Tension-based detection of damage to a conveyor belt

Abstract

A method for automatically detecting the appearance of an anomalous source of concentrated resistance to the movement of a conveyor belt is implemented with the aid of a computing device connected to a device for measuring the amount of tensioning force on a tensioning device of a belt conveyor. The condition of the conveyor belt is determined by monitoring and processing measurements of the amount of tensioning force on the tensioning device of the belt conveyor. The claimed method and system make it possible, by the processing of such measurements, to more precisely detect the presence of an anomalous source of resistance to the movement of the conveyor belt, indicating damage to the conveyor belt.

Description

METHOD AND SYSTEM FOR AUTOMATED DETERMINATION OF THE OCCURRENCE OF AN ANOMALOUS SOURCE OF CONCENTRATED RESISTANCE TO THE MOVEMENT OF A CONVEYOR BELT BY TENSION. FIELD OF TECHNOLOGY

[0001] This technical solution relates to the field of computer technology, in particular, to a method and system for the automated determination of the occurrence of an abnormal source of concentrated resistance to the movement of a conveyor belt.

[0002] Conveyor transport for bulk cargo transportation is used in many industries, including mining, processing, energy, chemicals, and in cargo handling. Bulk cargo, whether waste rock, ore, coal, coke, feedstock, concentrate, sinter, pellets, chemicals, or other materials, is transported directly on a conveyor belt from the loading point, typically near the tail drum, to the unloading point, typically near the head / drive drum. During conveyor operation, accidents may arise due to the entry of foreign objects, which can cause concentrated resistance to the conveyor belt and lead to belt damage. This can occur, in particular, due to the entry of heavy, large, and sharp-edged pieces of ore or foreign materials that contaminate ore, such as excavator teeth, scrap, rebar, or steel sheets.When loading a conveyor belt, jamming and damage to the conveyor belt, primarily a longitudinal tear, can occur. In this situation, an abnormal, concentrated source of resistance to conveyor belt movement occurs, i.e., one that is inconsistent with normal, trouble-free conveyor operation.

[0003] Accordingly, early detection of the presence of an abnormal source of concentrated resistance to conveyor belt movement can prevent damage to the conveyor belt, and consequently extend the service life of the conveyor belt.

[0004] Thus, the prior art includes systems for protecting conveyor belts from longitudinal ruptures, which operate on the principle of damaging elements vulcanized into the belt (inductive loops, inserts, antennas, etc.). An example One such solution is the CONTI RipProtect system manufactured by Continental® (https: / / www.continental-industry.com / en / solutions / conveyor-belt-systems / conveyor-services / belt-monitoring / products / conti-protect / conti-ripprotect). Inductive loops are vulcanized into the belt at a specific pitch at the customer's discretion (usually 50-150 running meters), so that if any of the inductive loops is damaged due to a belt break, the conveyor stops. In this case, the amount of damaged belt is limited by the pitch of the inductive loops installed in the conveyor belt, provided that the system is installed in the immediate vicinity of the cut.

[0005] The disadvantages of this type of solution are that such systems cannot be used for any tapes, since a tape with inductive loops is required, and inductive loops often fail, giving false signals.

[0006] There are laser systems known, for example, CONTI SurfaceProtect (https: / / www.continental-industry.com / en / solutions / conveyor-belt-systems / conveyor-services / belt-monitoring / products / conti-protect / conti-surfaceprotect), which use laser scanning of the belt surface for damage, including longitudinal belt tears.

[0007] The main disadvantages of such systems are that they are very sensitive to environmental conditions, positioning and the condition of the belt surface (problems arise when the belt surface is wet or when there is adhesion of the transported material that fills damaged areas), which leads to very strict operating conditions for these systems and a large number of false alarms.

[0008] There are systems known that control the width of the belt 5k-fabric-belt-rip-detector.html) or Belt width monitoring systems determine belt integrity by transverse vibration transmission (http: / / www.beltscan.com / products / belt-guard-10k-rip-detector-for-steel-cord-belts.html). Belt width monitoring systems operate on the principle that a longitudinal cut can cause the belt to separate or, conversely, narrow due to the overlapping of cut parts, changing its width. Ultrasonic or radar sensors are installed to monitor the location of the belt edges to determine belt width. Transverse vibration systems operate on the principle that a longitudinal cut disrupts the belt's integrity and prevents vibration from being transmitted across the belt.

[0009] The main disadvantages of belt width control systems are that if a cut does not result in the belt diverging or narrowing, the cut is not detected because the belt width does not change.

[0010] Systems based on the transmission of vibration across the belt are very sensitive to the type of belt frame and rubber compound and are not applicable to all types of belts. In addition, in the case of a longitudinal cut, the signal can effectively spread around the conveyor belt through the transported material, thereby not recording a longitudinal tear.

[0011] The common drawbacks of the above-mentioned systems are that they are not designed to detect abnormal sources of concentrated resistance to conveyor belt movement. Another drawback of such systems is that they are installed in close proximity to the suspected belt fault. If the fault occurs on the conveyor at a location remote from the system installation, the detection time for such fault increases significantly, leading to further damage, sometimes negating the usefulness of such a system.

