Belt conveyor idler monitoring device

Abstract

The utility model belongs to belt conveyor monitoring technical field especially is a kind of belt conveyor idler monitoring device, including belt conveyor frame, vibration sensor and infrared sensor, the both sides of the upper end of belt conveyor frame are equipped with multiple positioning pile, the inside of positioning pile is rotatably installed with drum by bearing, the outer sleeve of drum is equipped with conveying belt, vibration sensor is installed in one end of drum;The upper portion of belt conveyor frame is equipped with portal frame, the both sides of the lower portion of portal frame are fixedly connected support rod, infrared sensor is installed below portal frame, the detection direction of infrared sensor is towards drum;Through the collaborative work of vibration sensor directly installed on the bearing end cover of drum and infrared sensor installed on portal frame, the uninterrupted automatic monitoring to drum state is realized, vibration data collected by vibration sensor and temperature distribution data collected by infrared sensor are fused and analyzed, overcome the limitation of single sensor monitoring.

Description

Technical Field

[0001] This utility model belongs to the field of belt conveyor monitoring technology, and specifically relates to a belt conveyor idler roller monitoring device. Background Technology

[0002] Belt conveyors are crucial material conveying equipment in industrial production. They have a large number of idlers that operate at high speeds for extended periods. The health of these idlers directly affects the operating efficiency, safety, and cost of the entire conveying system, and therefore requires frequent inspection.

[0003] Currently, the monitoring of idlers mainly relies on regular manual inspections or simple online monitoring technology. Maintenance personnel check the status of idlers by listening for abnormal noises, touching to judge temperature, or observing whether they have stopped. This method cannot detect sudden faults in time. Usually, the problem is only discovered after the idler is completely damaged, causing belt wear or tear, or even causing a shutdown, resulting in huge losses. In addition, it relies on personal experience and lacks objective data support, making it easy to miss detections. At the same time, single vibration or temperature sensors have limitations. A sensor can usually only monitor one or a few idlers, and relying on a single data point is prone to false alarms or missed detections, failing to fully reflect the status of the idlers. Therefore, we propose a belt conveyor idler monitoring device. Utility Model Content

[0004] To address the issue that the monitoring of idlers in the aforementioned background technologies primarily relies on manual periodic inspections or simple online monitoring techniques, where maintenance personnel check the idler status by listening for abnormal noises, touching to check temperature, or observing whether the idler has stopped, it is difficult to detect sudden faults in a timely manner. Faults are often only discovered after the idler is completely damaged, causing belt wear or tear, or even resulting in a shutdown, leading to significant losses. Furthermore, this method relies on personal experience and lacks objective data support, making it prone to missed detections. Additionally, single vibration or temperature sensors have limitations; a single sensor typically can only monitor one or a few idlers, and relying on only one type of data can easily result in false alarms or missed detections, failing to comprehensively reflect the idler status. This invention provides a belt conveyor idler monitoring device.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a belt conveyor idler monitoring device, comprising a belt conveyor frame, a vibration sensor and an infrared sensor, wherein multiple positioning posts are installed on both sides of the upper end of the belt conveyor frame, a roller is movably installed on the inner side of the positioning posts via bearings, a conveyor belt is sleeved on the roller, and a vibration sensor is installed at one end of the roller;

[0006] A gantry frame is provided above the belt conveyor frame, and support rods are fixedly connected to both sides below the gantry frame. An infrared sensor is installed below the gantry frame, and the detection direction of the infrared sensor is towards the roller. An installation groove is opened on the lower end face of the gantry frame, and an installation plate is engaged in the installation groove. Positioning blocks are fixedly connected to both sides of the installation plate.

[0007] As a preferred embodiment of the belt conveyor idler monitoring device of this utility model, the gantry frame is fixedly installed on the belt conveyor frame by support rods on both sides.

[0008] In a preferred embodiment of the belt conveyor idler monitoring device of this utility model, the infrared sensor is mounted on the lower end of the mounting plate via the positioning block and bolts.

[0009] As a preferred embodiment of the belt conveyor roller monitoring device of this utility model, the vibration sensor is a miniature MEMS vibration sensor, which is directly installed on the bearing end cover of the roller.

