AU2021277427B2 - Belt state monitoring apparatus and method for self-powered belt conveyor - Google Patents
Belt state monitoring apparatus and method for self-powered belt conveyor Download PDFInfo
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M13/00—Testing of machine parts
- G01M13/02—Gearings; Transmission mechanisms
- G01M13/023—Power-transmitting endless elements, e.g. belts or chains
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N3/30—Investigating strength properties of solid materials by application of mechanical stress by applying a single impulsive force, e.g. by falling weight
- G01N3/303—Investigating strength properties of solid materials by application of mechanical stress by applying a single impulsive force, e.g. by falling weight generated only by free-falling weight
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- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N2203/0001—Type of application of the stress
- G01N2203/001—Impulsive
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N2203/02—Details not specific for a particular testing method
- G01N2203/06—Indicating or recording means; Sensing means
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Abstract
A belt state monitoring apparatus and method for a self-powered belt conveyor, comprising: an impact power generation sensor (2) mounted on a cushioning support roller (1), and a rotation power generation sensor (4) and a weighing sensor (5) which are mounted on a conventional support roller (3); the impact power generation sensor (2), the rotation power generation sensor (4), the weighing sensor (5), a signal acquiring and processing unit, a central processing unit, a database, and an interaction unit are electrically connected; the impact power generation sensor (2) and the rotation power generation sensor (4) are electrically connected to a confluence power supply unit. An apparatus capable of generating information and generating power is formed by using a blanking impact and rotation of belt support rollers, and achieves two functions of belt surface state detection and material flowrate measurement. Under a belt load condition, a material flow volume is measured in real time, real-time acquisition of material flow information is achieved, and under a belt no-load condition, a belt surface video is acquired in real time for monitoring.
Description
CROSS-REFERENCE TO RELATED APPLICATION The disclosure claims a priority to and benefits of Chinese Patent Application No. 202010434648.5 filed to China National Intellectual Property Administration on May 21, 2020, the entire content of which is incorporated herein by reference.
TECHNICAL FIELD The disclosure relates to an apparatus for monitoring a belt state of a self-powered belt conveyor. The apparatus is an online detection device, which is a safety detection device configured for testing belt quality of the belt conveyor to ensure production safety.
BACKGROUND A belt conveyor is one of key devices for conveying coal under-pit. Not only a state of a belt surface (such as bulge, tearing, breakage) relates to safe and reliable operation of the belt, but also a change of coal flow on belt surface directly affects energy consumption of the belt conveyor. Methods for detecting the state of the belt surface in existing arts generally employ no-load and loading separated detection, that is, separately detecting the state of the belt surface under no-load when the belt conveyor is shutdown, and separately detecting the change of the coal flow under a loading state, which requires to be installed two sets of systems to complete, and independently supply power for each system. Therefore, it is inconvenient for installation and usage, and field effect of an application scene is poor.
SUMMARY In order to solve the problem existing in the related art, the disclosure provides an apparatus for monitoring a belt state of a self-powered belt conveyor. With mounting a power generation sensor on the belt conveyor, the apparatus and the method may not only perceive a motion state of a belt and monitor belt quality in real time, but also generate power for the apparatus itself to use and improve safety of the belt conveyor. In an aspect the disclosure is implemented by: an apparatus for monitoring a belt state of a self-powered belt conveyor, including: impact power generation sensors respectively provided on a plurality of impact idlers at a receiving section of a belt conveyor, each of at least two conventional idlers of the belt conveyor being provided with a rotary power generation sensor and a weighing sensor; each impact power generation sensor, each rotary power generation sensor and each weighing sensor being electrically connected to a signal acquiring and processing unit, the signal acquiring and processing unit being electrically connected to a central processing unit, and the central processing unit being electrically connected to a database; and the impact power generation sensors and the rotary power generation sensors being electrically connected to a confluence power supply unit; the apparatus is configured to perform: a no-load monitoring process: acquiring, by a binocular video sensor, a video image of a belt surface video image in real time under a condition of a belt being no-load, comparing a presently acquired video image of the belt surface with a previously acquired video image of the belt surface to determine whether surface breakage, tearing or bulge occurs on the belt surface, and in response to the surface breakage, tearing or bulge occurring on the belt surface, alarming and shutting down for maintenance; a monitoring process during normal operation, comprising: at block 1, collecting impact information: in a case that materials fall down from an upper conveyor and impact the plurality of impact idlers, logging, by the impact power generation sensors, strength and frequencies