A Multi-Sensor-Based Intelligent Monitoring System for Belt Conveyors

Abstract

This utility model discloses a multi-sensor-based intelligent monitoring system for conveyor belts. It comprises a first monitoring camera, a second monitoring camera, and supplementary lighting. The first monitoring camera is positioned directly above the conveyor belt and angled downwards along its length to capture images of the conveyor belt. The second monitoring camera is positioned parallel to the length of the conveyor belt below it to capture images of the area below the conveyor belt. The supplementary lighting is equidistantly distributed below the conveyor belt along its length. All three monitoring cameras are connected to a computer system. This utility model has the advantage of monitoring material drop or accumulation on the conveyor belt, facilitating early detection of belt misalignment and reducing losses.

Description

Technical Field

[0001] This utility model relates to the field of industrial automation equipment monitoring technology, and in particular to a multi-sensor-based intelligent monitoring system for belt conveyors. Background Technology

[0002] Belt conveyors are machines that use belts to transport materials and are widely used in industries such as metallurgy and mining. Belt misalignment is the most common fault during belt conveyor operation. The root cause of misalignment is that the resultant force in the belt width direction is not zero or the tension in the vertical direction of the belt width is uneven. The main reasons for this phenomenon are as follows: (1) the internal structure of the belt becomes uneven due to prolonged belt operation; (2) long-term lack of cleaning leads to severe scaling on the belt surface; (3) uneven rollers cause belt misalignment; (4) uneven distribution of transported materials on the belt. Belt misalignment can cause system failures and shutdowns, affecting production efficiency, and can also cause abnormal damage to major components of the equipment, making it more likely to cause safety accidents.

[0003] In recent years, with the development of artificial intelligence technology, visual recognition and audio recognition technologies have been increasingly applied to equipment monitoring. Based on machine learning, these technologies can identify information that traditional sensors cannot detect through image and audio features, thus compensating for the shortcomings of transmission sensors. Regarding belt conveyor monitoring, a Chinese patent document (CN110092137A) discloses a belt conveyor misalignment detection system. This system determines the misalignment location by detecting abnormal sounds, acquires images of the misalignment location using a camera, and judges the severity of the misalignment based on image recognition. It is evident that real-time monitoring of belt conveyors can be achieved through video / image recognition and audio recognition technologies.

[0004] Existing technologies using video / image recognition to determine belt conveyor misalignment typically involve capturing images of the belt from above and judging its misalignment status by whether the belt's edge deviation exceeds a set threshold. However, for bulk granular materials, material may already be scattered or accumulating before the deviation exceeds the threshold, making visual identification of misalignment inherently delayed. Therefore, the applicant proposes to add the identification and monitoring of material drop or accumulation to the existing solutions, enabling early detection and adjustment to minimize losses. However, the long conveyor path of belt conveyors, the uncertain location of material drop or accumulation, and the dim lighting in the area beneath the conveyor all negatively impact image and recognition quality. Therefore, determining the appropriate configuration of the monitoring device is a pressing issue. Utility Model Content

[0005] In view of the shortcomings of the prior art, the technical problem to be solved by this utility model is: how to provide a multi-sensor-based intelligent monitoring system for belt conveyors that can monitor the material falling or accumulating state of the belt conveyor, which is conducive to early detection of belt conveyor deviation and reduction of losses.

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

[0007] A multi-sensor-based intelligent monitoring system for conveyor belts includes a computer system with visual recognition capabilities, a first monitoring camera, a second monitoring camera, and supplementary lighting. The first monitoring camera is positioned directly above the conveyor belt and tilted downwards along its length to capture images of the conveyor belt. The second monitoring camera is positioned parallel to the length of the conveyor belt below it to capture images of the area below the conveyor belt. The supplementary lighting is equidistantly positioned below the conveyor belt along its length. The first monitoring camera, the second monitoring camera, and the supplementary lighting are all connected to the computer system.

[0008] By employing the above structure, supplementary lights are installed below the conveyor belt, allowing the second monitoring camera to acquire clearer images and improving the accuracy of the computer system's identification. Furthermore, because the second monitoring camera is parallel to the conveyor belt and positioned along its length, it can capture images of a longer area in front of its lens. Simultaneously, the supplementary lights are evenly spaced along the length of the conveyor belt, resulting in more uniform brightness across the entire area below the belt, improving image quality. Additionally, the evenly spaced supplementary lights create reference points along the depth of field of the second monitoring camera, allowing the computer system to simultaneously identify material falling or accumulating while also using these reference points to assist in determining the location of the material falling or accumulating. In this scheme, the first monitoring camera also acquires images of the conveyor belt from above. Even if the second monitoring camera does not detect material falling or accumulating in its image, the belt deviation can be assessed by checking if it exceeds a set threshold, thus establishing a dual-judgment system.

