Surface profile measuring device, surface profile measuring method, and belt management method

Abstract

Provided are a surface shape measurement device, a surface shape measurement method, and a belt management method that make it possible to accurately measure the thickness of a belt. A surface shape measurement device (10) that measures the surface shape of a belt that is wound around a pulley includes: a belt surface measurement device (11) that measures the surface position of the belt and the surface position of the pulley at a section at which the belt contacts the pulley; and a control device (15) that, on the basis of the measured surface position of the pulley, corrects the surface position of the belt and calculates the surface shape of the belt.

Description

[Technical Field]

[0001] TECHNICAL FIELD The present disclosure relates to a surface profile measuring device, a surface profile measuring method, and a belt management method, and more particularly to a surface profile measuring device, a surface profile measuring method, and a belt management method for measuring the surface profile of a belt wound around a pulley. [Background technology]

[0002] A belt conveyor, which includes a conveyor belt wound around a pair of pulleys as a driving means, is known as a conveying device for conveying materials such as raw materials. In a belt conveyor, the thickness of the conveyor belt needs to be controlled to prevent the conveyor belt from breaking.

[0003] For example, Patent Documents 1 and 2 disclose an apparatus and a system for measuring the unevenness of the surface of a conveyor belt by a light cutting method using a line laser. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2017-32346 [Patent Document 2] Japanese Patent Publication No. 2020-76767 Summary of the Invention [Problem to be solved by the invention]

[0005] In the technology of Patent Document 1, the unevenness of the conveyor belt is measured at a position away from the pulley, so the conveyor belt is prone to become unstable, such as swinging up and down, making it difficult to improve the accuracy of measuring the unevenness of the conveyor belt.On the other hand, in the technology of Patent Document 2, the unevenness of the conveyor belt is measured at the part where the conveyor belt contacts the pulley, but there is a problem that the thickness of the conveyor belt cannot be measured accurately if the pulley around which the conveyor belt is wound is eccentric or tilted.

[0006] In view of the above circumstances, an object of the present disclosure is to provide a surface profile measuring device, a surface profile measuring method, and a belt management method that can measure the thickness of a belt with high accuracy. [Means for solving the problem]

[0007] (1) A surface profile measuring device according to an embodiment of the present disclosure, A surface shape measuring device for measuring the surface shape of a belt wound around a pulley, a belt surface measuring device for measuring the surface position of the belt and the surface position of the pulley at a portion where the belt contacts the pulley; and a control device that corrects the surface position of the belt based on the measured surface position of the pulley and calculates the surface shape of the belt.

[0008] (2) As one embodiment of the present disclosure, in (1), the belt surface measuring device measures the surface positions of both ends of the pulley in the width direction that are exposed from the ends of the belt in the width direction, The control device estimates the surface position of the portion of the pulley other than both ends in the width direction from the surface positions of both ends in the width direction of the pulley, and corrects the surface position of the belt based on the estimated surface positions of the pulley.

[0009] (3) As an embodiment of the present disclosure, in (1) or (2), The belt surface measuring device measures the surface position of the belt over at least the entire length in the conveying direction.

[0010] (4) As an embodiment of the present disclosure, in any one of (1) to (3), The control device estimates the inclination of the pulley in the width direction from the surface position of the pulley, and corrects the surface position of the belt based on the inclination.

[0011] (5) As an embodiment of the present disclosure, in any one of (1) to (4), The control device estimates the eccentricity of the pulley in the circumferential direction from the surface position of the pulley, and corrects the surface position of the belt based on the eccentricity.

[0012] (6) A surface profile measuring method according to an embodiment of the present disclosure includes: A surface shape measuring method for measuring the surface shape of a belt wound around a pulley, comprising: measuring a surface position of the belt and a surface position of the pulley at a portion where the belt contacts the pulley; The surface position of the belt is corrected based on the measured surface position of the pulley, and the surface shape of the belt is calculated.