[0012] To overcome the above-mentioned shortcomings, a new principle based on belt conveyor tension force analysis is proposed. This principle ensures reliable and accurate detection of the occurrence of an abnormal source of concentrated resistance to conveyor belt movement by recording tension measurements on the belt conveyor tensioner. Furthermore, this principle enables the detection of an abnormal source of concentrated resistance to conveyor belt movement regardless of the conveyor belt length and the location of the belt damage, and, as a result, offers high versatility. SUMMARY OF THE INVENTION

[0013] The claimed solution is aimed at overcoming the technical problem of quickly identifying an abnormal source of concentrated resistance to the movement of a conveyor belt by monitoring the tension force on the belt conveyor tensioner.

[0014] The technical result is an increase in the accuracy and speed of determining the occurrence of an abnormal source of concentrated resistance to the movement of a conveyor belt.

[0015] Another technical result is the ability to record damage to the conveyor belt at any point along the conveyor.

[0016] In a preferred embodiment of the invention, a method is proposed for the automated determination of the occurrence of an abnormal source of concentrated resistance to the movement of a conveyor belt, performed with the help of a computing device associated with at least one device for measuring the magnitude of the tension force on the tension device of the belt conveyor, wherein the method comprises the steps of: a) obtaining measurement data of the magnitude of the tension force on the tension device of the belt conveyor from at least one device for measuring the tension force; b) performing, with the help of the computing device, processing of the measurements obtained in step a), during which they are compared with at least one reference value of the tension force on the tension device of the belt conveyor and / or with at least one reference pattern of the tension force on the tension device of the belt conveyor;c) determining the occurrence of an abnormal source of concentrated resistance to the movement of the conveyor belt in the event that, in step b), a deviation of the measurement data of the tensile force on the tensioning device of the belt conveyor is detected from at least one reference value of the tensile force on the tensioning device of the belt conveyor and / or compliance with at least one reference pattern of the tensile force on the tensioning device of the belt conveyor, indicating the occurrence of an abnormal source of concentrated resistance to the movement of the conveyor belt, and / or deviations from one or more reference patterns of the tensile force on the tensioning device of the belt conveyor, corresponding to the trouble-free operation of the belt conveyor; d) recording in the memory of the computing device the data on the detected abnormal source of concentrated resistance to the movement of the conveyor belt and / or transmitting them to an external device.

[0018] In one particular implementation example, the magnitude of the tensile force is measured by a strain gauge.

[0019] In another particular example of implementation, at step b), the obtained measurements undergo a preliminary averaging or smoothing procedure.

[0020] In another particular example of implementation, at step b), the reference value is set based on a specified or average value of the tension force on the tension device of the belt conveyor, obtained in the time range preceding the moment of measurement, or is calculated based on the obtained values ​​of the tension force preceding the moment of measurement.

[0021] In another particular example of implementation, at step b), the reference value in the form of the average value of the tension force on the tension device of the belt conveyor is set based on a moving average constructed on the basis of averaging functions over N measurements of the tension force on the tension device of the belt conveyor, where N ≥ 1.

[0022] In another particular example of implementation, the window on which the moving average is calculated is shifted back relative to the moment of measurement of the current value of the tension force on the tension device of the belt conveyor by a specified period of time or a specified number of measurements of the tension force on the tension device of the belt conveyor.

[0023] In another particular example of implementation, a deviation from a given reference value is the fact of exceeding or falling below the reference value, or a deviation from the reference value by more than a given amount, or by more than a given percentage of the reference value.

[0024] In another particular example of implementation, at step c) the presence of an abnormal source of resistance to the movement of the conveyor belt is determined if a deviation from the reference value of the tension force on the tension device of the belt conveyor is recorded a specified and / or more number of times during a specified period of time or a specified and / or more number of times in a row.

[0025] In another particular example of implementation, at step b), the processing of the values ​​obtained from the device for measuring the tension force on the tension device of the belt conveyor occurs in a time or frequency representation.

[0026] In another particular example of implementation, at step b), the computing device is configured to recognize reference patterns of occurrence of an abnormal source of concentrated resistance to movement of the conveyor belt and / or deviations from reference patterns of trouble-free operation of the conveyor when analyzing the time and / or frequency representation of the tension force on the tension device of the belt conveyor and / or analyzing the characteristic function (CF) of the tension force on the tension device of the belt conveyor using artificial intelligence (AI) technology.

[0027] In another particular example of implementation, the reference pattern of occurrence of an anomalous source of concentrated resistance to the movement of a conveyor belt has the form of a “step”.

[0028] In another particular example of implementation, in step b), a Fourier transform or Fourier series expansion is used to obtain a frequency representation of the tension force on the belt conveyor tensioner.

[0029] In another particular example of implementation, at step b), for the frequency representation of the tension force on the tension device of the belt conveyor, the amplitude spectrum of the tension force on the tension device of the belt conveyor is analyzed to identify anomalous harmonics and / or sections of the spectrum corresponding to a reference pattern indicating the occurrence of an anomalous source of concentrated resistance to the movement of the conveyor belt or a discrepancy with the reference pattern corresponding to the trouble-free operation of the belt conveyor.

[0030] In another specific example of implementation, data processing is carried out using artificial intelligence (AI) technology.

[0031] In another particular example of implementation, an external device is connected to a computing device via a wired or wireless data transmission channel.

[0032] In another particular example of implementation, the external device is at least one of: a monitor, an interactive screen, a computer, a laptop, a tablet, a smartphone, a smart wearable device, a removable storage medium, a belt conveyor control controller, or a belt conveyor control system.

