A material transport system with integrated condition monitoring and energy-saving functions

Abstract

This utility model discloses a material transport system with integrated status monitoring and energy-saving functions, belonging to the technical field of material transport equipment. It includes an upper-level terminal, a lower-level controller, and at least three belt conveyors connected in sequence. All belt conveyors are connected to the lower-level controller, which in turn is connected to the upper-level terminal. Each belt conveyor's drive motor is equipped with an integrated temperature and vibration sensor to detect abnormal vibration and temperature. High-definition cameras are installed under the belts to detect belt tears. A material flow detection device is installed above the belts to detect material passing through a designated location and control the start and stop of the next-level belt conveyor accordingly. This utility model effectively solves the problems of high energy consumption during belt conveyor startup, low transport efficiency, and insufficient equipment health status monitoring in existing material transport systems.

Description

Technical Field

[0001] This utility model relates to the field of material transport equipment technology, and in particular to a material transport system with comprehensive status detection and energy-saving and consumption-reducing functions. Background Technology

[0002] Traditional material handling systems typically consist of multiple belt conveyors. These conveyors are usually controlled by starting sequentially against the material flow direction and stopping sequentially with the material flow direction. This method results in long system start-up times and high energy consumption during idle operation of upstream equipment. Furthermore, as the core of the transportation system, the operating status of the belt conveyor directly affects the efficiency and safety of the entire production line. Therefore, developing a system that can both enable start-up with the material flow direction to reduce energy consumption and monitor the health status of the belt conveyor in real time to prevent malfunctions is particularly important. Utility Model Content

[0003] This invention proposes a material transport system with comprehensive condition detection and energy-saving functions to solve the problems of high start-up energy consumption, low transport efficiency, and insufficient equipment health status monitoring in existing material transport systems.

[0004] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0005] A material transport system with integrated status detection and energy-saving functions includes an upper terminal, a lower controller, and at least three belt conveyors connected in sequence. All belt conveyors are connected to the lower controller, which is in turn connected to the upper terminal. Each belt conveyor's drive motor is equipped with a temperature and vibration integrated sensor for detecting abnormal vibration and temperature. Each belt conveyor's belt is equipped with a high-definition camera for detecting belt tears. Each belt conveyor's belt is equipped with a material flow detection device for detecting material passing through a set position and controlling the start and stop of the next-level belt conveyor. All temperature and vibration integrated sensors, high-definition cameras, and material flow detection devices are connected to the lower controller.

[0006] Furthermore, the lower-level controller includes multiple PLC substations and a PLC master station. Each belt conveyor corresponds to one PLC substation, and the corresponding temperature and vibration integrated sensor, high-definition camera, and material flow detection device are all connected to the PLC substation. All PLC substations are connected to the PLC master station, and the PLC master station is connected to the upper-level terminal.

[0007] Furthermore, the belt conveyor is provided with three units: a first belt conveyor, a second belt conveyor, and a third belt conveyor. The third belt conveyor is located at the feeding end, the second belt conveyor is the next stage after the third belt conveyor, and the first belt conveyor is the next stage after the second belt conveyor. The material flow detection device is provided above the belts of both the third and second belt conveyors. The material flow detection device includes a first sensor, a second sensor, and a third sensor arranged sequentially along the material conveying direction. All sensors are connected to the PLC substation.

[0008] Furthermore, the first, second, and third sensors are all ultrasonic sensors or infrared sensors.

[0009] Furthermore, the material transport system also includes a hard disk recorder, which is connected to the PLC master station.

[0010] Furthermore, each belt of the belt conveyor is equipped with an infrared emitter, and all infrared emitters are connected to the corresponding PLC substation.

[0011] Furthermore, the drive motor of the belt conveyor is also connected to a current detection device for monitoring current changes, and the current detection device is connected to the PLC substation.

[0012] Furthermore, the host terminal is a PC or an industrial control computer.

[0013] By adopting the above technical solution, this utility model has the following beneficial effects:

[0014] 1. This utility model, by utilizing a forward-flow start-up method and precise control of the material flow detection device, effectively reduces belt idling time, achieving significant energy savings and shortening start-up time. Compared to the traditional reverse-flow start-up method where upstream equipment runs idle for extended periods, this system, through the coordinated action of monitoring points of the material flow detection device, ensures that each stage of the belt conveyor starts only before the material flow arrives, avoiding unnecessary idling of the upstream belt conveyor and significantly reducing the power consumption of the drive motor. Simultaneously, this on-demand start-up mode also shortens the time from system startup to normal operation, improving system startup efficiency and further enhancing the economy and timeliness of material transportation.