of impacts on the belt; at block 2, collecting load-bearing information: in a case that the materials move along with the belt, monitoring, by the rotary power generation sensors at different intervals, load-bearing and motion statuses of the belt and loads of corresponding idlers; at block 3, storing the strength of the impacts and frequency densities respectively: after a signal acquiring and processing unit collects the strength of the impacts, classifying the strength of the impacts into a plurality of strength classes and then storing the strength of the impacts respectively based the plurality of strength classes, and analyzing the frequency densities based on the received frequencies of the impacts, and respectively storing the frequency densities at different classifications; at block 4, analyzing and comparing: receiving, by the central processing unit, the strength and frequencies of the impacts of the belt and the load-bearing of the belt, and analyzing stretching of the belt, and storing an analysis result and synchronizing data, and comparing present data with previous data to determine a quality condition of the belt; and at block 5, uploading and displaying: uploading the analysis result to a conveying chain upper computer or an under-pit equipment monitoring center in a wireless communication manner, and displaying the analysis result on a monitoring terminal in a form of a table or a coordinate graph; a power generation process: conveying electric energy generated by the rotary power generation sensors during a no-load monitoring process to a confluence power supply unit, collecting and rectifying, by the confluence power supply unit, the acquired electric energy, and converting the electric energy into a stabilized power supply for supplying to each unit, and storing excess electric energy in a storage battery; and conveying electric energy generated by the impact power generation sensors and the rotary power generation sensors during the monitoring process of the normal operation to the confluence power supply unit, collecting and rectifying, by the confluence power supply unit, the collected electric energy into the stabilized power supply for supplying to each unit, and storing the excess electric energy in the storage battery. Further, the signal acquiring and processing unit is further electrically connected to a binocular video sensor and a lidar sensor. Further, each impact power generation sensor includes: a stator fixedly provided on a frame of the belt conveyor and a rotor capable of moving up and down with the impact idler. Further, the stator is an electromagnetic coil winding, and the rotor is a permanent magnet. Further, the impact power generation sensor is a piezoelectric patch. Further, the rotary power generation sensor is a generator. Further, the confluence power supply unit is provided with a storage battery. A method for monitoring a belt state of a self-powered belt conveyor based on the above monitoring apparatus includes: a no-load monitoring process: acquiring, by a binocular video sensor, a video image of a belt surface video image in real time under a condition of a belt being no-load motion, comparing a presently acquired video image of the belt surface with a previously acquired video image of the belt surface to determine whether surface breakage, tearing or bulge occurs on the belt surface, and in response to the surface breakage, tearing or bulge occurring on the belt surface, alarming and shutting down for maintenance; a monitoring process during normal operation, including: at block 1, collecting impact information: in a case that materials fall down from an upper conveyor and impact the plurality of impact idlers, logging, by impact power generation sensors, strength and frequencies of impacts on the belt; at block 2, collecting load-bearing information: in a case that the materials move along with the belt, monitoring, by rotary power generation sensors at different intervals, load-bearing and motion statuses of the belt and loads of corresponding idlers; at block 3, storing the strength of the impacts and frequency densities respectively: after a signal acquiring and processing unit collects the strength of the impacts, classifying the strength of the impacts into a plurality of strength classes and then storing the strength of the impacts respectively based on the plurality of strength classes, and analyzing the frequency densities based on the received frequencies of the impacts, and respectively storing the frequency densities at different classifications; at block 4, analyzing and comparing: receiving, by a central processing unit, the strength and frequencies of the impacts of the belt and the load-bearing of the belt, and analyzing stretching of the belt, and storing an analysis result and synchronizing data, and comparing present data with previous data to determine a quality condition of the belt; at block 5, uploading and displaying: uploading the analysis result to a conveying chain upper computer or an under-pit equipment monitoring center in a wireless communication manner, and displaying the analysis result on a monitoring terminal in a form of a table or a coordinate graph; a power generation process: conveying electric energy generated by the rotary power generation sensors during the no-load monitoring process to a confluence power supply unit, collecting and rectifying, by the confluence power supply unit, the collected electric energy, and converting the electric energy into a stabilized power supply for supplying to each unit, and storing excess electric energy in a storage battery; conveying electric energy generated by the impact power generation sensors and the rotary power generation sensors during the monitoring process of the normal operation to the confluence power supply unit, collecting and rectifying, by the confluence power supply unit, the collected