[0033] In another particular example of implementation, the computing device is connected to the belt conveyor control system in one of the following ways: via relay outputs, via the Modbus protocol, or via Profibus or Profinet networks.

[0034] In another particular example of implementation, at step d), the computing device generates a signal for stopping the belt conveyor, transmitted to the belt conveyor control system, upon determining the occurrence of an abnormal source of concentrated resistance to the movement of the conveyor belt.

[0035] In another particular example of implementation, the GUI is implemented on an external device and / or on a computing device.

[0036] In another particular example of implementation, the computing device is additionally configured with the ability to configure it and / or monitor the result of the analysis of the state of the conveyor belt using an external device.

[0037] In another particular example of implementation, a video stream is additionally generated with an image of the conveyor belt surface, obtained from a video camera.

[0038] In another particular example of implementation, the computing device additionally generates an alarm signal to notify the belt conveyor operator of the occurrence of an abnormal source of concentrated resistance to the movement of the conveyor belt, transmitted to an external device and / or a sound and / or light alert device.

[0039] In another preferred embodiment, a system for automated determination of the occurrence of an abnormal source of concentrated resistance to the movement of a conveyor belt is claimed, comprising a computing device connected to at least one device for measuring the magnitude of the tension force on a tension device of a belt conveyor, in which the computing device is configured to: receive measurement data of the magnitude of the tension force on the tension device of the belt conveyor from at least one device for measuring the tension force; processing the received measurements, during which they are compared with at least one reference value of the tension force on the tension device of the belt conveyor and / or with at least one reference pattern of the tension force on the tension device of the belt conveyor;determining the occurrence of an abnormal source of concentrated resistance to the movement of the conveyor belt in the event that a deviation is detected in the measurement data of the tension force on the tension device of the belt conveyor from at least one reference value of the tension force on the tension device of the belt conveyor and / or compliance with at least one reference pattern of the tension force on the tension device of the belt conveyor, indicating the occurrence of an abnormal source of concentrated resistance to the movement of the conveyor belt and / or a deviation from one or more reference patterns of the tension force on the tension device of the belt conveyor, corresponding to the trouble-free operation of the belt conveyor; recording in memory data about the detected anomalous source of concentrated resistance to the movement of the conveyor belt and / or transmitting them to an external device. BRIEF DESCRIPTION OF DRAWINGS

[0040] Fig. 1 illustrates a general diagram of the implementation of the claimed solution.

[0041] Fig. 2 illustrates a block diagram of the implementation of the claimed method for monitoring the state of a conveyor belt.

[0042] Fig. 3A - 3B illustrate examples of processing signals received from a device for measuring the tension force on a belt conveyor tension device.

[0043] Fig.4A - 4B illustrate an example of signal processing in terms of harmonic analysis.

[0044] Fig. 5 illustrates an example of expansion of a linear function into a Fourier series.

[0045] Fig. 6 illustrates a general view of the computing device. IMPLEMENTATION OF THE INVENTION

[0046] As shown in Fig. 1, the solution consists in creating an automated method for monitoring the condition of a conveyor belt (101) during the transportation of material (105), in particular ore, rocks and other types of material fed onto the belt (101) through a loading hopper (104). The movement of the conveyor belt (101) is carried out by rotating the head (drive) (102) and tail (103) drums, there may be several drive drums, they are driven by electric motors, which in turn are started using a control controller (not shown).

[0047] The main indicators of the conveyor belt condition within the framework of the claimed solution are the parameters of the magnitude of the tension force on the tensioning device (111) (or tensioning device), which ensures the tension of the belt (101) necessary for transmitting the traction force to the said belt (101). The tensioning force indicators are read using one or more tension force measuring devices (106), which are placed on the elements of the belt conveyor, such as the tensioning device (111) and / or its elements, for example, tension ropes or the frame of the tensioning device and / or on the elements connected to the tensioning device, for example, the conveyor frame (110).

[0048] The tensile force measuring device (106) can be, for example, a tension sensor, such as a load cell (tensile force strain gauge), for example, a WIKA F9204 cable tension strain gauge for up to 40 tons, BZA series tension force measuring sensors, CF series belt tension measuring load cells, etc. Accordingly, the tensile force measuring devices (106) are designed to convert the sensor deformation value into an electrical signal. Furthermore, in one particular embodiment, the tensile force measurement can be performed by piezoelectric, fiber optic sensors, etc.

[0049] The tension force data on the tensioning device (111), recorded by the device (106), are transmitted via a data transmission channel to the computing device (107) for subsequent processing. The computing device (107) may be, for example, a computer, a computing unit, a single-board computer, a system on a chip (SoC), etc.

[0050] A wired and / or wireless connection may be used as a data transmission channel, for example, a connection via a physical connection (USB, LAN, RS-232, etc.), or via a wireless connection (Bluetooth, BLE, WLAN, etc.). The computing device (107) may be implemented in a single housing with the tension force measuring device (106). Furthermore, the tensioning device (111) may contain several independent tension force measuring devices (106).

[0051] The computing device (107) is connected to an external device (108), which is typically a computer, server, or control panel, which stores data on the state of the conveyor belt and subsequently transmits information on the state of the belt to end users (109), such as a conveyor operator or maintenance personnel. In one embodiment, the external device (108) may be a belt conveyor control controller or a remote belt conveyor control system,

[0052] An external device (108) is connected to the computing device (107) via a wired or wireless data transmission channel similar to those previously indicated. The external device (108) may be, for example, a monitor, interactive screen, computer, laptop, tablet, smartphone, smart wearable device, removable storage medium, belt conveyor control controller, or a remote belt conveyor control system.

