A longitudinal tear intelligent detection device for a conveyor belt

Abstract

The utility model discloses a kind of longitudinal tear intelligent detection devices of conveying belt, mainly related to conveying belt intelligent monitoring technical field;Including mounting bracket, the mounting bracket is installed between upper belt and lower belt of belt conveyor, and mounting bracket is located between the adjacent two idlers of belt conveyor;The mounting bracket is provided with laser box body, camera box body in inclination, be equipped with a line laser in the laser box body, the laser emission line of the a line laser is perpendicular to the lower surface of upper belt, and laser line center and upper belt transverse angle is 30-90 °;Infrared camera is equipped in the camera box body, the angle of view of the infrared camera is towards the lower surface of upper belt, and angle of view center meets in the laser line of upper belt lower surface, and angle of view center and upper belt longitudinal angle is 30-45 °;The utility model can detect the surface damage of the belt on belt conveyor in real time by the cooperation of a line laser and infrared camera.

Description

Technical Field

[0001] This utility model relates to the field of intelligent monitoring technology for conveyor belts, specifically an intelligent detection device for longitudinal tearing of conveyor belts. Background Technology

[0002] Conveyor belts, as core equipment in bulk material transport systems, are widely used in industries such as mining, ports, power, cement, and steel. The operating status of the conveyor belt directly affects the continuity and safety of the entire production line, and stable operation is a key indicator related to production efficiency and economic benefits. However, in complex industrial environments, conveyor belts are highly susceptible to various damages due to long-term exposure to high loads, material impacts, roller compression, idler wear, and other stresses. Special application environments may also involve high temperatures and humidity. For example, sharp foreign objects often puncture the conveyor belt and become lodged between the chute, idler, or roller and the conveyor belt. Conveyor belts are long-distance, high-speed devices; as the belt travels, a long tear can appear. If not detected in time, the tear will continue to grow, eventually leading to a longitudinal belt tear. Longitudinal tearing is one of the most serious and destructive failure modes. Once a tear occurs, if it is not detected and stopped in time, it will lead to the entire conveyor belt tearing and damage to related equipment. In severe cases, it can even cause localized temperature increases on the conveyor belt, resulting in fires and major safety accidents, causing huge economic losses to the entire production line.

[0003] Currently, there are several methods for detecting longitudinal tears in conveyor belts, and each of them has certain problems, as detailed below: 1) Mechanical detection devices involve suspending a thin rope or lever below the conveyor belt. When the belt tears longitudinally and sags, it triggers the rope or lever, activating an emergency stop switch or a metal or rubber baffle installed behind the feed inlet and below the load-bearing section of the belt. The torn belt scrapes against the baffle, causing it to shift and triggering the switch. Mechanical detection devices require contact to trigger the switch and are subject to wear, as they may wear down from normal contact with the belt, requiring regular maintenance and replacement. They are delayed, acting as "post-incident" detection, only triggering after a tear has occurred and the belt has sagged to a certain extent, failing to provide early warning; they are prone to false alarms, as impacts from large materials, belt misalignment, and vibrations can all cause false triggering; furthermore, their installation location is limited, typically only able to be installed at a specific point (such as behind the feed inlet), making continuous monitoring impossible.

[0004] 2) Embedded detection devices: During belt manufacturing, a continuous row of magnetic wires or conductive coils is embedded longitudinally into the belt. Detectors are installed at the head and tail of the conveyor, and a series of RFID tags are embedded in the belt, with readers installed along the route. Tear is detected by detecting breaks in the tag sequence. This type of detection device is only applicable to new belts and must be pre-embedded during manufacturing; it cannot be used for retrofitting existing belts. It is extremely expensive, with specially customized belts being costly and requiring a matching detection system. Maintenance is difficult; if the detection circuit itself is damaged, diagnosis and repair are very difficult. Its application scope is narrow, typically only used in extremely high-value applications where tearing is absolutely unacceptable.

