CN104692077A - Device for monitoring longitudinal tear of adhesive tape conveyer belt - Google Patents
Device for monitoring longitudinal tear of adhesive tape conveyer belt Download PDFInfo
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- CN104692077A CN104692077A CN201510049002.4A CN201510049002A CN104692077A CN 104692077 A CN104692077 A CN 104692077A CN 201510049002 A CN201510049002 A CN 201510049002A CN 104692077 A CN104692077 A CN 104692077A
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- transfer device
- super sonic
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- adhesive tape
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
- B65G43/02—Control devices, e.g. for safety, warning or fault-correcting detecting dangerous physical condition of load carriers, e.g. for interrupting the drive in the event of overheating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2812/00—Indexing codes relating to the kind or type of conveyors
- B65G2812/02—Belt or chain conveyors
- B65G2812/02128—Belt conveyors
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- Control Of Conveyors (AREA)
- Belt Conveyors (AREA)
Abstract
The invention relates to the field of conveyer belt monitoring, in particular to monitoring of longitudinal scratch marks and cracks of a conveyer belt by adopting an ultrasonic technology. According to a device for monitoring longitudinal tear of the adhesive tape conveyer belt, an ultrasonic emitter sensor and an ultrasonic receiver sensor form a sensor pair, one or more sensor pairs are mounted under the conveyer belt, the ultrasonic emitter sensors and the ultrasonic receiver sensors of all the sensor pairs are connected to a central control unit, and an output interface of the central control unit is connected with an alarm device and a conveyer start-stop controller; the central control unit is used for judging a current state of the rubber conveyer belt according to whether an ultrasonic wave is monitored or not and characteristics of a monitored ultrasonic signal.
Description
Technical field
The present invention relates to load-transfer device monitoring field, particularly adopt ultrasonic technology to monitor the longitudinal cut of load-transfer device and crack.
Background technology
Belt conveyer continuative transport ability is strong, operating efficiency is high, be easy to realize automatic control, has been widely used in the transport of various bulk material.Load-transfer device is the important component part of ribbon conveyer, and load-transfer device mainly contains plain sail core belt, syntheticfibres core belt, Steel cord belt etc.Along with band conveyor is towards high speed, the future development of extensive, extra long distance, high spud angle, Steel cord belt is also more and more widely used.Steel cable core conveying belt drastically increases pulling strengrth, but the ability of its longitudinal anti tear is not improved, and is only the intensity of rubber itself, thus easily causes longitudinal tear.Belt conveyer is the main artery of factories and miness production and transport, once there is longitudinal tear, will bring great direct and consequential damage; Especially the steel cable core conveying belt of high speed, long distance, high spud angle, its loss is larger.
Load-transfer device longitudinal tear accident happens occasionally, and is worth the even more load-transfer device of millions of unit, once there is longitudinal tear accident, all may damages, cause huge economic loss within very short time.Namely allow to repair, also need suitable manpower and time, impact is greatly produced on normal production.The use amount of China Leather belt conveyor was increasing in recent years, and the increasing extent of its application is wide, and the accident that longitudinal tear occurs is also more and more frequent.
In recent years the domestic and international operation to adhesive tape is theoretical, longitudinal tear mechanism and anti-tear application engineering carried out certain research and development, have developed diversifiedly to tear monitoring device, is summed up and mainly contains following several types:
Imaging method
The method utilizes surface deflection sensor (super sonic or laser) to survey " crack ", and main employing high-precision ultrasonic line sensor, accurately judges length and the width in belt crack, also can monitor the abnormal condition of belt surface.System is made up of parts such as CCD high-precision ultrasonic line sensor, power supply, programming controller, general control system, combined aural and visual alarm, liquid crystal display, explosion-resistant enclosure and automatic flushing devices.Automatically detect the speed that belt feeder runs after system electrification, enter detected state.When belt by foreign matter penetrate cause that crack appears tearing in belt, overlap, leakage coal, bandwidth narrow and abnormal sideslip time, detecting device can export trip signal within the fastest time, stop the concurrent visual alarm of speaking of operation of belt feeder, prompting user takes measures.Because delivery system running environment is generally poor, the easy contamination monitoring of dust, muddy water talks investment, so need to adopt spray washing device, regularly automatically cleans the dust on monitor surface, dirt, otherwise can make thrashing.
