detection technology according to claim 4, characterized in that, A carbon nanotube film or a metal film is disposed on the outside of the infrared receiver tube.

Images