[0010] As a preferred embodiment of the belt conveyor idler monitoring device of this utility model, a drive roller is installed at one end of the inner side of the conveyor belt, one end of the drive roller is connected to a drive motor, and a linkage roller is installed at the other end of the inner side of the conveyor belt.

[0011] In a preferred embodiment of the belt conveyor idler monitoring device of this utility model, the drive motor is connected to the drive roller, and the drive roller and the linkage roller tension the conveyor belt and drive it to circulate.

[0012] Compared with the prior art, the beneficial effects of this utility model are as follows: By using a vibration sensor directly installed on the end cover of the roller bearing and an infrared sensor installed on the gantry, continuous automatic monitoring of the roller status is achieved, completely replacing the dangerous and inefficient manual inspection method. By fusing and analyzing the vibration data collected by the vibration sensor and the temperature distribution data collected by the infrared sensor, the limitations of single sensor monitoring are overcome, enabling a more comprehensive and accurate judgment of the roller's health status. This significantly reduces the false alarm rate and missed alarm rate, improves diagnostic reliability, and prevents the problem that monitoring of idlers mainly relies on manual periodic inspections or simple online monitoring technology, which is prone to missed detections and cannot fully reflect the status of the idlers. Attached Figure Description

[0013] The accompanying drawings are provided to further illustrate the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the present invention, but do not constitute a limitation thereof. In the drawings:

[0014] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0015] Figure 2 This is a schematic diagram of the belt conveyor of this utility model;

[0016] Figure 3 This is a schematic diagram of the gantry frame structure in this utility model;

[0017] Figure 4 This is a schematic diagram of the structure of the gantry and mounting plate in this utility model.

[0018] In the diagram: 1. Belt conveyor frame; 2. Positioning pile; 3. Roller; 4. Conveyor belt; 5. Drive motor; 6. Drive roller; 7. Linkage roller; 8. Vibration sensor; 9. Gantry frame; 10. Support rod; 11. Mounting plate; 12. Infrared sensor; 13. Positioning block; 14. Mounting groove. Detailed Implementation

[0019] 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.

[0020] Example 1

[0021] like Figures 1-4 As shown;

[0022] A belt conveyor idler monitoring device includes a belt conveyor frame 1, a vibration sensor 8, and an infrared sensor 12. Multiple positioning stakes 2 are installed on both sides of the upper end of the belt conveyor frame 1. A roller 3 is movably installed on the inner side of the positioning stakes 2 via bearings. A conveyor belt 4 is installed on the outer side of the roller 3. A vibration sensor 8 is installed at one end of the roller 3. A gantry frame 9 is provided above the belt conveyor frame 1. Support rods 10 are fixedly connected to both sides of the lower part of the gantry frame 9. An infrared sensor 12 is installed below the gantry frame 9. The detection direction of the infrared sensor 12 is towards the roller 3. An installation groove 14 is opened on the lower end face of the gantry frame 9. An installation plate 11 is engaged and installed in the installation groove 14. Positioning blocks 13 are fixedly connected to both sides of the installation plate 11.

[0023] In this implementation scheme: The coordinated operation of the vibration sensor 8, directly mounted on the bearing end cover of roller 3, and the infrared sensor 12, mounted on the gantry 9, enables continuous automatic monitoring of the roller 3's condition, completely replacing the dangerous and inefficient manual inspection method. By fusing and analyzing the vibration data collected by the vibration sensor 8 with the temperature distribution data collected by the infrared sensor 12, the limitations of single-sensor monitoring are overcome, allowing for a more comprehensive and accurate assessment of the roller 3's health status. This significantly reduces false alarm and false negative rates, improving diagnostic reliability. The engaging design of the mounting groove 14 and mounting plate 11, along with the positioning blocks 13 on both sides, allows the infrared sensor 12's installation position to be flexibly adjusted along the length of the conveyor belt for precise alignment with the idler roller assembly. The vibration sensor 8 is directly mounted on the roller 3 shaft. Unlike the indirect installation or monitoring methods commonly used in the prior art that only target a few key idlers, this application achieves direct contact monitoring of each idler. Direct installation on the bearing end cover allows the vibration sensor to capture the micro-vibration signal inside the bearing without attenuation, greatly improving the ability to identify early faults and overcoming the signal attenuation problem caused by indirect installation in the prior art. Each idler is equipped with an independent vibration sensor, realizing synchronous real-time monitoring of all idlers, avoiding the signal confusion and missed detection problems when one sensor monitors multiple idlers in the prior art. The infrared sensor 12 is installed below the gantry 9 spanning the belt conveyor and fixed by the mounting plate 11 and positioning block 13. Its detection direction is precisely towards the roller group, realizing non-contact, large-area, multi-target synchronous scanning.