electric energy into the stabilized power supply for supplying to each unit, and storing the excess electric energy in the storage battery. Further, the blocks 1 to 2 further include: starting a binocular video sensor to detect the volume of the materials flow in real time, and starting a lidar sensor to monitor the velocity of the materials flow. The block 3 further includes: converting the volume of the materials flow and the velocity of the materials flow in combination with a density of a materials stack into information of materials flow quantity, analyzing the information of the materials flow quantity, classifying a size and a weight of the materials flow and then respectively storing. The block 4 further includes: analyzing a quality state of the belt in combination the strength and frequencies of the impacts with the load-bearing of the belt and the information of the materials flow quantity. The disclosure provides a set of apparatuses that may generate information and electric energy through the impacts of the falling down materials and rotation of the idlers of the belt. Therefore, two functions of detecting the state of the belt surface and the materials flow quantity are completed. Under a condition of the belt being loaded, the volume of the materials flow detected in real time, in combination with the velocity of the belt and the density of the materials stack is converted into the materials flow quantity to acquire the information of the materials flow quantity in real time, and under the condition of the belt being no-load, the belt surface video is acquired in real time, and in response to the surface breakage, tearing or bulge occurring on the belt surface, it may alarm and shut down for maintenance. The apparatus is powered through electric energy generated by sensors without an external power supply, which saves energy and makes installation and usage more flexible and convenient.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic diagram of a structure of an apparatus being provided on a belt conveyor in Embodiment One and Embodiment Two. FIG. 2 is a system block diagram of an apparatus in Embodiment One. FIG. 3 is a system block diagram of an apparatus in Embodiment Two.
DETAILED DESCRIPTION Embodiment One: This embodiment is an apparatus for monitoring a belt state of a self-powered belt conveyor. As illustrated in FIGS. 1 and 2, FIG. 1 is a schematic diagram of the monitoring apparatus being provided on a belt conveyor, and FIG. 2 is a block diagram of structure principle. This embodiment includes: impact power generation sensors 2 respectively provided on a plurality of impact idlers 1 at a receiving section of a belt conveyor. Each of at least two conventional idlers 3 of the belt conveyor is provided with a rotary power generation sensor 4 and a weighing sensor 5. Each impact power generation sensor, each rotary power generation sensor and each weighing sensor are electrically connected to a signal acquiring and processing unit. The signal acquiring and processing unit is electrically connected to a central processing unit. The central processing unit is electrically connected to a database and an interaction unit respectively. The impact power generation sensors and the rotary power generation sensors are electrically connected to a confluence power supply unit. A main idea of this embodiment is as follows: with monitoring the impact idlers for receiving falling down materials and monitoring rotation of conventional idlers, the received impacts and frequencies of the belt and a stretching condition of the belt during a motion process are logged, and quality of the belt is monitored through a method of big data analysis. When data is accumulated to a certain degree, diagnosis of the quality of the belt may be achieved, that is to say, when the belt is subjected to a certain number of large impacts and a certain number of large stretching, interior of the belt generates a quantitative change. It may be determined whether the belt needs to be maintained or replaced based on a size of the quantitative change. On the basic of the above idea, this embodiment provides with the impact sensors and rotary sensors. Data monitoring and accumulation are performed by using the two types of sensors and matched weighing sensors, to finally achieve a purpose of evaluating the quality of the belt. In some embodiments, the impact sensor and the rotary sensor are designed as sensors with a capability of generating electric power. In general, a signal output by each sensor is a faint electric signal as long as it may convey information. However, energy generated by the impact idlers in some embodiments is relatively large, a relatively sensor is therefore used. It would be a pity if the energy was discarded after detection, therefore, in some embodiments, the energy is collected as energy of instruments, which acquires necessary information and save energy. Similarly, in some embodiments, when a motion state of the belt is detected, the rotary power generation sensor is configured to convert a translational motion of the belt into a rotary motion of an idler. Pulling force on the belt is estimated based on rotation generated by friction between the belt and the idler in combination with a present weight carried by the belt weighed by a weighing sensor, so as to obtain evaluation of quality of the belt through big data analysis. In some embodiments, the rotary power generation sensor corresponds to the weighing sensor one to one, that is, a conventional idler is mounted with the rotary power generation sensor and the weighing sensor together. It is noted that the belt conveyor in some embodiments is provided with an impact resistance section, that is, some impact idlers that may bounce up and down are specifically configured at or near a head position of the belt conveyor. During operating, the impact idlers on the impact