[0013] (7) A belt management method according to an embodiment of the present disclosure includes: (6) The belt is managed based on the surface shape of the belt calculated by the surface shape measuring method. [Effects of the Invention]

[0014] According to the present disclosure, it is possible to provide a surface profile measuring device, a surface profile measuring method, and a belt management method that accurately measure the thickness of a belt. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a diagram showing an example of the configuration of a surface profile measuring apparatus according to an embodiment. [Figure 2]FIG. 2 is a diagram illustrating how the surface shape (surface position) of a conveyor belt is measured by a belt surface measuring device. [Figure 3A] FIG. 3A is a diagram for explaining the influence of the tilt and eccentricity of the pulley on the surface shape data of the conveyor belt. [Figure 3B] FIG. 3B is a diagram for explaining the influence of the tilt and eccentricity of the pulley on the surface shape data of the conveyor belt. [Figure 4] FIG. 4 is a flowchart illustrating an example of a surface shape measuring method according to an embodiment. [Figure 5A] FIG. 5A is a diagram for explaining a method for correcting the influence of the tilt of the pulley. [Figure 5B] FIG. 5B is a diagram for explaining a method for correcting the influence of the tilt of the pulley. [Figure 6A] FIG. 6A is a diagram for explaining a method for correcting the influence of eccentricity of a pulley. [Figure 6B] FIG. 6B is a diagram for explaining a method for correcting the influence of eccentricity of a pulley. DETAILED DESCRIPTION OF THE INVENTION

[0016] Hereinafter, a surface profile measuring device, a surface profile measuring method, and a belt management method according to an embodiment of the present disclosure will be described with reference to the drawings. In each drawing, identical or corresponding parts are designated by the same reference numerals. In the description of this embodiment, the description of identical or corresponding parts will be omitted or simplified as appropriate.

[0017] <Surface shape measuring device> FIG. 1 shows an example of the configuration of a surface profile measuring device 10 according to this embodiment. FIG. 2 shows how the belt surface measuring device 11 of the surface profile measuring device 10 measures the surface profile of a conveyor belt 30 of a belt conveyor 1. As shown in FIG. 2, the surface profile measuring device 10 measures the surface profile of a conveyor belt 30 wound around a pulley 20. Here, the pulley 20 is an example of a driving means. The conveyor belt 30 is also an example of a belt. The surface profile measuring device 10 is a device for measuring the surface profile of a belt driven in a traveling direction by a driving means. Although the belt is not limited to the conveyor belt 30, in this embodiment, the belt is described as a conveyor belt 30 driven by the pulley 20. Here, the traveling direction is the direction in which the belt moves due to the driving force from the driving means. In this embodiment, the traveling direction is also referred to as the conveying direction. The conveying direction is the direction in which an object loaded on the surface 31 of the conveyor belt 30 moves while the conveyor belt 30 is in operation.

[0018] In the belt conveyor 1, it is necessary to control the thickness of the conveyor belt 30 so that the conveyor belt 30 does not break. The thickness of the conveyor belt 30 can be controlled by calculating the thickness of the conveyor belt 30 from the surface profile measured by the surface profile measuring device 10. If the surface profile can be measured accurately, the thickness of the conveyor belt 30 can be accurately obtained by calculation. Here, the surface profile refers to the shape including the irregularities of the surface 31 of the conveyor belt 30. For example, a portion of the surface 31 of the conveyor belt 30 that is recessed from the surrounding area can indicate that the thickness of the conveyor belt 30 is thinner than the surrounding area.

[0019] As shown in FIG. 1 , the surface profile measuring device 10 according to this embodiment includes a belt surface measuring device 11 and a control device 15. The control device 15 includes a calculation device 12 and an analysis device 14. The surface profile measuring device 10 is a device in which the belt surface measuring device 11, the calculation device 12, and the analysis device 14 work in cooperation with each other to measure the surface profile of a conveyor belt 30. The calculation device 12 obtains conveyor belt operation information 13 as needed. The conveyor belt operation information 13 is information about the operation and status of the conveyor belt 30, and is obtained, for example, from a control device of the belt conveyor 1. The belt surface measuring device 11 and the control device 15 are connected via a network such as a LAN (Local Area Network), and may be able to send and receive information obtained by measurement (measurement data). The control device of the belt conveyor 1 may also be connected via the same network such as a LAN. Details of the components of the surface profile measuring device 10 will be described later.