Embedding inlay technique
This method normally adopts in belt or belt surface buries the methods such as plain conductor, coil, magnetic or certain conduction, permeability magnetic material in advance underground, by the integraty of pre-buried thing in monitoring belt, check implement judges whether belt longitudinal tear occurs.
At the end of the seventies, English, moral just start to adopt the method burying plain conductor in belt underground.But due to the continuous motion of belt, inevitably produce the sustained stress of rolling cut, make plain conductor be worn and torn and rupture.In order to overcome this shortcoming, the hollow tubular that the polyester fiber that Britain's application friction coefficient is less is made is enclosed within outside wire, and sulfuration is in rubber conveyer belt, and guardwire does not produce fatigue damage.
Another shortcoming burying the detecting device of wire in belt underground of development in the past often because the time is long, chemical reaction easily occurs between the rubber composition on wire and belt, thus destroy the electric conductivity of wire nipple, causes misoperation.In order to address this problem, the less zinc-plated steel cable of Germany's diameter is as wire, and this wire is embedded in apart from belt carrying and in the belt upper layer of certain distance, is parallel to belt surface.In the connector area of wire, relative wire is tightened mutually, and the end shield of amounting at wire nipple place has light alloy sheath, thus makes wire avoid contacting the rubber composition on belt top, improves the reliability of system.Also some country buries conductive rubber, light transmitting fiber etc. underground in belt.The shortcoming of this type of fender guard is complex process, Cheng Mugao.In addition, in a sense, owing to there being the problem of a blending between insert and rubber, if process is not good at, the intensity of belt can be reduced.
Embedding inlay technique detecting device has significant limitation in actual applications:
, this type of fender guard is that complex process, cost are high;
, the detection of a large amount of belt of installation and operation cannot be applied to;
, easily erroneous judgement, impact is produced;
, because belt is embedded in detection material, the maintenance of belt user is had higher requirement.
X-ray fluoroscopy method
During x-ray fluoroscopy detector X-ray penetrable material, material exists if any locality is abnormal, then the decay through this position transmitted intensity will to occur value different for normal position with surrounding canonical through the decay of this position transmitted intensity.This detecting device by inweaving horizontal sheetmetal or metal gauze in adhesive tape, once longitudinal direction or transverse direction are torn, these sheetmetals rupture, and X-ray machine will send alerting signal in time or conveyer is shut down.
, can not misoperation be there is in advantage: monitoring accuracy is higher.
Shortcoming: need stop production monitoring, work capacity is large, and impact is produced; Complex structure, tape liner enters metal gauze and adds belt cost; Equipment volume is large; There is radiation.
Visit leakage method
Adopt and visit leakage method as longitudinal tear warning device, its core concept, after there is longitudinal tear, has material to stretch out belt crack or material from leakage in the tear place of belt.Thereby produce rod type detector, string of a musical instrument formula device, leak material detector etc.Rod type detector is that a rod or pipe bent are become trough idler shape, is arranged between the impact idler below flute profile load-transfer device and forms.Like this, if any the material piercing through load-transfer device, this material will stir the deflection of flute profile rod, force limit switch or load transducer action, belt conveyer is shut down.String of a musical instrument formula device and bar type detector similar, this device is by nylon wire as probe, and be placed between impact idler and fit through aperture and flute profile band lower surface, one end of line fills a spring retainer switch.When the material piercing through load-transfer device stumbles this line, line is broken or tension force increase, all can make limit switch action.Leak material detector to be made up of pallet, fulcrum, bob-weight and switch etc.After load-transfer device is by longitudinal tear, the material on load-transfer device leaks in pallet by breach, and the weight of material overcomes the weight of bob-weight, makes whole device around fulcrum, forces limit switch action.