resistance section of the belt conveyor is provided below a discharge port of an upper conveyor 6 (see FIG. 1), and specifically configured to receive the materials input from the upper conveyor. When the material falls onto the belt, the impact idlers may move downwards under the impact of the materials and play a buffer role. And the impact idlers may automatically return to an original position without the impact. Therefore, in some embodiments, utilizing this up and down motion, energy of the up and down motion is collected, both as a sensor output signal and an energy output. Compared with the impact idlers, other idlers without impact resistance capacity are referred to as conventional idlers, or simply as idlers. In order to analyze more data and enhance analysis and diagnosis capabilities, in some embodiments, a sensor for detecting a shape of a materials stack on the belt and a sensor for detecting a motion velocity of a materials flow may be further added, the former sensor may be a binocular video sensor or a 3D camera, and the latter sensor may be a lidar or a sonar sensor. The former sensor and latter sensor may also be used interchangeably, that is, the video sensor also may measure the motion velocity of the materials flow, and the lidar sensor or sonar sensor may measure the shape of the materials stack. The shape and the motion velocity of the materials stack are also important factors for determining the quality of the belt. A distribution of the materials may be obtained by determining the shape of the materials stack, and the distribution and weight of the materials are very important for determining an unevenness degree of force on the belt. The shape of the materials stack and the weighing sensor may be configured to determine the density of the materials stack, further to calculate parameters such as a degree of dry and wet of the materials, and a stacking angle of the materials, which are important information for the latter conveying process. In some embodiments, the signal acquiring and analysis unit, the central processing unit, the database, the interaction unit and the like may be integrated in one industrial PC, or integrated in other devices with electronic digital storage, operation and display functions, such as an embedded system, an enhanced single-chip microcomputer and other electronic devices, and may even be integrated into a centralized control computer system of the entire belt conveying system, and perform centralized data sharing and big data analysis with other belt conveying devices. Embodiment Two: This embodiment is an improvement of the above embodiments, and is a refinement of the signal acquiring and analysis unit in the above embodiments. The signal acquiring and processing unit in the embodiment is further electrically connected to a binocular video sensor 7 and a lidar sensor 8, as illustrated in FIG. 1. A block diagram illustrating an electrical connection principle refers to FIG. 3. The binocular video sensor and the lidar sensor are mounted above the belt conveyor and may be mounted on a door-shaped support structure. As illustrated in FIG. 1, the support structure is across the belt conveyor, and the two sensors look down the passing belt and the materials on the belt. The binocular video sensor is a 3D stereoscopic photographic device that may calculate a size and a distance of an observed object based on a parallax between two cameras. In the embodiment, this characteristic of the binocular video sensor may be configured to calculate the volume and shape of the materials stack. The lidar sensor is a sensor capable of measuring a motion velocity of an object through Doppler Effect, also measuring the shape of the object through the Doppler Effect. The shape of the object is the shape of the materials stack in the embodiment. However, a precision of the lidar sensor is lower relative to a precision of the binocular video sensor. Embodiment Three: This embodiment is a refinement of the above embodiments, and a refinement of the impact power generation sensor in the above embodiments. The impact power generation sensor in the embodiment includes: a stator fixedly provided on a frame of the belt conveyor and a rotor capable of moving up and down with the impact idler. The impact power generation sensor in the embodiment is a device for generating electric power by utilizing the up and down motion. A process for generating power may generate the electric power through an electromagnetic field, and also may generate the electric power through a piezoelectric effect produced by a piezoelectric patch when impacted. Embodiment Four: This embodiment is a refinement of the above embodiments, and a refinement of the impact power generation sensor in the above embodiments. The stator in the embodiment is an electromagnetic coil winding, and the rotor is a permanent magnet. When the permanent magnet of the rotor moves up and down along with the impact idler, an induced current is generated in the electromagnetic coil of the stator to form a power generation output. Moreover, generation of the induced current also causes a certain damping effect, which is equivalent to that a damper is provided on the impact idler. Thus, invalid vibration of the impact idler is reduced. Embodiment Five: This embodiment is a refinement of the above embodiments, and a refinement of the impact power generation sensor in the above embodiments. The impact power generation sensor in the embodiment is the piezoelectric patch. The piezoelectric patch is provided on the stator, and the rotor is simply an impact surface that impacts the piezoelectric patch to cause the piezoelectric patch generating the electric power. In this case, a buffer device may be provided, that is, one set of buffer device is provided at the position where the piezoelectric patch is mounted, so as to avoid the piezoelectric patch being damaged