[0005] 3) Sensor-based detection devices: Sensors are installed between idlers below the belt. After the belt tears, material leaks out from the crack and accumulates to a certain height, triggering the sensor. This type of detection device actually detects "material leakage" rather than directly detecting "tears." A pair of transmitters and receivers are installed on both sides of the belt width. During normal operation, the signal is unobstructed; when the belt tears and sags, the sag blocks the signal, triggering an alarm. Vibration sensors are installed on the idler supports. When the belt tears and passes over the idler, it generates abnormal vibration signals, which are analyzed to determine the cause. The above solutions still have a lag and are still secondary detection methods after a tear has occurred. They have poor environmental adaptability; photoelectric and ultrasonic sensors experience a sharp decrease in detection distance and accuracy in environments with heavy dust and moisture, resulting in a high false alarm rate; the sensor mirrors need to be kept clean, and debugging is relatively complex.

[0006] 4) Vision-based inspection system (current mainstream and development direction) uses an industrial camera to capture images of the belt in real time and automatically identifies tear features through image software algorithms. A high-speed camera is installed below the belt bearing section and aimed at the lower surface of the upper belt. At the same time, a laser line is emitted to the belt surface and the shape of the laser line is read by the camera. The normal belt surface is flat and the laser line is straight; if there is a tear or bulge, the laser line will be distorted and thus accurately measured. This type of solution has obvious advantages: it does not contact the belt at all, there is no wear, and the life is long. It can provide early warning and can identify small cracks as soon as they appear, preventing catastrophic tearing. However, existing vision inspection systems often have the following problems: (1) High environmental requirements, requiring protective covers and cleaning devices to prevent dust and water mist from contaminating the lens and affecting the image quality; (2) The laser is installed vertically, and when the belt surface is polished, the refracted light will form a light spot that affects the camera image, thus affecting the accuracy of the vision inspection results. Summary of the Invention

[0007] The purpose of this invention is to solve the problems existing in the prior art and to provide an intelligent detection device for longitudinal tearing of conveyor belts. Through the cooperation of a linear laser and an infrared camera, it can detect surface damage of the belt on the conveyor belt in real time.

[0008] To achieve the above objectives, this utility model employs the following technical solution: A conveyor belt longitudinal tear intelligent detection device includes a mounting bracket, which is installed between the upper and lower belts of a belt conveyor and between two adjacent idlers of the belt conveyor. The mounting bracket is inclinedly equipped with a laser housing and a camera housing. A linear laser is installed in the laser housing, with its laser emission line perpendicular to the lower surface of the upper belt, and the center of the laser line forming a lateral angle of 30-90° with the upper belt. An infrared camera is installed in the camera housing, with its viewing angle facing the lower surface of the upper belt, and the center of its viewing angle intersecting the laser line on the lower surface of the upper belt, forming a longitudinal angle of 30-45° with the upper belt.

[0009] Preferably, the top front end of the laser housing is provided with a forward-extending laser housing flange; the top front end of the camera housing is provided with a forward-extending camera housing flange.

[0010] Preferably, the front end of the laser housing is provided with an electric laser housing scraper for cleaning the laser protective lens; the front end of the camera housing is provided with an electric camera housing scraper for cleaning the camera protective lens.

[0011] Preferably, the laser protective mirror protrudes from the front end face of the laser housing, and the camera protective mirror protrudes from the front end face of the camera housing.

[0012] Preferably, the angles between the laser housing, the camera housing, and the horizontal plane are all adjustable.

[0013] Preferably, the laser housing can rotate and be locked about a vertical axis.

[0014] Preferably, the laser housing is mounted on the mounting bracket via a laser housing mounting frame. The laser housing is hinged to the top of the laser housing mounting frame via a first hinge member. Both sides of the first hinge member are provided with first locking screws. The laser housing mounting frame is provided with first arc-shaped holes adapted to the first locking screws. The laser housing is provided with first screw holes adapted to the first locking screws.

[0015] Preferably, the bottom end of the laser housing mounting bracket is hinged to the top of the mounting bracket via a second hinge member. Both sides of the second hinge member are provided with second locking screws. The laser housing mounting bracket is provided with a second arc-shaped hole adapted to the second locking screw, and the mounting bracket is provided with a second screw hole adapted to the second locking screw.