Because spy leakage method broadens with breach after belt longitudinal tear, thus cause material to stretch out or based on the principle of leaking, so once after belt tearing, if belt does not have breach or breach wide not, material would not occur and stretch out belt crack or leakage, then this method cannot detect.After load-transfer device is by longitudinal tear, only have load-transfer device has material and the breach of load-transfer device is enough to make material from leakage time, this device just can work, otherwise is just of little use.
Summary of the invention
Technical matters to be solved by this invention is: how to provide a kind of effectively, the method for quick detection load-transfer device generation longitudinal tear and implement device.
The technical solution adopted in the present invention is: a kind of adhesive tape load-transfer device longitudinal tear monitoring device, a super sonic emission sensor and a super sonic receiving sensor partner sensor pair, a pair or multipair sensor are to being arranged on immediately below load-transfer device, the super sonic emission sensor that all the sensors is right and super sonic receiving sensor are all linked into central controller, and central controller output interface connects warning device and conveyer on off controller.Central controller sends driving pulse to the super sonic emission sensor that each sensor is right, super sonic emission sensor sends super sonic, super sonic is propagated by the super sonic receiving sensor direction of load-transfer device to correspondence, super sonic receiving sensor real-time listening ultrasonic signal, and the signal back central controller listened to, central controller according to whether listen to super sonic and listen to ultrasonic signal feature judge rubber conveyer belt the present situation.
As a kind of optimal way: adopt multipair sensor to when being arranged on immediately below load-transfer device, multipair sensor is to being arranged on immediately below load-transfer device two cross-sectional planes, and the sensor pair of second cross-sectional plane superposes with the sensor of first cross-sectional plane and is staggered; By adopting multipair sensor pair, shorten the distance between super sonic emission sensor and super sonic receiving sensor, be conducive to hypracoustic transmission, ensure that the reliability of detection, simultaneously, adopt sensor installation pair on two cross-sectional planes, and make the sensor of second cross-sectional plane pair superpose staggered mode with the sensor of first cross-sectional plane, make to monitor the bandwidth that width covers whole load-transfer device.
As a kind of optimal way: central controller periodically sends driving pulse to the super sonic emission sensor that each sensor is right successively, when the super sonic emission sensor that pair of sensors is right is wherein in work, the right super sonic emission sensor of other sensor is all in closed condition, avoid sensor between super sonic interference.
As a kind of optimal way: the frequency that super sonic emission sensor adopts is 40KHz-150KHz.Super sonic good directionality, penetrating capacity is strong, is easy to obtain the acoustic energy comparatively concentrated, and can be used for finding range, tests the speed, cleans, welds, rubble, sterilizing etc., in medical science, military affairs, industry, agriculturally has a lot of application.Hypracoustic scope is very wide, and when super sonic is propagated in media as well, its propagation distance of intensity increases and weakens, and this is absorbed in communication process due to ultrasonic energy, and the density of ultrasonic absorption and medium, astringency, permeability of heat and ultrasonic frequency etc. are relevant.And the absorptive coefficient of medium again to square being directly proportional of ultrasonic frequency, thus high frequency ultrasound is abnormal violent in decay, and ambient temperature also can affect hypracoustic propagation performance in addition.In the monitoring of load-transfer device longitudinal tear and fender guard; according to the difference of load-transfer device rubber constituent, load-transfer device characteristic and ambient temperature, we select the super sonic in 40KHz-150KHz frequency limit, this range effect good directionality; penetrating capacity is strong, is easy to obtain the acoustic energy comparatively concentrated.
As a kind of optimal way: super sonic emission sensor and super sonic receiving sensor are wheeled construction, upwards malleation is at the lower surface of conveyors carried band for the tire protector of wheel sensor, and when load-transfer device runs, wheel sensor is rotated under static friction force effect.Tire top and load-transfer device lower surface form Structure deformation district, improve sensor to and load-transfer device between hypracoustic communication effect.