[0020] 2, a conveyor belt 30, which is the object of measurement by the surface profile measuring device 10, is wound around a pulley 20. When the pulley 20 rotates, the conveyor belt 30 moves, and an object placed on a surface 31 of the conveyor belt 30 can be conveyed. Here, the surface 31 of the conveyor belt 30 is the surface (outer surface) opposite to the surface of the conveyor belt 30 facing the pulley 20 (inner surface).

[0021] <Belt surface measuring device> As shown in FIG. 2 , the belt surface measuring device 11 measures the surface shapes of the conveyor belt 30 and the pulley 20. The belt surface measuring device 11 can identify the surface positions of the conveyor belt 30 and the pulley 20 through measurement. In other words, it can be said that local information on the surface shape is the surface position. Therefore, hereinafter, measurement by the belt surface measuring device 11 may be referred to as "measuring the surface position." The belt surface measuring device 11 can simultaneously measure the surface position of the conveyor belt 30 and the pulley 20 at the portion where the conveyor belt 30 contacts the pulley 20. In this embodiment, the belt surface measuring device 11 is a non-contact measuring device that measures the surface positions of the conveyor belt 30 and the pulley 20 without contacting them. The belt surface measuring device 11 performs measurement while the pulley 20 and the conveyor belt 30 are rotating. It is preferable that the belt surface measuring device 11 measures the surface position of at least the entire length of the conveyor belt 30 in the conveying direction.

[0022] In this embodiment, the belt surface measuring device 11 is a laser light-cutting type device such as a light-cutting shapemeter. The belt surface measuring device 11 can measure the surface position of the conveyor belt 30 over the entire width direction by irradiating the conveyor belt 30 and the pulley 20 with a linear laser beam. The belt surface measuring device 11 can measure the surface position of both ends of the pulley 20 in the width direction that are exposed from the ends of the conveyor belt 30 in the width direction.

[0023] The belt surface measuring device 11 is installed in a position where it can irradiate the conveyor belt 30 with a laser beam from diagonally above the pulley 20 so that the surface positions of the conveyor belt 30 and the pulley 20 can be measured simultaneously at the portion where the conveyor belt 30 contacts the pulley 20. The belt surface measuring device 11 may be configured to be held near the pulley 20 by a holding member 40 installed on the ground. At this time, in order to accurately measure the thickness direction of the conveyor belt 30, the belt surface measuring device 11 is installed so that the direction of irradiation of the laser beam passes through the center 22 of the pulley 20. Since the belt surface measuring device 11 measures the surface position of the conveyor belt 30 at the portion where the conveyor belt 30 contacts the pulley 20, the conveyor belt 30 does not shake up and down, and the conveyor belt 30 can be measured in a stable position. Furthermore, the surface positions of the conveyor belt 30 and the pulley 20 can be measured simultaneously at the same position. Therefore, compared to a configuration in which the surface positions of the conveyor belt 30 and the pulley 20 are measured separately using two measuring devices, the number of measuring devices can be reduced, and the surface position of the conveyor belt 30 can be accurately corrected according to the surface position of the pulley 20.

[0024] In this way, the belt surface measuring device 11 performs measurements to obtain information on the surface position of the conveyor belt 30 and information on the surface position of the pulley 20. However, the obtained information on the surface position of the conveyor belt 30 includes the eccentricity and inclination of the pulley 20.

[0025] As another configuration example, a device other than the laser light cutting type can be used as the belt surface measuring device 11. However, it is preferable that the belt surface measuring device 11 is a non-contact type measuring device that can measure the conveyor belt 30 and the pulley 20 without contacting them so that the surface positions of the conveyor belt 30 and the pulley 20 can be measured while they are rotating.

[0026] <Control device> The control device 15 includes a calculation device 12 and an analysis device 14. The control device 15 corrects the surface position of the conveyor belt 30 based on the surface position of the pulley 20 measured by the belt surface measurement device 11, and calculates the surface shape of the conveyor belt 30. The control device 15 may be configured with a processor that performs calculations and a memory unit that stores data used in the calculations (e.g., surface position information). The processor may be, for example, a general-purpose processor or a dedicated processor specialized for a specific process, but is not limited to these and may be any processor. The memory unit is one or more memories. The memory may be, for example, a semiconductor memory, a magnetic memory, an optical memory, etc., but is not limited to these and may be any memory. The control device 15 may be, for example, a computer.