by impact. Embodiment Six: This embodiment is a refinement of the above embodiments, and a refinement of the rotary power generation sensor in the above embodiments. The rotary power generation sensor in the embodiment is a generator. Rotary power generation is a very mature power generation mode, which has high efficiency, however, has a disadvantage of damping the rotation of the idler. Therefore, the rotary power generation sensor may not select a generator with too large power, so as to avoid interference on the motion of the belt. Due to high power generation efficiency, even a micro generator with a small power may also provide sufficient energy for each processing unit and other sensors to use. Embodiment Seven: This embodiment is a refinement of the above embodiments, and a refinement of a confluence power supply unit in the above embodiment. The confluence power supply unit in the embodiment is provided with a storage battery. Although the impact power generation sensor may generate a very strong electric power, since impact is an intermittent motion and is unsteady, a large capacitor requires to be configured for stabilization. Basically in this way, when excessive electric quantity is generated, the storage battery stores energy, which may have a better effect. Due to rapid development of modem power batteries, it is a good choice to store excess energy with the storage battery, so that the entire device may be completely separated from a mains power supply to form a completely independent system. Embodiment Eight: This embodiment is a method for monitoring a belt state of a self-powered belt conveyor based on the above monitoring apparatus. The basic idea of the embodiment includes the following acts. With logging strength and frequencies of the belt being impacted by materials, and a pulling force on the belt when carrying the materials, an expert system is formed by accumulating the foregoing data. During on-site monitoring, a quality evaluation on the belt is achieved based on analysis and comparison of the previous data, so as to avoid safety accidents such as belt breakage. The method includes the following detailed processes and steps. This embodiment includes three processes, which respectively are a no-load monitoring process, namely, performing an optical observation on a belt surface when there are no materials on the belt, a second process which is to monitor when the belt conveyor performs conveying operation, and a third process which is a power generation process. First, the no-load monitoring process includes the following acts. A binocular video sensor acquires a video image of a belt surface in real time under a condition of a belt being no-load motion. A presently acquired video image of the belt surface is compared with a previously acquired video image of the belt surface to determine whether surface breakage, tearing or bulge occurs on the belt surface. In response to the surface breakage, tearing or bulge occurring on the belt surface, alarming and shutting down for maintenance are performed. In exiting arts, the belt surface is usually inspected by personnel with their eyes. However, in the embodiment, a method for analyzing the video image is employed. Due to rapid development of modern video image analysis technologies, comparison and analysis on the video image has been very mature, therefore, it is possible to evaluate a present condition of the belt by logging an image of the belt surface with good quality and comparing it with a present image of the belt surface. It is even possible to compare videos from a plurality of periods to obtain slight changes on the belt surface, thereby monitoring possible failure points on the belt and achieving early warning. This inspecting process in the embodiment is completely completed via video image analysis software without any manual work. Second, a monitoring process during normal operation includes the following acts. At block 1, impact information is collected. When the materials fall down from an upper conveyor and impact the impact idlers, impact power generation sensors log impact strength and frequencies of impacts on the belt. Due to a limitation of precision of the sensor itself, the logged impact strength has a certain threshold. A relatively small impact may not be logged, which does not affect accuracy of logging. Since an impact that may form the impact on the belt and cause an influence on the belt surface is relatively large, the relatively small impact may be ignored. At block 2, load-bearing information is collected. In a case that the materials move along with the belt, load-bearing and motion statuses of the belt and loads of corresponding idlers are monitored by rotary power generation sensors at different intervals. Collection of the load-bearing information is completed via the rotary power generation sensor and the weighing sensor together. When the load-bearing of the belt is relatively small, a friction force of the belt on the idler is relatively small, combined with a damping effect of the generator itself, the rotary power generation sensor is not rotated sufficiently. The present pulling force bome by the belt may be determined by comparing with an actual motion velocity of the belt and comparing data of the adjacent rotary power generation sensor and the weighing sensor. At block 3, storing is performed respectively. After a signal acquiring and processing unit collects the strength of the impacts, the strength of the impacts are classified into a plurality of strength classes and then stored respectively. And frequency densities are analyzed based on the received frequencies of the impacts, and the frequency densities at different classifications are respectively stored. Storing data is a very important block because storing data correctly may play a function of big data analysis. In the embodiment, various pieces of data