Accompanying drawing explanation
Fig. 1 is structural representation of the present invention;
Fig. 2 is schematic diagram load-transfer device occurring longitudinal tear;
Fig. 3 is the parts transversely generalized section of Steel cord rubber conveyer belt;
Fig. 4 is the plan sketch of Steel cord rubber conveyer belt vulcanized joint;
Fig. 5 is the arrangement of the monitoring of Steel cord rubber conveyer belt longitudinal tear and the wheeled ultrasonic transduter of fender guard;
Fig. 6 is Fig. 5 section line 2-2 place wheel sensor schematic diagram;
Fig. 7 is the hardware block diagram that load-transfer device Longitudinal Surveillance system realizes;
Fig. 8 is the control flow chart that load-transfer device Longitudinal Surveillance system realizes.
Detailed description of the invention
As depicted in figs. 1 and 2, a kind of adhesive tape load-transfer device longitudinal tear monitoring device, a super sonic emission sensor and a super sonic receiving sensor partner sensor pair, a pair or multipair sensor are to being arranged on immediately below load-transfer device, the super sonic emission sensor that all the sensors is right and super sonic receiving sensor all access central controller, and central controller 30 output interface connects warning device and conveyer on off control device.When central controller 30 sends pumping signal to super sonic emission sensor Tn, super sonic emission sensor Tn can produce certain frequency super sonic, this super sonic injects rubber conveyer belt, repeatedly launch through rubber conveyer belt upper and lower surface, along the transversal surface forward direction perpendicular to adhesive tape service direction.Shown in Fig. 1, if longitudinal tear does not occur load-transfer device, after certain hour, super sonic receiving sensor Rn can receive the super sonic transmitted; Shown in Fig. 2, if load-transfer device generation longitudinal tear accident, super sonic receiving sensor Rn will not receive ultrasonic signal, or, even if receive, also compared with normal situation is much weak for its signal strength, and the time of cost when the time receiving signal is intact compared with load-transfer device will be grown.Whether longitudinal tear occurs to be exactly judge according to the power of ultrasonic signal received and the time of ultrasonic signal propagation.
When receiving sensor receives super sonic, just can illustrate that the rubber conveyer belt between this receiving sensor and the emission sensor of matching with it is intact; When receiving sensor fails the ultrasonic signal receiving expection, can illustrate that the rubber conveyer belt between this receiving sensor and the emission sensor of matching with it there occurs longitudinal tear; When receiving sensor receives fainter super sonic, illustrate that darker cut has appearred in the rubber conveyer belt between this receiving sensor and the emission sensor of matching with it, but do not penetrate.
When detect tear or cut situation time, this device output switching signal immediately, trigger alarm, and control travelling apron and shut down, thus avoid tearing further expansion.
Shown in Fig. 3, Fig. 4, rubber conveyer belt 1 is made up of the galvanized steel wire rope 4 that upper rubber cover 5, lower rubber cover 6 and the coated longitudinal direction of core glue 7 are evenly distributed.Upper rubber cover 5 and lower rubber cover 6 surface smoothing, but in use, owing to being collided and being rubbed, surface can become uneven, for improving the performance of rubber conveyer belt, usually adds some fabric components wherein, these become branch to weaken hypracoustic conduction, such as fire retardant.The easier conducting ultrasonic energy of natural rubber, and asynthetic rubber's conducting ultrasonic energy is just very poor.The easy conducting ultrasonic energy of elastomeric material that usual conveying band joint sulfuration is used, this material is generally easy to the wire rope core of sulfuration and bonding.
Further, this device also can monitor the defect of rubber conveyer belt vulcanized joint, when the joint just vulcanizated detects, if receiving sensor receive ultrasonic signal strength weak time, show to there is sulfuration defect between this receiving sensor and the emission sensor of matching with it, need sulfuration again; Similarly, use after a period of time at load-transfer device, obviously weaken if receiving sensor receives ultrasonic signal strength at certain vulcanized joint place, then show that the Steel cord 4 of this joint and the binding force of core glue 7 reduce, there is potential safety hazard, reminding user detects further, therefore, can look-ahead to the inefficacy of vulcanized joint.