[0053] In the case of connecting the computing device (107) to the belt conveyor control system, in the event of recognition of an abnormal source concentrated resistance to the movement of the conveyor belt (101), for example, when a belt (101) breaks due to a jamming of a piece of ore or material clogging the ore (an excavator tooth, a steel lining of a dump truck body, reinforcement, a pipe, scrap, etc.) or clogging (blocking) of the loading chute of the conveyor or as a result of contact of the belt (101) with stationary elements of the conveyor, etc., the computing device (107) generates an alarm signal to notify the operator (109) of the belt conveyor about the presence of an abnormal source of concentrated resistance to the movement of the conveyor belt (101), transmitted to an external device (108) and / or a sound and / or light notification device (alarm system). Also, this signal can forcibly stop the conveyor to prevent damage to the conveyor belt (101) and / or promptly repair the damaged section of the belt (101) and prevent the spread of further damage to the belt (101).

[0054] The external device (108) and the computing device (107) may contain a graphical user interface (GUI) for displaying the results of measuring the belt tension force, indicating the detection of an abnormal source of concentrated resistance to the movement of the conveyor belt (101), or displaying various types of information and for configuring the system.

[0055] The computing device (107) is additionally configured with the possibility of configuring it and / or tracking the result of the analysis of the state of the conveyor belt (101) using an external device (108).

[0056] Additionally, one or more cameras can be installed on the conveyor, forming a video stream with an image of the surface of the conveyor belt (101), received from the video camera.

[0057] Fig. 2 presents a description of the implementation of a method (200) for the automated determination of the occurrence of an anomalous source of concentrated resistance to the movement of a conveyor belt (101) within the framework of the implementation of the claimed solution. At step (201), the computing device (107) receives measurement data of the tension force on the tensioning device (111) from the measuring device (106).

[0058] The tensioning device (111) may be a tension carriage, a tension drum, a hydraulic and / or pneumatic tensioning system, a trolley-truck tensioning device, a winch or screw tensioning device, etc. The tensioning device (111) is designed to provide tension to the belt (101) to ensure its operation without slipping. Depending on the length Depending on the conveyor's performance, belt speed, load type, height difference between the conveyor's loading and unloading points, the location and design of the drive stations, the availability of space, and other conveyor characteristics, the most suitable tensioning devices (111) can be installed. However, it's worth noting that the operating principle of these devices is the same and relies on tensioning one of the conveyor's drums.

[0059] A distinctive feature of the claimed method (200) is the ability to detect conveyor belt damage, such as a longitudinal cut (tear) caused by the jamming (jamming) of ore-contaminating objects or large ore pieces, and, as a result, the occurrence of an abnormal source of resistance to conveyor belt movement (101), the presence of which determines belt damage. It is worth noting that, in the claimed technical solution, the term "conveyor belt damage" should be understood as conveyor belt deformation, which leads to a disruption of its structure and / or functionality. Thus, conveyor belt damage may include: abrasion, fraying, cut, tear, sidewall destruction, etc.Furthermore, by measuring tension at the belt conveyor's tensioning device (111), the accuracy and consistency of tension force measurements are improved compared to sensors embedded in the belt. This reduces the influence of tension force and belt sag on the measured values, and eliminates errors associated with transporting large-piece materials, which create localized stresses in the conveyor belt, leading to noise and measurement errors. Also, sensors embedded in the conveyor belt do not provide continuous tension telemetry, as they only provide tension readings as the belt passes through the scanner's reading area, and the next measurement is possible only after the embedded sensor passes through the scanner again.In addition, the said solution provides the ability to measure the tension force of the conveyor belt (101) without the need to modify and / or retrofit the conveyor belt with certain equipment (use of built-in measuring sensors in the belt web, installation of external scanners for sensors, image capture sensors, etc.).

[0060] The device (106) can be mounted directly on the tensioning device (111) or on its components, such as the carriage, the frame, the tension drum, or the tension ropes. The parameters received by the device (106) include the tension force, for example, using a strain gauge.

[0061] To obtain more accurate and efficient measurements of the magnitude of the tension force on the tension device (111) of the belt conveyor, it is necessary that the tension on the tension device be an uncontrolled variable, and the position of the tension device, on the contrary, be controlled, i.e. be fixed.

[0062] Next, at step (202), the obtained data are processed using the software logic of the computing device (107), during which the obtained values ​​of the indicators of the magnitude of the tension force on the tension device (111) are compared with one or more established reference values ​​of the parameters of the tension force on the tension device of the belt conveyor (111), on the basis of which the presence of an anomaly in the operation of the conveyor (100) is determined, which indicates the occurrence of an anomalous source of concentrated resistance to the movement of the conveyor belt (101).