[0015] 2. This utility model monitors belt tearing in real time, promptly detecting and addressing safety hazards, ensuring the safe and stable operation of the belt conveyor system, avoiding long-distance tearing and production downtime losses caused by belt tears, and reducing maintenance costs. The system is equipped with high-definition cameras and infrared emitters installed under the belt of the conveyor. The infrared emitters enhance the contrast of the belt surface, allowing the high-definition cameras to more clearly capture whether the belt is torn or damaged. All high-definition cameras are connected to a lower-level controller. When a high-definition camera detects a tear, it immediately transmits a signal to the lower-level controller, which then stops the corresponding belt conveyor and quickly feeds the information back to the upper-level terminal. Staff can receive timely warnings and take inspection and maintenance measures. This real-time monitoring mechanism can detect belt tears as soon as they appear, effectively preventing further tearing and avoiding long-distance tearing caused by the failure to detect belt tears in time, as is common in traditional systems. This reduces the high replacement costs caused by large-scale belt damage.

[0016] 3. This utility model monitors the status of the drive motor of a belt conveyor, analyzing its vibration, temperature, and current for any abnormalities. This allows for early detection of potential motor malfunctions, enabling timely repair or replacement and preventing production interruptions and increased maintenance costs caused by motor failures. The system incorporates a temperature and vibration integrated sensor on the drive motor to detect vibration and temperature changes. A current detection device is also connected to the drive motor to monitor current fluctuations. Both devices are connected to a lower-level controller. The temperature and vibration integrated sensor collects real-time data on the motor's vibration frequency, amplitude, and temperature, while the current detection device monitors current fluctuations during motor operation. The lower-level controller analyzes this data and promptly transmits abnormal information to the upper-level terminal when abnormal vibrations are detected (e.g., vibration frequency exceeding the normal range, excessive amplitude), excessively high temperature, or abnormal current fluctuations. This alerts staff to inspect the drive motor. This early warning system allows for repair or replacement before serious motor failures occur, preventing production interruptions due to sudden motor malfunctions and reducing the high costs associated with emergency repairs. Attached Figure Description

[0017] Figure 1 This is a schematic diagram showing the arrangement of the integrated temperature and vibration sensor and the high-definition camera proposed in Embodiment 1 of this utility model;

[0018] Figure 2 This is a schematic diagram of the arrangement of the material flow detection device proposed in Embodiment 1 of this utility model;

[0019] The components in the attached diagram are labeled as follows: 1-Host terminal, 2-Hard disk burner, 3-PLC master station, 4-PLC substation, 5-Belt conveyor, 6-Temperature and vibration integrated sensor, 7-High-definition camera, 8-Material flow detection device. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0021] Example 1

[0022] like Figure 1-2 As shown, a material transport system with integrated status monitoring and energy-saving functions includes a host terminal 1, a lower-level controller, and at least three belt conveyors 5 connected in sequence. All belt conveyors 5 are connected to the lower-level controller, which in turn is connected to the host terminal 1. In this embodiment, three belt conveyors 5 are provided: a first belt conveyor, a second belt conveyor, and a third belt conveyor. The third belt conveyor is located at the feeding end, the second belt conveyor is the next level after the third belt conveyor, and the first belt conveyor is the next level after the second belt conveyor. The drive motors of all three belt conveyors 5 are connected to the lower-level controller, and their operating status is controlled by the lower-level controller. The host terminal 1 is a PC or an industrial control computer. In this embodiment, the host terminal 1 is a PC.

[0023] Each drive motor of the belt conveyor 5 is equipped with a temperature and vibration integrated sensor 6 for detecting abnormal vibration and temperature of the drive motor. Each belt of the belt conveyor 5 is equipped with a high-definition camera 7 for detecting whether the belt is torn. Each belt of the belt conveyor 5 is equipped with a material flow detection device 8 for detecting whether material is passing through a set position and thereby controlling the start and stop of the next-level belt conveyor 5. All temperature and vibration integrated sensors 6, high-definition cameras 7 and material flow detection devices 8 are connected to the lower-level controller.

[0024] The lower-level controller includes multiple PLC substations 4 and a PLC master station 3. Each belt conveyor 5 corresponds to one PLC substation 4. The corresponding temperature and vibration integrated sensor 6, high-definition camera 7, and material flow detection device 8 are all connected to the PLC substation 4. All PLC substations 4 are connected to the PLC master station 3, and the PLC master station 3 is connected to the upper-level terminal 1.