are discriminated and classified, and different data at different classifications are respectively stored for application. For example, the strength of the impacts is generally classified into seven classifications, such as, weak, medium weak, medium, medium strong, strong, very strong and extremely strong. Comparison analysis is performed on seven classifications respectively, so as to obtain a correct conclusion. With the storage, the data may be quickly extracted, and waste of resources and time may be reduced. At block 4, analyzing and comparing are performed. A central unit receives the strength and frequencies of the impacts of the belt and the load-bearing of the belt, analyzes stretching of the belt, and stores an analysis result and synchronizing data, and compares present data with previous data to determine a quality condition of the belt. A key of the embodiment is to analyze the previous data and compare the previous data with the present data, therefore, it is a very important process to store and analyze the previous data. Without support of the previous data, the present determination may not achieve an application effect. At block 5, uploading and displaying are performed. The analysis result is uploaded to a conveying chain upper computer or an under-pit equipment monitoring center in a wireless communication manner, and the analysis result is displayed on a monitoring terminal in a form of a table or a coordinate graph. The analysis result may be uploaded to the conveying chain upper computer or the under-pit equipment monitoring center in the wireless communication manner such as 4G or 5G or under-pit ultra WIFI6, and displayed on the screen in an electronic display manner. The analysis result may be made into the table, also made into a histogram, or the form of the coordinate graph, with a direct visual way to convey necessary information, such as the current quality of the belt surface and stretching quantity of the belt. The power generation process includes the following acts. Electric energy generated by the rotary power generation sensors during the no-load monitoring process is conveyed to a confluence power supply unit. The acquired electric energy is collected and rectified by the confluence power supply unit, and the electric energy is converted into a stabilized power supply for supplying to each unit, and excess electric energy is stored in the storage battery. Electric energy generated by the impact power generation sensors and the rotary power generation sensors during the monitoring process of the normal operation is conveyed to the confluence power supply unit. The collected electric energy is collected and rectified by the confluence power supply unit, and the electric energy is converted into the stabilized power supply for supplying to each unit. The excess electric energy is stored in the storage battery. Since the collected electric energy is unstable energy, the collected electric energy is required to be rectified and stabilized with a large capacitor, or stabilized with other electronic devices, such that the power supply is suitable for a requirement of an electronic circuit. Embodiment Nine: This embodiment is an improvement of Embodiment Eight, and a refinement of monitoring the data in Embodiment Eight. The blocks 1 to 2 in the embodiment further include: starting the binocular video sensor to detect the volume of the materials flow in real time, and starting the lidar sensor to monitor the velocity of the materials flow. The velocity of the materials detected by the lidar sensor is an actual motion velocity of the materials flow, and the velocity of the materials flow detected by the rotary power generation sensor is a rotary velocity of the idler generated by friction of the belt against the idler. Therefore, the velocity of the materials flow detected by the lidar sensor is not equal to the velocity of the materials flow detected through rotation of the idler. In the embodiment, a difference between the two velocities is configured to evaluate the quality of the belt, so as to monitor the current quality state of the belt. The block 3 further includes: converting the volume of the materials flow and the velocity of the materials flow, in combination with a density of a materials stack, into information of materials flow quantity, analyzing the information of the materials flow quantity, classifying a size and a weight of the materials flow and then respectively storing. The block 4 further includes: analyzing a quality state of the belt in combination the strength and frequencies of the impacts with the load-bearing of the belt and the information of the materials flow quantity. Adding two data sources enables analysis more accurate and determination more accurate. Finally, it is noted that, the above is only intended to illustrate the technical solution disclosed herein and not constitutes a limitation of the disclosure. Although the disclosure has been described in detail with reference to the preferred arrangement, it is understood by those skilled in the art that modifications or equivalent substitutions may be made to the technical solutions of the disclosure (such as the form and structure of the belt conveyor, the form and structure of the sensors used, the form and structure of the processing unit, etc.) without departing from the spirit and scope of the technical solutions of the disclosure. The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any suggestion that such prior art forms part of the common general knowledge. It will be understood that the terms "comprise" and "include" and any of their derivatives (e.g. comprises, comprising, includes, including) as used in this specification. The following claims are to be taken to include features to which the term refers and is not meant to exclude the presence of any additional features unless otherwise stated or implied.