[0063] The data received from the device (106) can also be analyzed in terms of the compliance of the operating pattern of a given tensioning device (111) with a reference pattern, which will indicate the occurrence of an anomalous source causing increased resistance to the movement of the conveyor belt (101). For example, a drop in the belt tensioning force in the form of a "step" (a sharp drop in the tensioning force on the tensioning device) may indicate the occurrence of a source causing resistance to the movement of the conveyor belt. Also, the reference pattern of the load (tension) on the tensioning device (111) of the conveyor can represent an operating pattern corresponding to the trouble-free operation of the conveyor (100), which indicates the normal condition of the conveyor belt (101). This makes it possible to identify deviations (discrepancies) with this kind of pattern, which also indicates the occurrence of an anomalous source of concentrated resistance to the movement of the conveyor belt (101).Furthermore, in another particular embodiment, an operating pattern corresponding to trouble-free operation of the conveyor may be formed taking into account the type and / or size and / or other parameters of the material transported by the conveyor. For example, an operating pattern corresponding to trouble-free operation of the conveyor may include an operating pattern corresponding to trouble-free operation of the conveyor when transporting large-sized materials. Said pattern may also be created taking into account the length and / or throughput of the conveyor.

[0064] The reference value is set based on at least one of: the nominal value of the tension force on the tensioning device (111), the average value tension force on the tension device (111), extreme tension values, or one or more previous load (tension) values ​​on the tension device (111) of the belt conveyor, obtained in the time range preceding the moment of measurement. The data and patterns obtained in the time period are typically collected during normal operation of the conveyor (100) in the absence of belt damage. Data and patterns can also be collected upon the occurrence of abnormal sources of resistance to the movement of the conveyor belt (101) and recording readings during emergency operation of the conveyor. This makes it possible to determine the type of data and patterns indicating the occurrence of abnormal sources of concentrated resistance causing resistance to the movement of the belt (101) when it is damaged.

[0065] At step (203), based on the results of comparing the tension force on the tension device (111) of the conveyor (100) with the reference value and / or reference pattern, the computing device (107) makes a decision on the presence or absence of an anomalous source of concentrated resistance to the movement of the conveyor belt (101). If an anomalous source of resistance to the movement of the conveyor belt (101) is detected, then at step (204) the detected anomalous source is recorded in the memory of the computing device (107). Furthermore, in yet another particular embodiment, this information can also be transmitted at step (205) to an external device (108) for storage and / or subsequent use.

[0066] In Fig. 3A-3B an example of the analysis of the tension force on the tensioning device (111) is shown in terms of their comparison with the reference value (30) and / or, for example, the reference pattern (304) of the tensioning force readings on the tensioning device, indicating the presence of an abnormal source of resistance to the movement of the conveyor belt (101) or, conversely, is compared with the reference pattern corresponding to the trouble-free operation (301) of the conveyor (100). Also, a characteristic pattern of a drop in tension (for example, of the "step" type (308)) can be considered as a reference pattern when an abnormal source of resistance to the movement of the conveyor belt occurs, for example, when a longitudinal tear of the conveyor belt occurs, creating a drop (302).The received signal (300) from the device (106), characterizing the tension force on the tensioning device (111), is analyzed for its deviation from the established reference value (30), in particular, when a drop (302) occurs below the reference value (30). the fact of an anomalous source of concentrated resistance to the movement of the conveyor belt is recorded (101).

[0067] The fact of recording a drop (302) in the load (tension force) on the tensioning device (111) indicates the occurrence of damage to the belt (101). The effect of a load drop on the tensioning device (111) of a belt conveyor and the subsequent drop below the reference value of the load is caused by the fact that when an abnormal source of resistance to the movement of the belt (101) occurs, for example in the case of a jamming of a piece of ore or material clogging the ore, such as an excavator tooth, a steel lining of a dump truck body, reinforcement, a pipe, scrap, etc., or a jamming (clogging) of the conveyor loading chute or as a result of contact of the belt with stationary elements of the conveyor, such an abnormal source impedes the movement of the belt (101), thereby creating a concentrated resistance to the movement of the belt (101).Thus, for example, ore-contaminating material or a large-sized sharp-pointed piece of ore can pierce the belt during transportation and, accordingly, will slow down the movement of the belt at the place where the cut occurs, contacting with the elements of the conveyor, thereby creating additional stretching of the belt on the conveyor and the occurrence of slack on the tensioning device, provided that the tensioning device has a fixed position (the position is a controlled parameter), which leads to a drop in tension on the tensioning device and the occurrence of a sharp “stepwise” drop in the level of tension on the tensioning device (111), which is detected by the device (106).

[0068] The pattern of the emerging tension (load) (303) on the tensioning device (111) is compared with the reference pattern (304) of the load, which indicates that there is an abnormal source in the belt that causes resistance to the movement of the conveyor belt (101).

[0069] In case of a cut of the belt (101), its movement proceeds in characteristic jerks, which is associated with the uneven destruction of the belt web upon contact with the cutting object (foreign ore-contaminating material, a large piece of ore, a stationary element of the conveyor, etc.). The pattern of such movement will correspond to the reference pattern of the load (304) on the tensioning device (111), for example, characterized by the periodicity of the occurrence of a short-term increase / drop in the tension force, or, conversely, it may differ from the reference pattern of the load or the parameters of the load on the tensioning device corresponding to the trouble-free operation (301) of the conveyor (100), which indicates the appearance of an abnormal source of concentrated resistance to the movement of the belt (101). Also, the pattern of the fall loads (for example, of the “step” type) when a rupture occurs, differs from the reference pattern corresponding to the trouble-free operation (301) of the conveyor (100) and also indicates the occurrence of an abnormal source of concentrated resistance to the movement of the belt (101).