[0025] Material flow detection devices 8 are installed above the belts of both the third and second belt conveyors. Each material flow detection device 8 includes a first sensor, a second sensor, and a third sensor arranged sequentially along the material conveying direction. All sensors are connected to the PLC substation 4. The first, second, and third sensors are all ultrasonic sensors or infrared sensors. In this embodiment, the first, second, and third sensors are all ultrasonic sensors.

[0026] like Figure 2 As shown, three sensors of the material flow detection device 8 are installed at appropriate positions above the third belt conveyor and the second belt conveyor. The detection data is uploaded to the PLC substation 4 of each belt conveyor 5 using the monitoring substation, and then uploaded to the PLC master station 3 via Ethernet communication. The PLC master station 3 writes the material flow start program and sets the interlock parameters.

[0027] Upon startup, the system first starts the third belt conveyor, and material transport can begin once it is running at full speed. When the material flow passes the first sensor monitoring point of the third belt conveyor, the first sensor sends a feedback signal to the lower-level controller. The lower-level controller immediately sends a start command to the second belt conveyor, which then starts automatically. When the material flow reaches the third sensor monitoring point of the third belt conveyor, the second belt conveyor has already started and reached full speed. Similarly, when the material flow passes the first sensor monitoring point of the second belt conveyor, the first sensor sends a feedback signal to the lower-level controller, which immediately sends a start command to the first belt conveyor, which then starts automatically. When the material flow reaches the third sensor monitoring point of the second belt conveyor, the first belt conveyor has already started and reached full speed.

[0028] The monitoring points of the material flow detection device also play a precise control role: when the first sensor detects material, the lower-level controller sends a start command to the next-stage (previous-stage) belt conveyor. When the second sensor detects material and the preceding-stage belt conveyor is not running, the lower-level controller stops the belt conveyor at this stage. When the third sensor detects material, and the preceding-stage belt conveyor is not running, if the second and third sensors simultaneously detect the material arrival signal, the lower-level controller stops the belt conveyor at this stage and sends a start command to the preceding-stage belt conveyor to prevent material accumulation.

[0029] In addition, the material handling system also includes a hard disk recorder 2, which is connected to the PLC master station 3. The hard disk recorder 2 is mainly used for long-term storage and backup of belt image data, ensuring the integrity and traceability of the detection data, and providing strong support for subsequent fault analysis and preventive maintenance.

[0030] Infrared emitters are installed under the belt of each belt conveyor 5, and all infrared emitters are connected to the corresponding PLC substation 4. To enhance image contrast and clarity, especially under low light conditions, the infrared emitters provide stable and clear auxiliary infrared light.

[0031] The drive motor of belt conveyor 5 is also connected to a current detection device for monitoring current changes, which is connected to PLC substation 4. To further ensure the safety of belt conveyor starting with material flow, this invention introduces the drive motor current of belt conveyor 5 into the PLC system to analyze and record the belt's no-load current, on-load current, and full-load current.

[0032] This invention, through its forward-flow start-up method and precise control of the material flow detection device 8, effectively reduces belt idling time, achieving significant energy savings and shortening start-up time. Compared to the traditional reverse-flow start-up method where upstream equipment runs idle for extended periods, this system, through the coordinated action of various monitoring points of the material flow detection device 8, ensures that each stage of the belt conveyor 5 starts only before the material flow arrives, avoiding unnecessary idling of the upstream belt conveyor 5 and significantly reducing the power consumption of the drive motor. Simultaneously, this on-demand start-up mode also shortens the time from system startup to normal operation, improving system startup efficiency and further enhancing the economy and timeliness of material transportation.

[0033] This invention monitors belt tearing in real time, promptly detecting and addressing safety hazards to ensure the safe and stable operation of the belt conveyor system. It avoids long-distance tearing and production stoppages caused by belt tears, reducing maintenance costs. The system includes a high-definition camera 7 installed under the belt of the belt conveyor 5, equipped with an infrared emitter. The infrared emitter enhances the contrast of the belt surface, allowing the high-definition camera 7 to more clearly capture whether the belt is torn or damaged. All high-definition cameras 7 are connected to a lower-level controller. When a high-definition camera 7 detects a tear, it immediately transmits a signal to the lower-level controller. The lower-level controller then stops the corresponding belt conveyor 5 and quickly feeds the information back to the upper-level terminal 1. Staff can receive timely warnings and take inspection and maintenance measures. This real-time monitoring mechanism can detect belt tears as soon as they appear, effectively preventing further tearing and avoiding long-distance tearing caused by the failure to detect belt tears in traditional systems. This reduces the high replacement costs caused by large-scale belt damage and also avoids production interruptions due to system downtime for maintenance, ensuring the continuous and stable operation of the transportation system.