[0027] <Arithmetic device> The calculation device 12 calculates the surface shape of the entire length in the conveying direction of the conveyor belt 30 based on the measurement data, which is information on the surface position, from the belt surface measuring device 11 and the conveyor belt operation information 13 acquired as needed. Here, the entire length in the conveying direction of the conveyor belt 30 may be referred to as the entire circumference or the entire circumferential length. Furthermore, the calculation of the surface shape may include determining the thickness of the conveyor belt 30, and may also include determining the unevenness of the surface 31 of the conveyor belt 30 by associating it with, for example, a two-dimensional map.

[0028] <Analysis equipment> The analysis device 14 is a device for obtaining an accurate surface shape of the conveyor belt 30 by removing information about the surface position (eccentricity and tilt) of the pulley 20 from information about the surface shape of the conveyor belt 30 calculated by the calculation device 12. Here, the surface position of the pulley 20 to be removed is the surface position over the entire width (total widthwise length) of the pulley 20. The analysis device 14 estimates the surface position of the portion of the pulley 20 other than both ends in the widthwise direction (total widthwise length) from the surface positions of both ends in the widthwise direction of the pulley 20 measured by the belt surface measuring device 11. For example, as shown by the dashed line in FIG. 5A , the analysis device 14 estimates the surface position of the pulley 20 as the straight line portion when the positions of both ends in the widthwise direction of the pulley 20 are connected by a straight line. Here, in this embodiment, the analysis device 14 estimates the entire widthwise length from the measured surface positions of both ends in the widthwise direction of the pulley 20, but may also perform a partial estimation (discrete estimation) of the pulley 20 in the widthwise direction.

[0029] <Surface shape measurement method> 3A and 3B show the surface shapes of the conveyor belt 30 and the pulley 20 as grayscale images based on measurement data obtained by the belt surface measuring device 11. In this embodiment, the surface position is obtained as a height position (hereinafter referred to as "height"), with the radial direction from the center 22 of the cylindrical pulley 20 being the height direction. The surface position of the conveyor belt 30 may be expressed as "high" when it is farther from the center 22 in the radial direction of the pulley 20, and "low" when it is closer to the center 22. In FIGS. 3A and 3B, black areas, such as those near the center in the width direction, indicate higher surface positions compared to white areas. FIG. 3A shows data that includes the effects of the inclination and eccentricity of the pulley 20. For example, black lines can be seen across the entire width due to the effects of eccentricity. Additionally, an asymmetric color distribution can be seen in the width direction. FIG. 3B shows data that removes the effects of the inclination and eccentricity of the pulley 20. In FIG. 3B, no black lines or asymmetric color distribution can be seen. By performing the correction process described below, data on the surface shapes of the conveyor belt 30 and the pulley 20 as shown in FIG. 3B is obtained.

[0030] FIG. 4 is a flowchart showing an example of a surface profile measuring method executed by the surface profile measuring apparatus 10 according to this embodiment.

[0031] The surface profile measuring device 10 waits when it determines that the conveyor belt 30 is not in operation based on the signal obtained from the conveyor belt operation information 13 (No in step S1). If the conveyor belt 30 is in operation (Yes in step S1), the surface profile measuring device 10 performs measurement using the belt surface measuring device 11 (step S2).

[0032] Next, the surface shape measuring device 10 identifies the position of the conveyor belt 30 in the conveying direction from the conveyor belt operation information 13, and stores the measurement data measured by the belt surface measuring device 11 in association with the identified position of the conveyor belt 30.

[0033] If the surface profile measuring device 10 has not yet measured the surface positions along the entire length (one revolution) of the conveyor belt 30 in the conveying direction (No in step S3), it continues the measurement. If the data for one revolution of the conveyor belt 30 has been measured (Yes in step S3), the surface profile measuring device 10 combines the data for one revolution based on the associated position information of the conveyor belt 30 in the conveying direction (step S4). Here, multiple pieces of measurement data may exist for one position. The surface profile measuring device 10 may, for example, select any of the measurement data, or may perform a calculation such as averaging and associate the calculated measurement data with that position.