[0070] The reference value (30) may be static or dynamic, since it may be selected based on either a given value of the tension force on the tensioning device (111), for example, a reference value that functions as a threshold level (30) in Fig. 3A, or based on an average value of the tension force indicators on the tensioning device for a certain period of time before the moment of comparison, for example, a moving average (30) in Fig. 3B. The tension force on the tensioning device (111) may depend on the length of the conveyor, the mass and load flow of the transported material, as well as the operating mode of the conveyor.

[0071] A drop below the reference value (30) is either the actual drop below the reference value, or a drop in the tension force readings on the tensioning device (111) below the reference value by a specified amount (e.g., 1, 5, 10, or more kN), or by more than a specified percentage of the reference value (e.g., 5-10%). The reference value in the form of an average value of the tension force on the tensioning device (111) can be specified based on a moving average (30), as shown in Fig. 3B, constructed based on averaging functions over N measurements of the tension force on the tensioning device, where N ≥ 1. In this case, the window over which the moving average is calculated can be shifted back relative to the moment of measurement of the current tension force value on the tensioning device by a specified period of time or a specified number of measurements of the tension force on the tensioning device.

[0072] Additionally, the presence of an abnormal source of concentrated resistance to the movement of the belt (101) can be recorded if a drop in the tension force on the tension device (111) below the reference value (30) is recorded a specified and / or more number of times during a specified period of time (for example, 100 milliseconds, 1 second, etc.) or a specified and / or more number of times in a row.

[0073] The data received from the measuring device (106) can be processed for presentation in time or frequency domain. The computing device (107) uses a built-in algorithm to recognize characteristic patterns of tension force on the tensioning device (111) in the presence of an anomalous source of concentrated resistance to conveyor belt movement. (101) during the analysis of the data received from the device (106), presented in the time and / or frequency representation. The frequency representation of the tensile force data on the tensioning device (111) can be obtained by performing a Fourier transform or a Fourier series expansion of the time representation of the tension parameters on the tensioning device (111), received from the load measuring device (106). The Fourier transform or the Fourier series expansion of the time representation of the tension parameters on the tensioning device (111) is performed on a time interval or window that moves forward in time (windows 305, 306, 307) of Fig. 4A.

[0074] For frequency representation of tension readings on the tensioning device (111), an analysis of the amplitude spectrum of tension on the tensioning device (111) can be performed to identify anomalous harmonics and / or sections of the spectrum corresponding to a reference pattern indicating the presence of an anomalous source, or a comparison with a reference pattern reflecting normal trouble-free operation of the conveyor (100), in the absence of anomalous sources of concentrated resistance to the movement of the conveyor belt.

[0075] The computing device (107) is configured to recognize characteristic patterns of occurrence of an anomalous source of concentrated resistance to movement of the conveyor belt (101) when analyzing the time and / or frequency representation of the tension force on the tension device (111) and / or analyzing the characteristic function (CF) of the tension on the tension device (111) using artificial intelligence (AI) technology, including analytical methods, artificial neural networks, etc.

[0076] For the frequency representation of the tension on the tensioning device (111), the amplitude spectrum of the tension on the tensioning device (111) is analyzed to identify anomalous harmonics and / or spectrum sections corresponding to a reference pattern indicating the presence of an anomalous source of concentrated resistance to the movement of the conveyor belt (101). Anomalous harmonics of the tension on the tensioning device (111) during the movement of the conveyor belt (101) in the frequency representation can be determined based on the peak and / or average values ​​of the spectrum and / or the shape of the spectrum of the tension on the tensioning device (111) in the trouble-free operation mode of the conveyor.

[0077] A conditional simplified example of identifying anomalous harmonics and sections in the amplitude spectrum of tension on a tensioning device during a rupture is shown in Fig. 4A - Fig. 4B, where a drop (“step”) and subsequent oscillation of the load are simplified shown by a piecewise broken line (the horizontal line (311) is the trouble-free operation of the conveyor (100), the descending line (312) is the load drop at the moment of occurrence of the anomalous source of concentrated resistance to movement, and the sawtooth line (313) is the continuing effect on the tension value of the anomalous source of concentrated resistance to the conveyor belt movement). The horizontal line (311) displays a conditionally constant tension force on the tensioner (111) before the belt damage (stable tension force), its expansion on the time window (305) in a Fourier series does not yield any harmonics (the amplitude spectrum is zero - this is an extremely exaggerated case, only as an example). Whereas, if we perform a Fourier series expansion on the time window (306), where the tension drop (312) occurs, a whole set of harmonics will appear.

[0078] As an example, we can expand the linear function y(x)= -х into a Fourier series of sines, for example, in the section [-3;3] with an expansion order of 25 (the first 25 harmonics), Fig. 5. Analytically, the expansion can be written using formula (1): where you can see a set of harmonic components. And the amplitude spectrum of frequencies is determined by the following set of amplitudes b n , decreasing inversely proportional to the ordinal number of the harmonic n according to formula (2): The first 7 (seven) terms of the expansion look like this:

[0079] Similarly, as shown in Fig. 4A, a conventional sawtooth tension force (313) on the tensioning device (111) arising as a result of jerks during the breaking of the belt web due to the jamming of cutting elements in the conveyor belt, for example, foreign ore-contaminating material or a piece of ore, which are an abnormal source of concentrated resistance to movement belt, in the frequency representation when decomposed in the time window (307) has its own harmonics and spectrum sections that differ in frequency and / or amplitude from the harmonics and spectrum of the trouble-free operation of the conveyor belt (in the example in Fig. 4B, in the trouble-free operation mode, the amplitude spectrum is zero), such harmonics and spectrum sections are also considered anomalous and their detection indicates the presence of an anomalous source of resistance to the movement of the conveyor belt. Thus, if, for example, a spectral analysis of the tension force on the tensioning device (111) is periodically carried out in a given time window, constantly shifting it forward in time (windows 305, 306, 307), then it is possible to detect anomalous harmonics and / or spectrum sections that indicate the presence of an anomalous source of concentrated resistance to the movement of the belt (101), for example, a stuck piece of ore or foreign material causing a cut in the belt.