[0024] In an optional embodiment, the gantry 9 is fixedly mounted on the conveyor frame 1 by support rods 10 on both sides of it.

[0025] In this implementation scheme: the gantry frame 9 is securely installed on the belt conveyor frame 1 by the support rod 10, forming a rigid monitoring platform higher than the conveyor belt. This avoids interference with material conveying and provides the infrared sensor 12 with the best monitoring field of view and installation stability.

[0026] In an optional embodiment, the infrared sensor 12 is mounted to the lower end of the mounting plate 11 via a positioning block 13 and bolts.

[0027] In this embodiment, the infrared sensor 12 is fixed to the bottom of the mounting plate 11 by the positioning block 13 and bolts. This connection method is firm and reliable, which can effectively prevent loosening caused by equipment vibration and ensure the continuous stability of the monitoring data of the infrared sensor 12. At the same time, the bolt connection also facilitates the disassembly, maintenance or replacement of the sensor.

[0028] In an optional embodiment, the vibration sensor 8 is a miniature MEMS vibration sensor 8, which is directly mounted on the bearing end cap of the roller 3.

[0029] In this implementation scheme, a miniature MEMS vibration sensor 8 is used and directly installed on the bearing end cover of the roller 3. This enables the most direct and sensitive acquisition of vibration signals inside the bearing, greatly improving the accuracy of vibration monitoring and the sensitivity of early fault detection.

[0030] In an optional embodiment, a drive roller 6 is installed at one end of the inner side of the conveyor belt 4, and a drive motor 5 is connected to one end of the drive roller 6. A linkage roller 7 is installed at the other end of the inner side of the conveyor belt 4. The drive motor 5 is connected to the drive roller 6. The drive roller 6 and the linkage roller 7 tension the conveyor belt 4 and drive it to circulate.

[0031] In this implementation scheme: the drive motor 5 drives the drive roller 6, and the linkage roller 7 provides tension, forming a complete and reliable belt drive system, which ensures the stable operation of the conveyor belt 4 and provides a stable and reliable monitoring object and working condition for the vibration sensor 8 and the infrared sensor 12.

[0032] Working principle:

[0033] The gantry frame 9 is fixed to the belt conveyor frame 1 by the support rods 10 on both sides, spanning the entire conveyor belt and providing a stable installation platform. The mounting plate 11 is embedded into the mounting groove 14 at the lower end of the gantry frame 9 by a snap-fit ​​method, and is finally fixed by the positioning blocks 13 at both ends and bolts, ensuring that its field of vision can cover the multiple sets of idlers that need to be monitored below.

[0034] The miniature MEMS vibration sensor 8 is directly mounted on the bearing housing at one end of the idler roller, enabling it to directly and sensitively sense the vibration changes inside the idler roller bearing. When the drive motor 5 starts and drives the conveyor belt 4 and all the rollers 3 to rotate through the drive roller 6 and the linkage roller 7, the vibration sensor 8 begins to continuously collect the vibration acceleration signal of the idler roller bearing. The vibration signal is converted into an electrical signal in real time. The data acquisition module inside or outside the sensor can perform preliminary filtering and amplification of the signal to eliminate some environmental noise interference.