Claims (9)
1. An apparatus for monitoring a belt state of a self-powered belt conveyor, comprising: impact power generation sensors respectively provided on a plurality of impact idlers at a receiving section of a belt conveyor, each of at least two conventional idlers of the belt conveyor being provided with a rotary power generation sensor and a weighing sensor; each impact power generation sensor, each rotary power generation sensor and each weighing sensor being electrically connected to a signal acquiring and processing unit, the signal acquiring and processing unit being electrically connected to a central processing unit, and the central processing unit being electrically connected to a database; and the impact power generation sensor and the rotary power generation sensor being electrically connected to a confluence power supply unit the apparatus is configured to perform: a no-load monitoring process: acquiring, by a binocular video sensor, a video image of a belt surface video image in real time under a condition of a belt being no-load, comparing a presently acquired video image of the belt surface with a previously acquired video image of the belt surface to determine whether surface breakage, tearing or bulge occurs on the belt surface, and in response to the surface breakage, tearing or bulge occurring on the belt surface, alarming and shutting down for maintenance; a monitoring process during normal operation, comprising: at block 1, collecting impact information: in a case that materials fall down from an upper conveyor and impact the plurality of impact idlers, logging, by the impact power generation sensors, strength and frequencies of impacts on the belt; at block 2, collecting load-bearing information: in a case that the materials move along with the belt, monitoring, by the rotary power generation sensors at different intervals, load-bearing and motion statuses of the belt and loads of corresponding idlers; at block 3, storing the strength of the impacts and frequency densities respectively: after a signal acquiring and processing unit collects the strength of the impacts, classifying the strength of the impacts into a plurality of strength classes and then storing the strength of the impacts respectively based on the plurality of strength classes, and analyzing the frequency densities based on the received frequencies of the impacts, and respectively storing the frequency densities at different classifications; at block 4, analyzing and comparing: receiving, by the central processing unit, the strength and frequencies of the impacts of the belt and the load-bearing of the belt, and analyzing stretching of the belt, and storing an analysis result and synchronizing data, and comparing present data with previous data to determine a quality condition of the belt; and at block 5, uploading and displaying: uploading the analysis result to a conveying chain upper computer or an under-pit equipment monitoring center in a wireless communication manner, and displaying the analysis result on a monitoring terminal in a form of a table or a coordinate graph; a power generation process: conveying electric energy generated by the rotary power generation sensors during a no-load monitoring process to a confluence power supply unit, collecting and rectifying, by the confluence power supply unit, the acquired electric energy, and converting the electric energy into a stabilized power supply for supplying to each unit, and storing excess electric energy in a storage battery; and conveying electric energy generated by the impact power generation sensors and the rotary power generation sensors during the monitoring process of the normal operation to the confluence power supply unit, collecting and rectifying, by the confluence power supply unit, the collected electric energy into the stabilized power supply for supplying to each unit, and storing the excess electric energy in the storage battery.
2. The apparatus of claim 1, wherein the signal acquiring and processing unit is further electrically connected to a binocular video sensor and a lidar sensor.
3. The apparatus of claim 2, wherein each impact power generation sensor comprises: a stator fixedly provided on a frame of the belt conveyor and a rotor capable of moving up and down with the impact idler.