[0016] Preferably, the camera housing is mounted on the mounting bracket via a camera housing mounting frame. The camera housing is hinged to the top of the camera housing mounting frame via a third hinge. Both sides of the third hinge are provided with third locking screws. The camera housing mounting frame is provided with a third arc-shaped hole adapted to the third locking screw. The camera housing is provided with a third screw hole adapted to the third locking screw.

[0017] Compared with the prior art, the beneficial effects of this utility model are as follows: This invention features a side-mounted laser housing, with the laser line vertically illuminating the bottom of the belt conveyor from one side off-center. This installation method solves the problem of light spots that occur when the laser is mounted in the forward direction. The use of an infrared camera to add infrared supplementary light can solve the problem of different ambient light intensities. By combining a linear laser with an infrared camera, surface damage on the belt conveyor can be detected in real time. Attached Figure Description

[0018] Figure 1 This is a three-dimensional structural diagram of the present invention.

[0019] Figure 2 This is a front view of the present invention.

[0020] Figure 3 This is a side view of the present invention.

[0021] Figure 4 This is an installation diagram of this utility model.

[0022] The attached diagram shows the following components: 1. Mounting bracket; 2. Upper belt; 3. Lower belt; 4. Idler roller; 5. Laser housing; 51. Laser housing flange; 52. Laser protective mirror; 53. Motorized laser housing scraper; 54. Laser housing mounting bracket; 55. First hinge; 56. First locking screw; 561. First arc-shaped hole; 57. Second hinge; 58. Second locking screw; 59. Second arc-shaped hole; 6. Camera housing; 61. Camera housing flange; 62. Camera protective mirror; 63. Motorized camera housing scraper; 64. Camera housing mounting bracket; 65. Third hinge; 66. Third locking screw; 661. Third arc-shaped hole. Detailed Implementation

[0023] The present invention will be further illustrated below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the present invention. Furthermore, it should be understood that after reading the teachings of this invention, those skilled in the art can make various alterations or modifications to the present invention, and these equivalent forms also fall within the scope defined in this application.

[0024] Example: As attached Figure 1-4As shown, the present invention is a conveyor belt longitudinal tear intelligent detection device, including a mounting bracket 1. The mounting bracket 1 can be a square frame welded from square tubes, aluminum alloys, etc. The mounting bracket 1 is installed between the upper belt 2 and the lower belt 3 of the belt conveyor, and the mounting bracket 1 is located between two adjacent idlers 4 of the belt conveyor. The mounting bracket 1 is fixed to the frame of the belt conveyor by screws.

[0025] The mounting bracket 1 is inclinedly equipped with a laser housing 5 and a camera housing 6. The laser housing 5 and camera housing 6 are installed at an angle, allowing dust on the housings to automatically fall off under the vibration of the belt conveyor during operation, preventing dust accumulation and falling rocks / coal. A linear laser is installed inside the laser housing 5, with its laser emission line perpendicular to the lower surface of the upper belt 2, and the center of the laser line forming a 30-90° angle with the lateral direction of the upper belt 2. An infrared camera is installed inside the camera housing 6, with its viewing angle facing the lower surface of the upper belt 2, and the center of its viewing angle intersecting the laser line on the lower surface of the upper belt 2, forming a 30-45° angle with the longitudinal direction of the upper belt 2. The upper belt 2, the linear laser, and the infrared camera form a triangular relationship.

[0026] In use, this invention employs an infrared camera for image acquisition, which continuously captures images of the laser line on the lower surface of the upper belt 2 at a certain angle. When the upper belt 2 is intact, the laser line captured by the infrared camera is a smooth, continuous straight line. When the upper belt 2 is torn, the belt surface at the tear will deform or break, causing the laser line illuminating that point to twist, break, or shift. Using triangulation, the two-dimensional image information of the laser line captured by the infrared camera is converted into three-dimensional contour information of the belt surface. Visual analysis software processes the three-dimensional contour data in real time. By analyzing the continuity and height difference of the laser line, it can accurately determine whether a tear has occurred and its severity. The degree of tear is divided into general and severe. According to the set threshold, a tear ≥2mm is defined as a general tear, triggering an alarm window that uploads the alarm time, location, image, and video clip for manual confirmation and appropriate action. A tear ≥10mm is defined as a severe tear, immediately activating the linkage switch to stop the belt operation, simultaneously activating the audible and visual alarm, triggering an alarm window that uploads the alarm time, location, image, and video clip for manual confirmation and appropriate action.

