CN105692118A

CN105692118A - Fault monitoring and early warning system and method for belt conveyor of mine

Info

Publication number: CN105692118A
Application number: CN201610207227.2A
Authority: CN
Inventors: 龚晓燕; 陈超明; 李�根; 张金锁; 刑书宝; 杨文清; 张军; 薛河; 赵宽; 古晓蒙; 焦婉莹; 秦少妮; 赵敏贤; 张永强
Original assignee: Xian University of Science and Technology
Current assignee: Xian University of Science and Technology
Priority date: 2016-04-01
Filing date: 2016-04-01
Publication date: 2016-06-22
Anticipated expiration: 2036-04-01
Also published as: CN105692118B

Abstract

The invention discloses a fault monitoring and early warning system and method for a belt conveyor of a mine. The fault monitoring and early warning system comprises an upper monitor, a conveyor working condition detecting device, a data acquiring device, an early warning prompting device and a timing circuit, wherein the conveyor working condition detecting device detects working conditions of a monitored belt conveyor in real time; the data acquiring device is connected with the conveyor working condition detecting device; the early warning prompting device is controlled by the upper monitor; and the timing circuit is connected with the upper monitor. The fault monitoring and early warning method comprises the following steps: 1, detecting the working conditions of the conveyor and synchronously uploading detection information; and 2, analyzing and processing of information of the working conditions of the conveyor: respectively analyzing and processing the information, which is acquired by the data acquiring device at various sampling times, of the working conditions of the conveyor by using the upper monitor in sequence according to the sampling times, and diagnosing faults of the monitored belt conveyor according to analyzed and processed results. The fault monitoring and early warning system is reasonable in design, easy and convenient to use and operate and good in using effect, can timely and accurately monitor faults of the belt conveyor, and can early warn in time.

Description

Mine belt conveyor fault monitoring and early warning system and method

Technical Field

The invention belongs to the technical field of fault monitoring of mining equipment, and particularly relates to a fault monitoring and early warning system and method for a mine belt conveyor.

Background

The belt conveyer, also called as rubber belt conveyer or belt conveyer, is a friction-driven machine for continuously conveying material, mainly comprising machine frame, conveying belt, supporting roller, drum, tension device and transmission device, the machine head and machine tail of the belt conveyer are respectively equipped with drum, and the drums mounted on the machine head and machine tail respectively include driving drum and steering drum (also called guide drum) positioned on one side of driving drum. A coal mine belt conveyor (also called a mine belt conveyor or a mine belt conveyor) is a belt conveyor installed in a roadway under a coal mine, and is widely used in various coal mines as a horizontal transportation or inclined transportation tool. At present, a belt conveyor is continuous transportation equipment which is most applied in underground coal mine and ground production systems, and has the advantages of strong transportation capacity, small working resistance, small power consumption, long transportation distance, long service life, low noise, safety, reliability and the like. The safe and stable operation of the mine belt conveyor is important for coal mine production. The coal mine underground roadway mainly comprises the following three types: the method comprises the following steps of developing a roadway, preparing the roadway and stoping the roadway, wherein the developed roadway refers to a basic roadway developed for well field development, such as a shaft bottom yard, a transportation roadway, a main return airway, a main goaf and the like; the preparation roadway refers to a roadway which is excavated for preparing a mining area, namely a roadway in the mining area, such as a mining area upper mountain, a mining area lower mountain, a mining area parking lot and the like; the stoping roadway is also called a coal mining roadway or a gateway, and refers to a roadway which forms a coal mining working face and serves the coal mining working face, such as an open cut hole, a working face transportation roadway, a working face return airway and the like.

If the belt conveyor is not used properly or overhauled and maintained in time, the belt conveyor is easy to break down, not only can the equipment be damaged, but also personal accidents can happen sometimes. At present, most of faults occurring in mine belt conveyors are in a post-processing mode, particularly, after the faults occur, the reasons of the faults are checked one by maintainers, labor and time are wasted, the reasons of the faults are mainly judged according to experience of the maintainers, and the reasons of the faults cannot be found out timely, quickly and accurately and corresponding processing measures are taken. Therefore, a fault monitoring and early warning system and method for the mine belt conveyor, which are simple and convenient to use and operate, convenient to implement and good in using effect, are needed to be designed, faults occurring in the mine belt conveyor can be timely and accurately monitored, early warning can be performed according to monitoring results, and workers are reminded to take corresponding treatment measures in time.