4. The apparatus of claim 3, wherein the stator is an electromagnetic coil winding, and the rotor is a permanent magnet.
5. The apparatus of any of claims 2 to 3, wherein the impact power generation sensor is a piezoelectric patch.
6. The apparatus of any of claims 1 to 5, wherein the rotary power generation sensor is a generator.
7. The apparatus of claim 6, wherein, the confluence power supply unit is provided with the storage battery.
8. A method for monitoring a belt state of a self-powered belt conveyor based on the apparatus of claim 7, wherein, the method comprises: a no-load monitoring process: acquiring, by a binocular video sensor, a video image of a belt surface video image in real time under a condition of a belt being no-load, comparing a presently acquired video image of the belt surface with a previously acquired video image of the belt surface to determine whether surface breakage, tearing or bulge occurs on the belt surface, and in response to the surface breakage, tearing or bulge occurring on the belt surface, alarming and shutting down for maintenance. a monitoring process during normal operation, comprising: at block 1, collecting impact information: in a case that materials fall down from an upper conveyor and impact the plurality of impact idlers, logging, by impact power generation sensors, strength and frequencies of impacts on the belt; at block 2, collecting load-bearing information: in a case that the materials move along with the belt, monitoring, by rotary power generation sensors at different intervals, load-bearing and motion statuses of the belt and loads of corresponding idlers; at block 3, storing the strength of the impacts and frequency densities respectively: after a signal acquiring and processing unit collects the strength of the impacts, classifying the strength of the impacts into a plurality of strength classes and then storing the strength of the impacts respectively, based on the plurality of strength classes and analyzing the frequency densities based on the received frequencies of the impacts, and respectively storing the frequency densities at different classifications; at block 4, analyzing and comparing: receiving, by a central processing unit, the strength and frequencies of the impacts of the belt and the load-bearing of the belt, and analyzing stretching of the belt, and storing an analysis result and synchronizing data, and comparing present data with previous data to determine a quality condition of the belt; and at block 5, uploading and displaying: uploading the analysis result to a conveying chain upper computer or an under-pit equipment monitoring center in a wireless communication manner, and displaying the analysis result on a monitoring terminal in a form of a table or a coordinate graph; a power generation process: conveying electric energy generated by the rotary power generation sensor during a no-load monitoring process to a confluence power supply unit, collecting and rectifying, by the confluence power supply unit, the acquired electric energy, and converting the electric energy into a stabilized power supply for supplying to each unit, and storing excess electric energy in a storage battery; and conveying electric energy generated by the impact power generation sensors and the rotary
. I
power generation sensors during the monitoring process of the normal operation to the confluence power supply unit, collecting and rectifying, by the confluence power supply unit, the collected electric energy into the stabilized power supply for supplying to each unit, and storing the excess electric energy in the storage battery.
9. The method of claim 8, wherein the blocks 1 to 2 further comprise: starting a binocular video sensor to detect the volume of the materials flow in real time, and starting a lidar sensor to monitor the velocity of the materials flow; the block 3 further comprises: converting the volume of the materials flow and the velocity of the materials flow in combination with a density of a materials stack into information of materials flow quantity, analyzing the information of the materials flow quantity, classifying a size and a weight of the materials flow and then respectively storing; the block 4 further comprises: analyzing a quality state of the belt in combination the strength and frequencies of the impacts with the load-bearing of the belt and the information of the materials flow quantity.
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| CN202010434648.5A CN111537225A (en) | 2020-05-21 | 2020-05-21 | Belt state monitoring device and method of self-powered belt conveyor |
| CN202010434648.5 | 2020-05-21 | ||
| PCT/CN2021/094968 WO2021233393A1 (en) | 2020-05-21 | 2021-05-20 | Belt state monitoring apparatus and method for self-powered belt conveyor |
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| AU2021277427A1 AU2021277427A1 (en) | 2022-02-17 |
| AU2021277427B2 true AU2021277427B2 (en) | 2022-12-22 |
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| AU (1) | AU2021277427B2 (en) |
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| CN111537225A (en) * | 2020-05-21 | 2020-08-14 | 煤炭科学研究总院 | Belt state monitoring device and method of self-powered belt conveyor |
| CN113184483B (en) * | 2021-04-22 | 2023-06-23 | 武汉菲舍控制技术有限公司 | Conveyer belt tearing prevention system and early warning method |
| CN113589070A (en) * | 2021-07-09 | 2021-11-02 | 西安交通大学 | Self-powered and self-sensing integrated rotating part health monitoring device |
| CN114593796A (en) * | 2022-02-22 | 2022-06-07 | 中国恩菲工程技术有限公司 | Belt type metering scale control system |
| CN115848935A (en) * | 2022-12-19 | 2023-03-28 | 中交机电工程局有限公司 | Telescopic leather-hanging type automatic discharging system |
| CN116142723B (en) * | 2023-03-20 | 2023-08-08 | 淮南市万维机电有限公司 | Belt feeder intelligent protection early warning system based on chip intelligent control |
| CN116135744B (en) * | 2023-03-20 | 2023-12-15 | 北京众驰自动化设备有限公司 | Method and device for detecting abrasion of conveying belt of belt conveyor |
| CN116513747B (en) * | 2023-05-29 | 2023-10-03 | 厦门力祺环境工程有限公司 | Intelligent integrated safety control method based on three-dimensional simulation model |
| CN117509071B (en) * | 2024-01-05 | 2024-03-15 | 苏州纽酷输送机械有限公司 | Transportation monitoring system for air cushion conveyor |
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| CN111537225A (en) | 2020-08-14 |
| AU2021277427A1 (en) | 2022-02-17 |
| WO2021233393A1 (en) | 2021-11-25 |
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