[0080] The processing of the data received from the tension force measuring device (106) by the computing device (107) can be performed using artificial intelligence (AI) technology, including analytical methods or artificial neural networks.

[0081] Additionally, the computing device (107) may be connected to the belt conveyor control system in one of the following ways: via relay outputs, via the Modbus protocol, or via Profibus or Profinet networks. With this connection principle, the computing device (107) generates a signal to stop the belt conveyor, transmitted to the belt conveyor control system, upon determining the presence of an abnormal source of concentrated resistance to the movement of the conveyor belt (101) based on the processing of data from the tension force measuring device on the belt conveyor tensioner (111).

[0082] Fig. 6 shows a general example of a computing device (400), for example, a computing unit (computing module), a computer, a server, a laptop, a smartphone, a SoC (System-on-a-Chip), etc., which can be used for the full or partial implementation of the claimed solution, in particular, for the implementation of devices (107, 108). In the general case, the device (400) contains such components as: one or more processors (401), at least one random access memory (402), a persistent data storage means (403), input / output interfaces (404) including relay outputs for connection to belt conveyor motion control controllers, an I / O means (405), and network interaction means (406).

[0083] The processor (401) of the device performs the basic computing operations necessary for the operation of the device (400) or the functionality of one or more of its components. The processor (401) executes the necessary machine-readable instructions contained in the RAM (402).

[0084] Memory (402) is typically implemented as RAM and contains the necessary software logic to provide the required functionality. Data storage (403) can be implemented as HDD, SSD, RAID array, network storage, flash memory, optical storage (CD, DVD, MD, Blue-Ray discs), etc. Data storage (403) enables long-term storage of various types of information, such as request processing history (logs), user identifiers, camera data, images, etc.

[0085] Interfaces (404) are standard means for connecting and working with computing devices. Interfaces (404) may represent, for example, relay connections, USB, RS232 / 422 / 485 or others, RJ45, LPT, UART, COM, HDMI, PS / 2, Lightning, FireWire, etc. for work, including, via Modbus protocols and Probfibus networks. The choice of interfaces (404) depends on the specific design of the device (400), which can be a computing unit (computing module), for example, based on a CPU (one or more processors), a microcontroller, etc., a personal computer, a mainframe, a server cluster, a thin client, a smartphone, a laptop, etc., as well as connected third-party devices.

[0086] The following can be used as I / O data means (405): keyboard, joystick, display (touch display), projector, touchpad, mouse, trackball, light pen, speakers, microphone, etc.

[0087] The network interaction means (406) are selected from a device that provides network reception and transmission of data, for example, an Ethernet card, a WLAN / Wi-Fi module, a Bluetooth module, a BLE module, an NFC module, an IrDa module, an RFID module, a GSM modem, etc. With the help of the means (406), the organization of data exchange is ensured via a wired or wireless data transmission channel, for example, a WAN, PAN, LAN, Intranet, Internet, WLAN, WMAN or GSM, a quantum data transmission channel, satellite communications, etc. The components of the device (400), as a rule, are connected via a common data transmission bus.

[0088] In these application materials, a preferred disclosure of the implementation of the claimed technical solution has been presented, which should not be used as limiting other, particular embodiments of its implementation, which do not go beyond the scope of the requested scope of legal protection and are obvious to specialists in the relevant field of technology.

Claims

FORMULA 1. A method for the automated determination of the occurrence of an abnormal source of concentrated resistance to the movement of a conveyor belt, carried out using a computing device connected to at least one device for measuring the magnitude of the tension force on a tension device of a belt conveyor, wherein the method comprises the steps of: a) obtaining measurement data of the magnitude of the tension force on the tension device of the belt conveyor from at least one device for measuring the tension force; b) performing, using the computing device, processing of the measurements obtained in step a), during which they are compared with at least one reference value of the tension force on the tension device of the belt conveyor and / or with at least one reference pattern of the tension force on the tension device of the belt conveyor;c) determining the occurrence of an abnormal source of concentrated resistance to the movement of the conveyor belt if, in step b), a deviation is detected in the measurement data of the magnitude of the tension force on the tension device of the belt conveyor from at least one reference value of the tension force on the tension device of the belt conveyor and / or compliance with at least one reference pattern of the tension force on the tension device of the belt conveyor, indicating the occurrence of an abnormal source of concentrated resistance to the movement of the conveyor belt, and / or deviations from one or more reference patterns of the tension force on the tension device of the belt conveyor, corresponding to the trouble-free operation of the belt conveyor;d) recording in the memory of the computing device the data on the detected anomalous source of concentrated resistance to the movement of the conveyor belt and / or transmitting them to an external device.

2. The method according to claim 1 is characterized in that the magnitude of the tension force is measured by a strain gauge.

3. The method according to claim 1, characterized in that at step b) the obtained measurements undergo a preliminary averaging or smoothing procedure.