[0009] Furthermore, the second monitoring camera is arranged in three sets along the width direction of the belt conveyor, located at the middle and both sides of the belt conveyor width direction respectively.

[0010] In this way, the second monitoring camera in the middle position can monitor the material falling or accumulating directly below the belt conveyor, while the second monitoring cameras on both sides can monitor the material falling or accumulating on both sides of the belt conveyor.

[0011] Furthermore, multiple monitoring cameras are arranged at intervals along the length of the belt conveyor, both the first and second monitoring cameras.

[0012] In this way, every segment along the length of the belt conveyor can be monitored, forming a complete monitoring coverage.

[0013] Furthermore, it also includes a distributed optical fiber auscultation sensor arranged along the length of the belt conveyor, the distributed optical fiber auscultation sensor being connected to the computer system.

[0014] In this way, the sound information of the rotating idlers at various positions of the belt conveyor can be collected by the distributed fiber optic stethoscope sensor, thereby enabling the monitoring of abnormal conditions of each idler.

[0015] Furthermore, it also includes an acoustic vibration temperature sensor, which is installed on the motor, roller, or reducer of the belt conveyor and is connected to the computer system.

[0016] This allows for the monitoring of abnormal noises, temperature changes, and vibrations in the motor, rollers, and reducer.

[0017] Furthermore, it also includes an intrusion detection camera with thermal imaging capabilities, which is positioned facing the belt conveyor and covers the operating area of ​​the belt conveyor, and the intrusion detection camera is connected to a computer system.

[0018] In this way, intrusion detection cameras with thermal imaging capabilities can monitor personnel who intrude into the work area.

[0019] Furthermore, multiple intrusion detection cameras are arranged along the conveying direction of the belt conveyor, and the monitoring areas of two adjacent intrusion detection cameras are connected to each other.

[0020] Furthermore, both the first and second monitoring cameras are self-cleaning cameras.

[0021] Furthermore, the first monitoring camera is located 2.5 to 3 meters above the belt conveyor, and its tilt angle relative to the belt conveyor is 40° to 50°.

[0022] In summary, this utility model has the following advantages:

[0023] 1. The image of the conveyor belt is acquired by the first monitoring camera, so that the computer system can monitor whether the conveyor belt is running off-track through visual recognition.

[0024] 2. By acquiring images of the area below the conveyor belt through a second monitoring camera, the computer system can use visual recognition to monitor whether there is material falling or accumulating, and assist in predicting whether the belt is running off-track.

[0025] 3. By monitoring the operating area of ​​the belt conveyor through intrusion detection cameras, intrusion by personnel can be detected.

[0026] 4. By setting up distributed fiber optic stethoscope sensors, the rotation status of the idler rollers at various positions can be obtained, and abnormal conditions of the idler rollers can be monitored based on sound signals. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the overall structure of the belt conveyor.

[0028] Figure 2 for Figure 1 A partial structural diagram of the belt conveyor.

[0029] Figure 3 This is a schematic diagram of the end structure of the belt conveyor.

[0030] Figure 4 This is a schematic diagram of the overall intelligent monitoring system. Detailed Implementation

[0031] The present invention will be further described in detail below with reference to the embodiments.

[0032] In practical implementation: such as Figures 1-4 As shown, a multi-sensor-based intelligent monitoring system for belt conveyors is deployed in a port's belt conveyor system. The belt conveyor system includes multiple belt conveyors, and the intelligent monitoring system includes a computer system with visual recognition capabilities, a first monitoring camera 1, a second monitoring camera 2, and supplementary lighting 3. The first monitoring camera 1 is positioned directly above the belt conveyor, tilted downwards along its length to acquire images of the conveyor belt. Specifically, the first monitoring camera 1 is located 2.5–3 meters above the belt conveyor, with an tilt angle of 40°–50° relative to the belt conveyor. The second monitoring camera 2 is positioned parallel to the belt conveyor along its length below it to acquire images of the area below the belt conveyor. The supplementary lighting 3 is equidistantly arranged below the belt conveyor along its length. All three monitoring cameras are connected to the computer system. Both the first and second monitoring cameras are self-cleaning cameras, and multiple cameras are spaced apart along the length of the belt conveyor. This allows for monitoring of every segment along the length of the belt conveyor, achieving full coverage monitoring.

[0033] In this embodiment, three sets of the second monitoring cameras 2 are arranged along the width direction of the belt conveyor, located at the middle and both sides of the belt conveyor. The second monitoring camera at the middle position can monitor the material falling or accumulating directly below the belt conveyor, while the second monitoring cameras at the sides can monitor the material falling or accumulating on both sides of the belt conveyor.