[0034] This invention monitors the status of the drive motor of the belt conveyor 5, analyzing its vibration, temperature, and current for any abnormalities. This allows for early detection of potential motor malfunctions, enabling timely repair or replacement and preventing production interruptions and increased maintenance costs. The system incorporates a temperature and vibration integrated sensor 6 on the drive motor to detect vibration and temperature changes. A current detection device is also connected to the drive motor to monitor current fluctuations. Both devices are connected to a lower-level controller. The temperature and vibration integrated sensor 6 collects real-time data on the motor's vibration frequency, amplitude, and temperature, while the current detection device monitors current fluctuations during motor operation. The lower-level controller analyzes this data and promptly transmits any abnormal vibrations (such as vibration frequency exceeding the normal range or excessive amplitude), excessively high temperatures, or abnormal current fluctuations to the upper-level terminal 1, alerting personnel to inspect the drive motor. With this early warning system, staff can repair or replace the motor before it malfunctions, avoiding production interruptions caused by sudden motor failures, reducing the high costs associated with emergency repairs, extending the lifespan of the drive motor, and ensuring the normal operation of the entire material transport system.

[0035] This utility model provides a material transport system with comprehensive status detection and energy-saving functions, including: sequential material flow start control: through PLC programming, multiple belt conveyors 5 in the material transport system are started sequentially according to the actual arrival of materials, reducing idle running time and energy consumption; comprehensive status monitoring: integrating belt condition monitoring (such as tear and wear detection) and belt motor health status monitoring (such as vibration and temperature monitoring), using sensors to collect data in real time, and analyzing and processing it through PLC to promptly detect potential faults and provide early warnings; using the collected data and algorithm models to predict equipment maintenance needs, optimize maintenance plans, reduce unplanned downtime, and improve the continuity and stability of material transport.

[0036] The above description is a detailed description of the preferred embodiments of the present utility model. However, the embodiments are not intended to limit the scope of the patent application of the present utility model. All equivalent changes or modifications made under the technical spirit of the present utility model should fall within the patent scope covered by the present utility model.

Claims

1. A material transport system with integrated status detection and energy-saving functions, comprising a host terminal, a lower controller, and at least three belt conveyors connected in sequence, all belt conveyors being connected to the lower controller, and the lower controller being connected to the host terminal, characterized in that: The drive motors of the belt conveyors are all equipped with integrated temperature and vibration sensors to detect abnormal vibration and temperature of the drive motors. High-definition cameras are installed under the belts of the belt conveyors to detect whether the belts are torn. Material flow detection devices are installed above the belts of the belt conveyors to detect whether material is passing through a set position and to control the start and stop of the next-level belt conveyor. All integrated temperature and vibration sensors, high-definition cameras and material flow detection devices are connected to the lower-level controller.

2. The material transportation system with integrated state detection and energy saving function according to claim 1, characterized in that: The lower-level controller includes multiple PLC substations and a PLC master station. Each belt conveyor corresponds to one PLC substation, and the corresponding temperature and vibration integrated sensor, high-definition camera, and material flow detection device are all connected to the PLC substation. All PLC substations are connected to the PLC master station, which is connected to the upper-level terminal unit.

3. The material transportation system with integrated state detection and energy saving function according to claim 2, characterized in that: The belt conveyor system consists of three units: a first belt conveyor, a second belt conveyor, and a third belt conveyor. The third belt conveyor is located at the feeding end, the second belt conveyor is the next stage below the third belt conveyor, and the first belt conveyor is the next stage below the second belt conveyor. Material flow detection devices are installed above the belts of both the third and second belt conveyors. Each material flow detection device includes a first sensor, a second sensor, and a third sensor arranged sequentially along the material conveying direction. All sensors are connected to the PLC substation.

4. The material transportation system with integrated condition detection and energy saving function according to claim 3, characterized in that: The first, second, and third sensors are all ultrasonic sensors or infrared sensors.

5. The material transport system with integrated condition detection and energy saving function according to claim 2, characterized in that: The material transport system also includes a hard disk recorder, which is connected to the PLC master station.

6. The material transport system with integrated condition detection and energy saving function according to claim 2, characterized in that: Each belt conveyor is equipped with an infrared emitter located beneath its belt, and all infrared emitters are connected to their corresponding PLC substations.

7. A material transport system with integrated status detection and energy-saving functions according to claim 6, characterized in that: The drive motor of the belt conveyor is also connected to a current detection device for monitoring current changes, and the current detection device is connected to the PLC substation.

8. The material transportation system with integrated condition detection and energy saving function according to claim 1, characterized in that: The host terminal is a PC or an industrial control computer.

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