4. The method according to claim 1, characterized in that in step b) the reference value is set based on a specified or average value of the tension force on the tension device of the belt conveyor, obtained in the time range preceding the moment of measurement or is calculated based on the obtained values ​​of the tension force preceding the moment of measurement.

5. The method according to claim 4, characterized in that in step b) the reference value in the form of an average value of the tension force on the tension device of the belt conveyor is set based on a moving average constructed on the basis of averaging functions over N measurements of the tension force on the tension device of the belt conveyor, where N ≥ 1.

6. The method according to claim5, characterized in that the window in which the moving average is calculated is shifted back relative to the moment of measuring the current value of the tension force on the tension device of the belt conveyor by a given period of time or a given number of measurements of the tension force on the tension device of the belt conveyor.

7. The method according to claim 1, characterized in that the deviation from the given reference value is the fact of exceeding or falling below the reference value or a deviation from the reference value by more than a given amount, or by more than a given percentage of the reference value.

8. The method according to claim1, characterized in that at step c) the presence of an abnormal source of concentrated resistance to the movement of the conveyor belt is determined if the deviation from the reference value of the tension force on the tension device of the belt conveyor is recorded a specified and / or more number of times during a specified period of time or a specified and / or more number of times in a row.

9. The method according to claim 1, characterized in that at step b) the processing of the values ​​obtained from the device for measuring the tension force on the tension device of the belt conveyor occurs in a time or frequency representation.

10. The method according to claim9, characterized in that at step b) the computing device is configured to recognize reference patterns of occurrence of an anomalous source of concentrated resistance to movement of the conveyor belt and / or deviations from reference patterns of trouble-free operation of the conveyor when analyzing the time and / or frequency representation of the tension force on the tension device of the belt conveyor and / or analyzing the characteristic. functions (XФ) of the tension force on the tension device of the belt conveyor using artificial intelligence (AI) technology.

11. The method according to claim 1, characterized in that the reference pattern of the occurrence of an anomalous source of concentrated resistance to the movement of the conveyor belt has the form of a "step".

12. The method according to claim 9, characterized in that in step b) to obtain a frequency representation of the tension force on the tension device of the belt conveyor, the Fourier transform or Fourier series expansion is used.

13. The method according to claim9, characterized in that at step b) for the frequency representation of the tension force on the tension device of the belt conveyor, the amplitude spectrum of the tension force on the tension device of the belt conveyor is analyzed to identify anomalous harmonics and / or spectrum sections corresponding to a reference pattern indicating the occurrence of an anomalous source of concentrated resistance to the movement of the conveyor belt or a discrepancy with the reference pattern corresponding to the trouble-free operation of the belt conveyor.

14. The method according to claim 9, characterized in that the data processing is carried out using artificial intelligence (AI) technology.

15. The method according to claim 1, characterized in that the external device is connected to the computing device via a wired or wireless data transmission channel.

16. The method according to claim1, characterized in that the external device is at least one of: a monitor, an interactive screen, a computer, a laptop, a tablet, a smartphone, a smart wearable device, a removable storage medium, a belt conveyor control controller, or a belt conveyor control system.

17. The method according to claim 16, characterized in that the computing device is connected to the belt conveyor control system in one of the following ways: via relay outputs, via the Modbus protocol or Profibus or Profinet networks.

18. The method according to claim 16, characterized in that at step d), the computing device generates a signal for stopping the belt conveyor, transmitted to the belt conveyor control system, upon determining the occurrence of an abnormal source of concentrated resistance to the movement of the conveyor belt.

19. The method according to claim 1, characterized in that the GUI is implemented on an external device and / or on a computing device.

20. The method according to claim 1, characterized in that the computing device is additionally configured with the possibility of its configuration and / or tracking the result of the analysis of the state of the conveyor belt, using an external device.

21. The method according to claim 1, characterized in that a video stream with an image of the surface of the conveyor belt, received from a video camera, is additionally generated.

22. The method according to claim 1, characterized in that the computing device additionally generates an alarm signal to notify the operator of the belt conveyor about the occurrence of an abnormal source of concentrated resistance to the movement of the conveyor belt, transmitted to an external device and / or a sound and / or light notification device.

23. A system for automated determination of the occurrence of an abnormal source of concentrated resistance to the movement of a conveyor belt, containing a computing device,connected to at least one device for measuring the magnitude of the tension force on the tension device of the belt conveyor, in which the computing device is configured to: receive measurement data of the magnitude of the tension force on the tension device of the belt conveyor from at least one device for measuring the tension force; process the received measurements, during which they are compared with at least one reference value of the tension force on the tension device of the belt conveyor and / or with at least one reference pattern of the tension force on the tension device of the belt conveyor; determine the occurrence of an abnormal source of concentrated resistance to the movement of the conveyor belt in the event,if a deviation is detected in the measurement data of the tension force on the tension device of the belt conveyor from at least one reference value of the tension force on the tension device of the belt conveyor and / or compliance with at least one reference pattern of the tension force on the tension device of the belt conveyor, indicating the occurrence of an abnormal source of concentrated resistance to the movement of the conveyor belt and / or a deviation from one or more reference patterns of the tension force on the tension device of the belt conveyor, corresponding to the trouble-free operation of the belt conveyor;, recording in memory the data about the identified anomalous source of concentrated resistance to the movement of the conveyor belt and / or transmitting it to an external device.

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