[0034] Supplemental lighting is installed below the conveyor belt, allowing the second monitoring camera to acquire clearer images and improving the accuracy of the computer system's identification. Furthermore, because the second monitoring camera is parallel to the conveyor belt and along its length, it can capture images of a longer area in front of its lens. Simultaneously, the supplemental lighting, evenly spaced along the length of the conveyor belt, ensures more uniform brightness across the area below, improving image quality. Additionally, the evenly spaced lighting creates reference points along the depth of field of the second monitoring camera, allowing the computer system to simultaneously identify material drop or accumulation and use these reference points to aid in determining the location of the material drop or accumulation. In this scheme, the first monitoring camera also acquires images of the conveyor belt from above. Even if the second monitoring camera does not detect material drop or accumulation in its image, the belt's deviation can be assessed by checking if it exceeds a set threshold, providing a dual-judgment system.

[0035] In this embodiment, a distributed fiber optic stethoscope sensor 4 is also included, which is arranged along the length of the belt conveyor and connected to the computer system. Thus, the distributed fiber optic stethoscope sensor can collect sound information about the rotation of idlers at various positions on the belt conveyor, thereby enabling the monitoring of abnormal conditions of each idler.

[0036] In addition, an acoustic, vibration, and temperature sensor 5 is also provided. This sensor is installed on the motor, drum, or reducer of the belt conveyor and is connected to the computer system. The acoustic, vibration, and temperature sensor 5 can be used to monitor abnormal noises, temperature changes, and vibrations in the motor, drum, and reducer.

[0037] To prevent personnel from intruding into the belt conveyor's operating area, intrusion detection cameras with thermal imaging capabilities are installed. These cameras are positioned facing the belt conveyor and cover its operating area. Each camera is connected to a computer system. Multiple intrusion detection cameras are arranged along the conveyor's transport direction, with the monitoring areas of adjacent cameras overlapping.

[0038] It should be noted that the main improvement of this invention over the prior art is the reasonable placement of supplementary lighting and a second monitoring camera below the conveyor belt. This allows the second monitoring camera to obtain clearer images, enabling the computer system's visual recognition to perform accurate identification based on the images. The entire implementation process does not involve any software improvements to existing recognition technologies. The technology of image-based recognition in computer systems is a mature existing technology.

[0039] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A multi-sensor based intelligent monitoring system for a belt conveyor, comprising a computer system with visual recognition function, characterized in that, It also includes a first monitoring camera (1), a second monitoring camera (2), and a supplementary light (3); the first monitoring camera (1) is set directly above the belt conveyor and tilted downwards towards the belt conveyor along its length direction to acquire images of the conveyor belt; the second monitoring camera (2) is set parallel to the belt conveyor along its length direction below the belt conveyor to acquire images of the area below the belt conveyor; the supplementary light (3) is equidistantly arranged below the belt conveyor along its length direction; the first monitoring camera (1), the second monitoring camera (2), and the supplementary light (3) are all connected to the computer system.

2. The multi-sensor based belt conveyor intelligent monitoring system as claimed in claim 1, wherein, The second monitoring camera (2) is set in three groups along the width direction of the belt conveyor, located in the middle and on both sides of the width direction of the belt conveyor.

3. The intelligent monitoring system for belt conveyors based on multiple sensors as described in claim 1 or 2, characterized in that, The first monitoring camera (1) and the second monitoring camera (2) are each provided in multiples at intervals along the length of the belt conveyor.

4. The intelligent monitoring system for belt conveyors based on multiple sensors as described in claim 3, characterized in that, It also includes a distributed optical fiber auscultation sensor (4) arranged along the length of the belt conveyor, the distributed optical fiber auscultation sensor (4) being connected to the computer system.

5. The intelligent monitoring system for belt conveyors based on multiple sensors as described in claim 3, characterized in that, It also includes an acoustic vibration temperature sensor (5), which is installed on the motor, drum or reducer of the belt conveyor and is connected to the computer system.

6. The intelligent monitoring system for belt conveyors based on multiple sensors as described in claim 3, characterized in that, It also includes an intrusion detection camera with thermal imaging capabilities, which is positioned facing the belt conveyor and covers the operating area of ​​the belt conveyor, and the intrusion detection camera is connected to a computer system.

7. The intelligent monitoring system for belt conveyors based on multiple sensors as described in claim 6, characterized in that, Multiple intrusion detection cameras are arranged along the conveyor belt direction, and the monitoring areas of two adjacent intrusion detection cameras are connected to each other.

8. The intelligent monitoring system for belt conveyors based on multiple sensors as described in claim 1 or 2, characterized in that, Both the first monitoring camera (1) and the second monitoring camera (2) are self-cleaning cameras.

9. The intelligent monitoring system for belt conveyors based on multiple sensors as described in claim 1, characterized in that, The first monitoring camera (1) is located 2.5 to 3 meters above the belt conveyor, and its tilt angle relative to the belt conveyor is 40° to 50°.

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