[0035] At the same time, the infrared sensor 12 installed on the gantry 9 starts to work. The infrared sensor 12 is like an infrared thermal imager. It performs periodic or continuous large-area scanning of multiple sets of rollers 3 within its field of view to generate a thermal imaging image of the temperature distribution of the entire idler group. It does not monitor a certain absolute temperature value, but rather quickly detects individuals with abnormally high temperatures by comparing the temperature differences of adjacent idlers under the same environment.

[0036] The vibration signal collected by vibration sensor 8 and the temperature image data collected by infrared sensor 12 are transmitted to the central processing unit of the cloud platform in the background via wired or wireless means. The central processing unit has built-in analysis algorithms to perform time-domain and frequency-domain analysis on the vibration signal, such as RMS value, peak value, and spectrum analysis, to determine whether there are abnormal vibration characteristic frequencies caused by bearing wear, eccentricity, imbalance, etc. At the same time, it identifies temperature anomalies in the thermal image and locates which roller has a temperature significantly higher than its adjacent rollers or the ambient temperature. The connection structure between vibration sensor 8 and infrared sensor 12 and the central processing unit is a mature existing technology, and its principle will not be elaborated here.

[0037] By combining vibration and temperature data for joint diagnosis, for example, "abnormal vibration + normal temperature" may indicate an early mechanical failure; "abnormal vibration + abnormal temperature" indicates a more serious failure; and "normal vibration + abnormal temperature" may point to poor lubrication or seizure risk. This multi-dimensional cross-validation greatly improves the accuracy and reliability of the diagnosis. Based on the diagnostic results, the central processing unit outputs the health status of each idler roller. This status information can be displayed on the monitoring screen in the control room, accurately locating the abnormal idler roller, such as the idler roller at the Xth belt conveyor frame or the Yth group of positioning piles. Warnings are issued through sound and light, SMS, and management system work orders to guide maintenance personnel to handle the situation precisely and prevent the accident from escalating. The innovative layout of integrating vibration sensor 8 directly into the bearing end cover and infrared sensor frame 12 on gantry 9 breaks through the single-point, single-dimensional, inefficient manual or simple monitoring mode in the existing technology, realizing fully automatic, multi-dimensional, and high-precision idler roller health status monitoring. This installation method improves the accuracy and comprehensiveness of data acquisition.

[0038] Finally, it should be noted that the above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A belt conveyor idler monitoring device, comprising a belt conveyor frame (1), a vibration sensor (8), and an infrared sensor (12), characterized in that: Multiple positioning piles (2) are installed on both sides of the upper end of the belt conveyor frame (1). A roller (3) is movably installed on the inner side of the positioning pile (2) through a bearing. A conveyor belt (4) is installed on the outer side of the roller (3). A vibration sensor (8) is installed at one end of the roller (3). A gantry frame (9) is provided above the belt conveyor frame (1). Support rods (10) are fixedly connected to both sides below the gantry frame (9). An infrared sensor (12) is installed below the gantry frame (9). The detection direction of the infrared sensor (12) is towards the roller (3). An installation groove (14) is opened on the lower end face of the gantry frame (9). An installation plate (11) is fitted in the installation groove (14). Positioning blocks (13) are fixedly connected to both sides of the installation plate (11).

2. The belt conveyor idler monitoring device according to claim 1, characterized in that: The gantry frame (9) is fixedly installed on the belt conveyor frame (1) by the support rods (10) on both sides.

3. The belt conveyor idler monitoring device according to claim 1, characterized in that: The infrared sensor (12) is mounted on the lower end of the mounting plate (11) via the positioning block (13) and bolts.

4. The belt conveyor idler monitoring device according to claim 1, characterized in that: The vibration sensor (8) is a micro MEMS vibration sensor (8), which is directly installed on the bearing end cover of the roller (3).

5. The belt conveyor idler monitoring device according to claim 1, characterized in that: A drive roller (6) is installed at one end of the inner side of the conveyor belt (4), and a drive motor (5) is connected to one end of the drive roller (6). A linkage roller (7) is installed at the other end of the inner side of the conveyor belt (4).

6. The belt conveyor idler monitoring device according to claim 5, characterized in that: The drive motor (5) is connected to the drive roller (6), and the drive roller (6) and the linkage roller (7) tension the conveyor belt (4) and drive it to circulate.

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