Disclosure of Invention

The invention aims to solve the technical problem of providing a fault monitoring and early warning system for a mine belt conveyor, which has the advantages of simple structure, reasonable design, simple and convenient installation and arrangement, lower investment cost, simple and convenient use and operation, good use effect and capability of timely and accurately monitoring the faults of the belt conveyor.

In order to solve the technical problems, the invention adopts the technical scheme that: the utility model provides a mine belt conveyor fault monitoring early warning system which characterized in that: the monitoring system comprises an upper monitor, a conveyor working condition detection device for detecting the working condition of a monitored belt conveyor in real time, a data acquisition device connected with the conveyor working condition detection device, an early warning prompting device controlled by the upper monitor and a timing circuit connected with the upper monitor, wherein the early warning prompting device and the data acquisition device are both connected with the upper monitor; the monitored belt conveyor is a belt conveyor arranged in an underground roadway of a coal mine;

the conveyor working condition detection device comprises a motor working condition detection device, a machine head working condition detection device arranged at the machine head of the monitored belt conveyor and a machine tail working condition detection device arranged at the machine tail of the monitored belt conveyor; the machine head working condition detection device comprises a smoke concentration detection unit, a belt speed detection unit for detecting the belt speed of the monitored belt conveyor in real time, a driving roller rotating speed detection unit for detecting the rotating speed of a driving roller installed on the machine head of the monitored belt conveyor in real time, a guide roller rotating speed detection unit for detecting the rotating speed of a guide roller installed on the machine head of the monitored belt conveyor in real time and a roller bearing temperature detection unit for detecting the surface temperature of a roller bearing of the driving roller in real time; the tail working condition detection device comprises a tearing sensor; motor operating mode detection device includes right driving drum's driving motor's three-phase current detecting element that the three-phase current carries out real-time detection respectively, right driving motor's three-phase winding's temperature carries out real-time detection respectively three-phase winding temperature detecting element, right driving motor's motor bearing temperature carries out real-time detection's motor bearing temperature detecting element and right driving motor's casing temperature carries out real-time detection's casing temperature detecting element, driving drum rotational speed detecting element, direction cylinder rotational speed detecting element, smog concentration detecting element, area speed detecting element, cylinder bearing temperature detecting element, tear sensor, three-phase current detecting element, three-phase winding temperature detecting element, motor bearing temperature detecting element and casing temperature detecting element all are connected with data acquisition device.

Above-mentioned mine belt conveyor fault monitoring early warning system, characterized by: the monitoring system also comprises a data transmitter connected with the data acquisition device, and the data transmitter is connected with the upper monitoring machine through an optical fiber.

Above-mentioned mine belt conveyor fault monitoring early warning system, characterized by: the number of the conveyor working condition detection devices and the number of the data acquisition devices are the same as that of the monitored belt conveyors, the number of the conveyor working condition detection devices and the number of the data acquisition devices are multiple, the plurality of conveyor working condition detection devices are used for respectively detecting the working conditions of the monitored belt conveyors in real time, the plurality of conveyor working condition detection devices are respectively connected with the plurality of data acquisition devices, and the plurality of data acquisition devices are all connected with an upper monitor; the monitored belt conveyors are respectively installed in the coal mine underground roadways, the monitored belt conveyors are connected to form a coal mine underground conveying system, and the coal mine underground roadways are development roadways, preparation roadways or stoping roadways.

Above-mentioned mine belt conveyor fault monitoring early warning system, characterized by: the conveyor working condition detection device also comprises a middle working condition detection device arranged at the middle position of the monitored belt conveyor, and the middle working condition detection device comprises a second deviation sensor; the machine head working condition detection device further comprises a first deviation sensor, and the machine tail working condition detection device further comprises a third deviation sensor; the first deviation sensor, the second deviation sensor and the third deviation sensor are all connected with the data acquisition device.