[0034] Here, the surface profile data obtained in step S3 includes the influence of the surface position (tilt and eccentricity) of the pulley 20. Therefore, the surface profile measuring device 10 analyzes the correct surface profile data of the conveyor belt 30 (step S5). The surface profile measuring device 10 corrects the surface position of the conveyor belt 30 based on the surface position (tilt and eccentricity) of the pulley 20, and calculates the surface profile of the conveyor belt 30 from which the influence of the tilt and eccentricity of the pulley 20 has been removed.

[0035] 5A and 5B are diagrams illustrating a method for correcting the effect of the tilt of the pulley 20. Here, the pulley 20 and the conveyor belt 30 wound around the pulley 20 can be distinguished in the width direction because a sudden difference in height (step) occurs at both ends (boundaries) of the conveyor belt 30. The pulley portion in FIGS. 5A and 5B is the portion where the pulley 20 is determined to be exposed. The belt portion in FIGS. 5A and 5B is the portion where the conveyor belt 30 is determined to be present. FIG. 5A shows an example of the surface position (surface shape) of the conveyor belt 30 before tilt correction calculated by the control device 15. From the difference in the surface position (height) at both ends of the pulley 20, it can be seen that the entire pulley is tilted in the width direction. It can also be seen that the surface position (surface shape) of the conveyor belt 30 is tilted due to the influence of the tilt of the pulley 20. 5B, the control device 15 corrects the influence of the tilt of the pulley 20 by rotating and translating the surface positions of the conveyor belt 30 and the pulley 20 so that the height of the pulley 20 becomes 0 (reference point). Here, the tilt of the pulley 20 can be measured (estimated) even when the pulley 20 (conveyor belt 30) is stopped.

[0036] 6A and 6B are diagrams illustrating a correction method when the pulley 20 is eccentric (the center 22 is misaligned). The eccentricity of the pulley 20 causes irregularities in the surface shape of the conveyor belt 30 in the conveying direction (circumferential direction). Here, the conveying direction distance on the horizontal axis indicates the distance from a reference position on the conveyor belt 30 in the conveying direction at which the surface shape (height) of the conveyor belt 30 is measured, and is expressed as a length from 0 to one revolution (total circumferential length). FIG. 6A shows the surface shapes at the center position in the width direction of the conveyor belt 30 and at both end positions in the width direction of the pulley 20 before eccentricity correction calculated by the control device 15. The moving average of the surface shape at the center of the width direction of the conveyor belt 30 (profile of the belt portion) and the moving average of the surface shape at both end positions in the width direction of the pulley 20 (profile of the pulley portion) coincide with each other. This shows that the surface shape of the belt portion is affected by the eccentricity of the pulley 20. As shown in FIG. 6B, the control device 15 corrects the effect of eccentricity of the pulley 20 by subtracting the profile of the pulley portion from the profile of the belt portion to obtain the difference. In the example of FIG. 6B, the fluctuation range of the surface shape of the conveyor belt 30 is approximately 2 mm. Compared to the fluctuation range of approximately 8 mm of the surface shape of the conveyor belt 30 before eccentricity correction (FIG. 6A), this fluctuation range is significantly smaller, and it can be seen that the surface shape of the conveyor belt 30 can be measured with high accuracy by the correction. Then, the control device 15 can accurately measure the thickness of the conveyor belt 30 based on the surface shape of the conveyor belt 30 obtained with high accuracy by the correction.

[0037] <How to manage your belt> Using the above-described surface profile measurement method, the conveyor belt 30 can be managed (monitored) based on the calculated surface profile of the conveyor belt 30. The surface profile measuring device 10 determines whether the thickness of the conveyor belt 30 is sufficient, for example, based on the calculated surface profile of the conveyor belt 30. If the surface profile measuring device 10 determines that the thickness is insufficient, it can notify an operator of an abnormality in the conveyor belt 30 or stop the conveyor belt 30. In this way, by managing the conveyor belt 30 based on the calculated surface profile of the conveyor belt 30, it becomes possible to accurately detect abnormalities in the conveyor belt 30 and to respond to the abnormality early.