[0027] Preferably, the top front end of the laser housing 5 is provided with a forward-extending laser housing flange 51; the top front end of the camera housing 6 is provided with a forward-extending camera housing flange 61. The cross-sections of both the laser housing flange 51 and the camera housing flange 61 are U-shaped with the opening facing downwards, which can protect the front end surfaces of the laser housing 5 and the camera housing 6 and reduce the probability of flying stones / falling coal damaging the lens.

[0028] Preferably, the front end of the laser housing 5 is provided with an electric laser housing scraper 53 for cleaning the laser protective mirror 52; the front end of the camera housing 6 is provided with an electric camera housing scraper 63 for cleaning the camera protective mirror 62. Both the electric laser housing scraper 53 and the electric camera housing scraper 63 include a rubber scraper and a motor for driving the rubber scraper to rotate, and the motor is fixed in the corresponding housing.

[0029] Preferably, the laser protective mirror 52 protrudes from the front end face of the laser housing 5, and the camera protective mirror 62 protrudes from the front end face of the camera housing 6. The lens surface is higher than the mounting plane, which is beneficial for scraping and removing sludge.

[0030] Preferably, the angles between the laser housing 5, the camera housing 6, and the horizontal plane are all adjustable. Furthermore, the laser housing 5 can rotate and lock around a vertical axis. The laser housing 5 can rotate not only vertically but also horizontally; the adjustable angle reduces installation accuracy requirements and allows for angle adjustments based on site conditions.

[0031] Preferably, to facilitate the adjustment of the laser housing angle, the laser housing 5 is mounted on the mounting bracket 1 via a laser housing mounting frame 54. The bottom end of the laser housing mounting frame 54 is a flat plate. The laser housing 5 is hinged to the top end of the laser housing mounting frame 54 via a first hinge 55. The first hinge 55 can be a screw. Both sides of the first hinge 55 are provided with first locking screws 56. The first locking screws 56 and the first hinge 55 are horizontally arranged. The laser housing mounting frame 54 is provided with a first arc-shaped hole 561 that corresponds to the first locking screw 56. The laser housing 5 is provided with a first screw hole that corresponds to the first locking screw 56. Loosening the first locking screw 56 allows the laser housing 5 to rotate around a horizontal axis. Tightening the first locking screw 56 fixes the laser housing 5 on the laser housing mounting frame 54.

[0032] Furthermore, the bottom end of the laser housing mounting bracket 54 is hinged to the top of the mounting bracket 1 via a second hinge 57. The second hinge 57 can be a screw, and both sides of the second hinge 57 are provided with second locking screws 58. The second locking screws 58 and the second hinge 57 are both arranged vertically. The laser housing mounting bracket 54 is provided with a second arc-shaped hole 59 that corresponds to the second locking screw 58, and the mounting bracket 1 is provided with a second screw hole that corresponds to the second locking screw 58. Loosening the second locking screw 58 allows the laser housing mounting bracket 54 to rotate around a vertical axis on the mounting bracket 1; tightening the second locking screw 58 fixes the laser housing mounting bracket 54 to the mounting bracket 1.