Meanwhile, the invention also discloses a mine belt conveyor fault monitoring and early warning method which has simple steps, reasonable design and convenient realization, can timely and accurately monitor the fault of the mine belt conveyor and can carry out early warning according to the monitoring result, and is characterized in that: the method comprises the following steps:

step one, conveyor working condition detection and synchronous uploading of detection information: the working condition of the monitored belt conveyor is detected in real time by the conveyor working condition detection device, the conveyor working condition information detected by the conveyor working condition detection device is collected by a data collection device according to a preset sampling frequency f, and the collected conveyor working condition information is synchronously transmitted to an upper monitor; wherein, f is 1 Hz;

step two, analyzing and processing the working condition information of the conveyor: the upper monitoring machine analyzes and processes the conveyor working condition information acquired at each sampling moment of the data acquisition device according to the sampling time sequence, and performs fault diagnosis on the monitored belt conveyor according to the analysis and processing result to obtain a fault diagnosis result;

the fault diagnosis result comprises whether the monitored belt conveyor has faults or not, the number of the faults and the type of each fault; the fault types of the monitored belt conveyor comprise a slip fault, a tearing fault, a roller fault, a smoke fault, a belt breakage fault, a motor bearing fault, a motor overload fault and a motor heat dissipation fault, wherein the motor bearing fault, the motor overload fault and the motor heat dissipation fault are all motor faults;

when the upper monitoring machine analyzes and processes the conveyor working condition information acquired by the data acquisition device at any sampling moment, the process is as follows:

step 201, synchronous storage of the conveyor working condition information: synchronously storing the received working condition information of the conveyor, wherein the stored working condition information of the conveyor is the working condition information of the conveyor to be processed currently;

step 202, fault diagnosis: calling a fault diagnosis module, analyzing and processing the current conveyor working condition information to be processed in the step 201, and respectively diagnosing whether the monitored belt conveyor has a slip fault, a tearing fault, a roller fault, a smoke fault, a belt breakage fault and a motor fault according to an analysis processing result;

when the monitored belt conveyor is diagnosed whether a slip fault exists at the moment, the process is as follows:

step 20111, slip fault preliminary diagnosis: according to the preset rated belt speed V of the monitored belt conveyor_SJudging the belt speed V detected by a belt speed detection unit in the current to-be-processed conveyor working condition information: when 0.3V_SIf V is less than 0.7Vs, the time is the time to be diagnosed, and the step 20112 is entered; otherwise, go to step 20113;

step 20112, further diagnosing the slip fault: respectively diagnosing the belt speeds V detected by the belt speed detection unit in the conveyor working condition information acquired by the data acquisition device in consecutive P seconds before the time to be diagnosed in step 20111: when the belt speed V detected by the belt speed detection unit in the conveyor working condition information collected by the data collection device in continuous P seconds before the moment to be diagnosed is more than 0.3V_SAnd when the value is less than 0.7Vs, the slip fault of the monitored belt conveyor at the moment is diagnosed; otherwise, diagnosing that the monitored belt conveyor has no slip fault at the moment; wherein P is a positive integer and P is 10-20;

step 20113, further diagnosing the slip fault: according to a preset roller rotation speed difference value V₀And diagnosing the rotating speed value V1 detected by the driving roller rotating speed detection unit and the rotating speed value V2 detected by the guide roller rotating speed detection unit in the current working condition information of the conveyor to be processed: when | V1-V2| ≧ V₀When the monitored belt conveyor has the slip fault, the slip fault is diagnosed to exist in the monitored belt conveyor; otherwise, diagnosing that the monitored belt conveyor has no slip fault at the moment; wherein, V₀＝0.25m/s～0.35m/s；

When the monitored belt conveyor is diagnosed whether the tearing fault exists or not, the diagnosis is carried out according to the information detected by the tearing sensor in the current condition information of the conveyor to be processed: when the tearing sensor in the current working condition information of the conveyor to be processed detects that the conveyor belt of the monitored belt conveyor is torn, the monitored belt conveyor is diagnosed to have tearing faults; otherwise, diagnosing that the monitored belt conveyor has no tearing fault at the moment;

when diagnosing whether the monitored belt conveyor has roller faults or not, diagnosing according to the temperature value T1 detected by the roller bearing temperature detection unit in the current working condition information of the conveyor to be processed: when T1 > T1₀When the roller fault exists, the roller fault of the monitored belt conveyor is diagnosed; otherwise, diagnosing that the monitored belt conveyor has no roller fault at the moment; wherein, T1₀Threshold value for preset roller bearing temperature determination and T1₀＝70℃～80℃；