[0038] As described above, the surface profile measuring device 10 and surface profile measuring method according to the present embodiment can eliminate the effects of tilt and eccentricity of the pulley 20 through the above-described configuration and processes, thereby enabling accurate measurement of the thickness of the conveyor belt 30. Furthermore, the belt management method according to the present embodiment makes it possible to accurately determine the thickness of the conveyor belt 30, and manage the conveyor belt 30 to prevent breakage or the like.

[0039] Although the embodiments of the present disclosure have been described based on the drawings and examples, it should be noted that those skilled in the art would easily be able to make various modifications or alterations based on the present disclosure. Therefore, it should be noted that these modifications and alterations are included within the scope of the present disclosure. For example, functions included in each component or step (process) can be rearranged so as not to cause logical inconsistencies, and multiple components or steps can be combined or divided into one. The embodiments of the present disclosure can also be realized as a program executed by a processor included in an apparatus or a storage medium on which a program is recorded. It should be understood that these are also included within the scope of the present disclosure.

[0040] In the above embodiment, the measurement object is the conveyor belt 30, but it is not limited to the conveyor belt 30. The belt to be measured may be any belt that is at least wound around the pulley 20. [Explanation of symbols]

[0041] 1 conveyor belt 10 Surface shape measuring device 11 Belt surface measuring device 12 Arithmetic unit 13 Conveyor belt operation information 14 Analysis device 15 Control device 20 pulleys 22 center 30 Conveyor Belt 31 Conveyor belt surface 40 Retaining member

Claims

1. A surface shape measuring device for measuring the surface shape of a belt wound around a pulley, a belt surface measuring device that simultaneously measures the surface position of the belt and the surface position of the pulley at a portion where the belt contacts the pulley while the belt is wound around the pulley; a control device that corrects the surface position of the belt based on the measured surface position of the pulley and calculates the surface shape of the belt, the belt surface measuring device measures the surface positions of both ends of the pulley in the width direction that are exposed from the ends of the belt in the width direction, The control device a surface position of a portion other than both ends of the pulley in the width direction is estimated from a straight line portion connecting the surface positions of both ends of the pulley in the width direction, an inclination of the pulley in the width direction is estimated from the estimated surface position of the pulley, and the surface position of the belt is corrected based on the inclination; A surface shape measuring device that estimates the eccentricity of the pulley in the circumferential direction from the surface positions at both ends of the pulley in the width direction by matching the trends of the moving average of the surface shape at the center of the belt in the width direction and the moving average of the surface shape at both ends of the pulley in the width direction, and corrects the surface position of the belt based on the eccentricity.

2. The surface shape measuring device according to claim 1 , wherein the belt surface measuring device measures the surface position of at least the entire length of the belt in the conveying direction.

3. A surface shape measuring method for measuring the surface shape of a belt wound around a pulley, comprising: With the belt wound around the pulley, a surface position of the belt and surface positions of both ends of the pulley in the width direction that are exposed from the ends of the belt in the width direction are simultaneously measured at a portion where the belt contacts the pulley; correcting the surface position of the belt based on the measured surface position of the pulley, and calculating the surface shape of the belt; Correcting the surface position of the belt includes: a surface position of a portion other than both ends of the pulley in the width direction is estimated from a straight line portion connecting the surface positions of both ends of the pulley in the width direction, an inclination of the pulley in the width direction is estimated from the estimated surface position of the pulley, and the surface position of the belt is corrected based on the inclination; a moving average of the surface shape at the width center of the belt and a moving average of the surface shape at both ends of the pulley in the width direction, the moving average being the same over time; and a moving average of the surface shape at both ends of the pulley in the width direction being the same over time; the eccentricity in the circumferential direction of the pulley is estimated from the surface positions at both ends of the pulley in the width direction, and the surface position of the belt is corrected based on the eccentricity.

4. A belt management method, comprising: managing the belt based on the surface shape of the belt calculated by the surface shape measuring method according to claim 3.

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