As shown in Figure 5, show for four pairs of sensors to being illustrated, T1, T2, T3 and T4 are super sonic emission sensor, and R1, R2, R3 and R4 are super sonic receiving sensors.T1 and R1, T2 and R2, T3 and R3, T4 and R4, every two form pair of sensors pair, and totally four is right.Each sensor wheel is towards upper malleation at carrying belt lower surface, and rotate under load-transfer device drives, each wheel shaft is strictly perpendicular to running direction of conveyor belt, and the wheel axis with the emission sensor in group and receiving sensor is positioned on same load-transfer device transversal surface.
Shown in Fig. 6, a wheeled ultrasonic transduter is arranged on carrying belt (load-transfer device of loaded material) below.Upwards malleation is at the lower surface of rubber belt conveyor carrying belt 11 for tire 84, and tire 84 can freely rotate under the driving of the quiet power of rubbing of rubber conveyer belt; Under the effect of positive pressure, the top of tire 84 with forms Structure deformation district with carrying belt 11 lower surface, ultrasonic beam 34 realizes propagation along super sonic axis 36 by this contact zone.
Hypracoustic scope is very wide, and when super sonic is propagated in media as well, its propagation distance of intensity increases and weakens, and this is absorbed in communication process due to ultrasonic energy, and the density of ultrasonic absorption and medium, astringency, permeability of heat and ultrasonic frequency etc. are relevant.And the absorptive coefficient of medium again to square being directly proportional of ultrasonic frequency, thus high frequency ultrasound is abnormal violent in decay, and ambient temperature also can affect hypracoustic propagation performance in addition.In the monitoring of Steel cord rubber conveyer belt longitudinal tear and fender guard, according to the difference of load-transfer device rubber constituent, load-transfer device characteristic and ambient temperature, we select the super sonic in 40KHz-150KHz frequency limit.
Fig. 7 shows central controller design frame chart.This central controller structure is based on FPGA and ARM platform, and it is primarily of parts such as multi-channel analog signal front end, FPGA signal handling equipment, ARM main frame and Peripheral Interfaces.Multi-channel analog signal front end comprises super sonic transceiver circuit, channel selecting module, Signal-regulated kinase and A/D modular converter.Super sonic transceiver circuit is for generation of the high voltage negative pulse of excitation ultrasonic transduter, and receive the ultrasonic electrical signal listened to from receiving sensor, this signal is sent into signal conditioning circuit and is carried out the process such as amplification, then under the control of FPGA, carries out A/D conversion.Channel selection circuit is in order to control the switch of super sonic passage.N group transmission circuit is identical, adopts time sharing mode.This N road transmission circuit is set to repeated work mode, and the activation sequence of its repeated freqnency and probe is determined, by setting in the main interface parameter setting option of ARM embedded computer according to particular cases such as the width of rubber conveyer belt.The excitation of transmission circuit has been come by FPGA, and when the burst pulse that FPGA exports is added on a certain transmission circuit, this transmission circuit is just started working.
Implementation procedure comprises:
Below Steel cord rubber transport bearing belt, a pair or multipair sensor pair are installed; According to the spacing between the quality of rubber materials characteristic determination ultrasonic transduter of the width of rubber conveyer belt, rubber conveyer belt and the quantity that uses ultrasonic transduter right.
FPGA presses some cycles to each channel emission driving pulse, 1st, n+1,2n+1,3n+1 ... trigger action first passage emission sensor works, 2nd, n+2,2n+2,3n+2 ... trigger action second channel emission sensor works, 3rd, n+3,2n+3,3n+3 ... trigger action third channel emission sensor works, 4th, n+4,2n+4,3n+4 ... trigger action four-way emission sensor works, the n-th, n+n, 2n+n, 3n+n ... trigger action n-th channel emission working sensor, each like this passage periodical duty successively.When the transmission circuit of a certain passage is started working, the transmitting and receiving circuit of other passage is all closed.