When the monitored belt conveyor is diagnosed whether smoke fault exists or not, diagnosing according to the concentration value n detected by the smoke concentration detection unit in the current conveyor condition information to be processed: when n > n₀When the smoke fault exists, the monitored belt conveyor is diagnosed to have the smoke fault; otherwise, diagnosing that the monitored belt conveyor has no smoke fault at the moment; wherein n is₀Determining a threshold value for a preset smoke concentration n₀＝0.08mg/m³～0.12mg/m³；

When the belt breakage fault of the monitored belt conveyor is diagnosed, the process is as follows:

step 20121, initial diagnosis of belt breakage fault: according to the preset rated belt speed V of the monitored belt conveyor_SJudging the belt speed V detected by a belt speed detection unit in the current to-be-processed conveyor working condition information: when V is less than or equal to 0.3V_SIf so, the time to be diagnosed is indicated, and the step 20122 is carried out; otherwise, diagnosing that the belt breakage fault does not exist in the monitored belt conveyor at the moment, and completing the belt breakage fault diagnosis process of the monitored belt conveyor at the moment;

step 20122, further diagnosing belt breakage faults: respectively diagnosing the belt speeds V detected by the belt speed detection unit in the conveyor working condition information collected by the data collection device in continuous Q seconds before the time to be diagnosed in the step 20121: when the belt speed V detected by the belt speed detection unit in the conveyor working condition information collected by the data collection device in continuous Q seconds before the moment to be diagnosed is not more than 0.3V_SWhen the belt is broken, the belt broken fault of the monitored belt conveyor is diagnosed; otherwise, diagnosing that the belt breakage fault does not exist in the monitored belt conveyor at the moment; wherein Q is a positive integer and Q is 3-10;

when the monitored belt conveyor is diagnosed to determine whether a motor fault exists, respectively diagnosing whether the monitored belt conveyor has a motor bearing fault, a motor overload fault and a motor heat dissipation fault according to the information detected by the motor working condition detection device in the current conveyor working condition information to be processed;

when the monitored belt conveyor is diagnosed for the motor bearing fault, diagnosing according to the temperature value T2 detected by the motor bearing temperature detection unit in the current conveyor condition information to be processed: when T2 > T2₀When the motor bearing fault exists, the motor bearing fault of the monitored belt conveyor is diagnosed; otherwise, diagnosing that no motor bearing fault exists in the monitored belt conveyor at the moment; wherein,T2₀threshold value for predetermined motor bearing temperature determination and T2₀＝75℃～85℃；

When the monitored belt conveyor is diagnosed whether the motor overload fault exists or not, the motor overload fault is diagnosed according to the information detected by the three-phase winding temperature detection unit and the three-phase current detection unit in the current condition information of the conveyor to be processed: when the temperature of the three-phase winding detected by the three-phase winding temperature detection unit is greater than T3₀And the three-phase currents detected by the three-phase current detection unit are all larger than I₀When the motor overload fault exists, the motor overload fault of the monitored belt conveyor is diagnosed; otherwise, diagnosing that the motor overload fault does not exist in the monitored belt conveyor at the moment; wherein, T3₀Threshold value for preset motor winding temperature determination and T3₀＝115℃～125℃；I₀Threshold value and I is judged for preset motor overload current₀＝A₁×I₁，A₁＝5～8；I₁The rated current of the driving motor is preset;

when the monitored belt conveyor is diagnosed whether the motor heat dissipation fault exists or not, diagnosing according to the temperature value T4 detected by the shell temperature detection unit in the current condition information of the conveyor to be processed: when T4 > T4₀When the motor heat dissipation fault exists, the monitored belt conveyor is diagnosed to have the motor heat dissipation fault; otherwise, diagnosing that the monitored belt conveyor has no motor heat dissipation fault; wherein, T4₀Threshold value for predetermined motor case temperature determination and T4₀＝35℃～45℃；

Step 203, outputting a fault diagnosis result: calling a fault diagnosis result output module, respectively diagnosing whether the monitored belt conveyor has a slip fault, a tearing fault, a roller fault, a smoke fault, a belt breakage fault and a motor fault according to the diagnosis results obtained in the step 202, outputting the fault diagnosis result of the monitored belt conveyor at the moment, and synchronously displaying the output fault diagnosis result of the monitored belt conveyor at the moment;

step 204, early warning judgment: calling an early warning judgment module, and judging whether to perform early warning according to the fault diagnosis result of the monitored belt conveyor output in the step 203: when at least one fault exists in the monitored belt conveyor, judging that the monitored belt conveyor has the fault, and controlling an early warning prompting device to give an alarm prompt; otherwise, judging that the monitored belt conveyor has no fault at the moment.