[0033] Preferably, the camera housing 6 is mounted on the mounting bracket 1 via a camera housing mounting bracket 64. The bottom end of the camera housing mounting bracket 64 is a flat plate, and the bottom end of the camera housing mounting bracket 64 is fixed to the mounting bracket 1 with screws. The camera housing 6 is hinged to the top end of the camera housing mounting bracket 64 via a third hinge 65. Both sides of the third hinge 65 are provided with third locking screws 66. The third hinge 65 and the third locking screws 66 are horizontally arranged. The camera housing mounting bracket 64 is provided with a third arc-shaped hole 661 that corresponds to the third locking screw 66. The camera housing 6 is provided with a third screw hole that corresponds to the third locking screw 66. Loosening the third locking screw 66 allows the camera housing 6 to rotate around a horizontal axis; tightening the third locking screw 66 locks the position of the camera housing 6.

Claims

1. A smart detection device for longitudinal tearing of conveyor belts, characterized in that: The system includes a mounting bracket (1), which is installed between the upper belt (2) and the lower belt (3) of the belt conveyor and is located between two adjacent idlers (4) of the belt conveyor. The mounting bracket (1) is inclinedly provided with a laser housing (5) and a camera housing (6). A line laser is provided in the laser housing (5), and the laser emission line of the line laser is perpendicular to the lower surface of the upper belt (2), and the center of the laser line is at a lateral angle of 30-90° with the upper belt (2). An infrared camera is provided in the camera housing (6), and the viewing angle of the infrared camera is towards the lower surface of the upper belt (2), and the center of the viewing angle intersects with the laser line on the lower surface of the upper belt (2), and the center of the viewing angle is at a longitudinal angle of 30-45° with the upper belt (2).

2. The intelligent detection device for longitudinal tearing of conveyor belts according to claim 1, characterized in that: The laser housing (5) has a forward-extending laser housing flange (51) at the front end of its top; the camera housing (6) has a forward-extending camera housing flange (61) at the front end of its top.

3. The intelligent detection device for longitudinal tearing of conveyor belts according to claim 1, characterized in that: The front end of the laser housing (5) is provided with an electric laser housing scraper (53) for cleaning the laser protective mirror (52); the front end of the camera housing (6) is provided with an electric camera housing scraper (63) for cleaning the camera protective mirror (62).

4. The intelligent detection device for longitudinal tearing of conveyor belts according to claim 3, characterized in that: The laser protective mirror (52) protrudes from the front end of the laser housing (5), and the camera protective mirror (62) protrudes from the front end of the camera housing (6).

5. The intelligent detection device for longitudinal tearing of conveyor belts according to claim 1, characterized in that: The angles between the laser housing (5), the camera housing (6) and the horizontal plane are all adjustable.

6. The intelligent detection device for longitudinal tearing of conveyor belts according to claim 1, characterized in that: The laser housing (5) can rotate around a vertical axis and be locked.

7. The intelligent detection device for longitudinal tearing of conveyor belts according to claim 1, characterized in that: The laser housing (5) is mounted on the mounting bracket (1) via a laser housing mounting frame (54). The laser housing (5) is hinged to the top of the laser housing mounting frame (54) via a first hinge (55). Both sides of the first hinge (55) are provided with first locking screws (56). The laser housing mounting frame (54) is provided with a first arc-shaped hole (561) adapted to the first locking screw (56). The laser housing (5) is provided with a first screw hole adapted to the first locking screw (56).

8. The intelligent detection device for longitudinal tearing of conveyor belts according to claim 7, characterized in that: The bottom end of the laser housing mounting bracket (54) is hinged to the top of the mounting bracket (1) through the second hinge (57). The second hinge (57) is provided with second locking screws (58) on both sides. The laser housing mounting bracket (54) is provided with a second arc-shaped hole (59) that is adapted to the second locking screw (58). The mounting bracket (1) is provided with a second screw hole that is adapted to the second locking screw (58).

9. The intelligent detection device for longitudinal tearing of conveyor belts according to claim 1, characterized in that: The camera housing (6) is mounted on the mounting bracket (1) via the camera housing mounting bracket (64). The camera housing (6) is hinged to the top of the camera housing mounting bracket (64) via a third hinge (65). Both sides of the third hinge (65) are provided with third locking screws (66). The camera housing mounting bracket (64) is provided with a third arc-shaped hole (661) adapted to the third locking screw (66). The camera housing (6) is provided with a third screw hole adapted to the third locking screw (66).

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