The control flow of the rubber conveyer belt of Steel cord shown in Fig. 8 tear device, first system initialization, training in rotation also records each channel ultrasonic from the time tn being transmitted into reception and experiencing.After initialization completes, gating a certain road ultrasonic transduter launches super sonic, and starts timer and start timing, if receiving sensor does not listen to the acoustic signals that corresponding emission sensor is launched within the tn time, show that rubber conveyer belt is torn, master control system produces to report to the police and exports.If receiving sensor listens to the acoustic signals that corresponding emission sensor is launched within the tn time, then master control system is resolved this signal, and store monitoring data, judge whether the super sonic received, compared with the beginning ripple that emission sensor is launched, waveform feature parameter change occurs simultaneously, if any, then show that rubber conveyer belt exists abnormal, master control system output alarm.After the tn time terminates, next passage of gating.
Claims (5)
1. an adhesive tape load-transfer device longitudinal tear monitoring device, it is characterized in that: a super sonic emission sensor and a super sonic receiving sensor partner sensor pair, a pair or multipair sensor are to being arranged on immediately below load-transfer device, the super sonic emission sensor that all the sensors is right and super sonic receiving sensor all access central controller, and central controller output interface connects warning device and conveyer on off control device.
2. a kind of adhesive tape load-transfer device longitudinal tear monitoring device according to claim 1, it is characterized in that: adopt multipair sensor to when being arranged on immediately below load-transfer device, multipair sensor is to being arranged on immediately below load-transfer device two cross-sectional planes, the sensor of the sensor of second cross-sectional plane pair and first cross-sectional plane, to alternating share overlapping arrangement, can cover the whole bandwidth of load-transfer device after the right detection transversal surface width of all the sensors is cumulative.
3. a kind of adhesive tape load-transfer device longitudinal tear monitoring device according to claim 1, it is characterized in that: central controller periodically sends transmitting driving pulse to the super sonic emission sensor that each sensor is right successively, when the super sonic emission sensor that pair of sensors is right is wherein in work, the right super sonic emission sensor of other sensor is all in closed condition.
4. a kind of adhesive tape load-transfer device longitudinal tear monitoring device according to any one claim of Claim 1-3, is characterized in that: the frequency that super sonic emission sensor adopts is 40KHz-150KHz.
5. a kind of adhesive tape load-transfer device longitudinal tear monitoring device according to claim 4, it is characterized in that: super sonic emission sensor and super sonic receiving sensor are wheeled construction, the tire protector of wheel sensor upwards malleation at the lower surface of conveyors carried band, when load-transfer device runs, wheel sensor is rotated under static friction force effect.
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CN201510049002.4A CN104692077B (en) | 2015-01-30 | 2015-01-30 | A kind of belt haulage band longitudinal tear monitoring device |
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CN201510049002.4A CN104692077B (en) | 2015-01-30 | 2015-01-30 | A kind of belt haulage band longitudinal tear monitoring device |
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CN106124619A (en) * | 2016-03-29 | 2016-11-16 | 中北大学 | A kind of belt ultrasound detection wheel seach unit group |
CN108082886A (en) * | 2018-01-15 | 2018-05-29 | 洛阳威尔若普检测技术有限公司 | A kind of Steel cord conveyer belt automatic monitoring system and monitoring method |
CN108082887A (en) * | 2018-01-19 | 2018-05-29 | 天津工业大学 | A kind of conveyer band discerption failure detector based on radar range finding technology |
CN111164030A (en) * | 2017-08-31 | 2020-05-15 | 横滨橡胶株式会社 | Monitoring system of conveyer belt |
CN114751138A (en) * | 2022-03-09 | 2022-07-15 | 国家能源集团国源电力有限公司 | Belt longitudinal tearing monitoring system and conveying equipment |
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CN108082886A (en) * | 2018-01-15 | 2018-05-29 | 洛阳威尔若普检测技术有限公司 | A kind of Steel cord conveyer belt automatic monitoring system and monitoring method |
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CN108082887A (en) * | 2018-01-19 | 2018-05-29 | 天津工业大学 | A kind of conveyer band discerption failure detector based on radar range finding technology |
CN114751138A (en) * | 2022-03-09 | 2022-07-15 | 国家能源集团国源电力有限公司 | Belt longitudinal tearing monitoring system and conveying equipment |
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