The method is characterized in that: when the fault diagnosis result is output in step 203, the upper monitor further needs to synchronously display the fault generation reasons of all fault types existing in the monitored belt conveyor and the processing measures suggested to be adopted according to a fault diagnosis database established in advance;

the fault diagnosis database stores fault diagnosis information of multiple fault types of the monitored belt conveyor, and the diagnosis information of each fault type comprises the name of the fault type, the fault generation reason and the suggested treatment measures.

The method is characterized in that: the conveyor working condition detection device in the first step further comprises a middle working condition detection device arranged at the middle position of the monitored belt conveyor, and the middle working condition detection device comprises a second deviation sensor; the machine head working condition detection device further comprises a first deviation sensor, and the machine tail working condition detection device further comprises a third deviation sensor; the first deviation sensor, the second deviation sensor and the third deviation sensor are all connected with the data acquisition device;

the fault diagnosis result also comprises a deviation correlation diagnosis result, and the deviation correlation diagnosis result comprises a deviation correlation diagnosis result of a tearing fault, a deviation correlation diagnosis result of a roller fault and a deviation correlation diagnosis result of a smoking fault;

in the second step, after diagnosing whether the monitored belt conveyor has a tearing fault, when the monitored belt conveyor has a tearing fault, the upper monitoring machine further needs to judge a deviation correlation diagnosis result of the tearing fault according to information detected by the first deviation sensor, the second deviation sensor and the third deviation sensor in the current condition information of the conveyor to be processed: when the first deviation sensor, the second deviation sensor or the third deviation sensor detects that the conveyer belt of the monitored belt conveyor deviates, judging that the deviation correlation diagnosis result of the tearing fault is that the conveyer belt deviates to cause the tearing fault; otherwise, judging that the deviation correlation diagnosis result of the tearing fault is that the tearing fault is irrelevant to the deviation of the conveying belt;

in the second step, after diagnosing whether a roller fault exists in the monitored belt conveyor, when the roller fault exists in the monitored belt conveyor, the upper monitoring machine further needs to judge a deviation correlation diagnosis result of the roller fault at the moment according to information detected by the first deviation sensor, the second deviation sensor and the third deviation sensor in the current to-be-processed conveyor condition information: when the first deviation sensor, the second deviation sensor or the third deviation sensor detects that the conveyer belt of the monitored belt conveyor deviates, judging that the deviation correlation diagnosis result of the roller fault is that the conveyer belt deviates to cause the roller fault; otherwise, judging that the deviation correlation diagnosis result of the roller fault is that the roller fault is irrelevant to the deviation of the conveying belt;

in the second step, after diagnosing whether the monitored belt conveyor has a smoke fault, when the monitored belt conveyor has a smoke fault, the upper monitor further needs to judge a deviation correlation diagnosis result of the smoke fault according to information detected by the first deviation sensor, the second deviation sensor and the third deviation sensor in the current working condition information of the conveyor to be processed: when the first deviation sensor, the second deviation sensor or the third deviation sensor detects that the conveyer belt of the monitored belt conveyor deviates, judging that the deviation correlation diagnosis result of the smoking fault is that the conveyer belt deviates to cause the smoking fault; otherwise, judging that the deviation correlation diagnosis result of the smoking fault is that the smoking fault is irrelevant to the deviation of the conveying belt.

The method is characterized in that: the fault diagnosis result in the second step further comprises a slip fault severity diagnosis result;

when diagnosing whether the monitored belt conveyor has a slip fault in this time in step two, and when diagnosing that the monitored belt conveyor has a slip fault in this time in step 20113, the upper monitor further needs to determine a severity diagnosis result of the slip fault in this time according to the concentration value n detected by the smoke concentration detection unit in the current conveyor condition information to be processed: when n > n₀Judging that the severity diagnosis result of the slip fault is a severe slip fault at the moment; otherwise, judging that the severity diagnosis result of the slip fault is the common slip fault.

The method is characterized in that: t1 stated in step 202₀＝75℃；n₀＝0.1mg/m³，T2₀＝80℃，T3₀＝120℃，T4₀The temperature is higher than 40 ℃; p-15 in step 20112, Q-4 in step 20122; v described in step 20113₀＝0.3m/s。

The method is characterized in that: in the first step, the number of the conveyor working condition detection devices and the number of the data acquisition devices are the same as that of the monitored belt conveyors, the number of the conveyor working condition detection devices and the number of the data acquisition devices are multiple, the plurality of conveyor working condition detection devices respectively detect the working conditions of the monitored belt conveyors in real time, the plurality of conveyor working condition detection devices are respectively connected with the plurality of data acquisition devices, and the plurality of data acquisition devices are all connected with an upper monitor;

when the conveyer working condition information is analyzed and processed in the second step, the upper monitor synchronously analyzes and processes the conveyer working condition information acquired by the data acquisition devices respectively; the analysis and processing methods of the conveyor working condition information acquired by all the data acquisition devices are the same;

when the conveyor working condition information acquired by any data acquisition device is analyzed, the conveyor working condition information acquired at each sampling moment of the data acquisition device is respectively analyzed according to the sampling time sequence, and the monitored belt conveyor is subjected to fault diagnosis according to the analysis processing result to obtain a fault diagnosis result; when the conveyor working condition information acquired at any sampling time of the data acquisition device is analyzed, the analysis is performed according to the method described in the step 201 to the step 204.

Compared with the prior art, the invention has the following advantages:

1. the mining belt conveyor fault monitoring and early warning system is simple in structure, reasonable in design, simple and convenient to install and arrange and low in investment cost.

2. The mining belt conveyor fault monitoring and early warning system is simple and convenient to use and operate, conveyor working condition information detected by the conveyor working condition detection device is synchronously acquired through the data acquisition device and is synchronously transmitted through the data transmitter, and only the received conveyor working condition information needs to be analyzed and processed in the upper monitoring room, so that a technician is not required to monitor the working state of the conveyor in a mine, the labor and the time are saved, and the working environment is safe.

3. The adopted conveyor working condition detection device is small in detection data volume and convenient to install and arrange, and mainly comprises a motor working condition detection device, a machine head working condition detection device arranged at a machine head of a monitored belt conveyor, a middle working condition detection device arranged at a middle position of the monitored belt conveyor and a machine tail working condition detection device arranged at a machine tail of the monitored belt conveyor, wherein each adopted detection device is detection equipment universal for technical personnel in the field, the installation, the arrangement and the use are simple and convenient, the detection precision is reliable, and the device is economical and practical.

4. The adopted conveyor working condition detection device is good in using effect and high in practical value, potential safety hazards existing in the conveyor can be timely and accurately monitored by analyzing and processing the working condition of the monitored belt conveyor in real time, and various types of faults can be diagnosed according to detected conveyor working condition information, so that the popularization and application prospect is wide.

5. The mining belt conveyor fault monitoring and early warning method has the advantages of simple steps, reasonable design, convenience in realization and low investment cost.

6. The mining belt conveyor fault monitoring and early warning method is high in data processing speed, can synchronously analyze and process to obtain a fault diagnosis result of the belt conveyor, and is high in instantaneity.

7. The adopted fault monitoring and early warning method for the mining belt conveyor is simple and convenient to operate, good in using effect and high in practical value, the fault diagnosis module is called to automatically diagnose whether the monitored belt conveyor has slip faults, tearing faults, roller faults, smoke faults, belt breakage faults and motor faults or not, and the diagnosis result is accurate; meanwhile, the fault diagnosis result can be synchronously displayed, and the intuitive, accurate and real-time effective fault diagnosis result is provided. Therefore, the invention can timely and accurately monitor the fault of the mining belt conveyor and can carry out early warning according to the monitoring result, thereby taking corresponding effective treatment measures according to the monitoring result.

The technical solution of the present invention is further described in detail by the accompanying drawings and embodiments.

Drawings

Fig. 1 is a circuit schematic block diagram of the fault monitoring and early warning system of the mine belt conveyor.

Fig. 2 is a flow chart of the fault monitoring and early warning method for the mine belt conveyor.

Description of reference numerals:

1-upper monitor; 2-early warning prompting device;

3-1-a machine head working condition detection device; 3-11-a first off tracking sensor;

3-12-driving roller rotation speed detection unit;

3-13-guide roller rotation speed detection unit;

3-14-smoke concentration detection unit; 3-15-belt speed detecting unit;

3-16-roller bearing temperature detecting unit; 3-2-middle working condition detection device;

3-21-a second deviation sensor; 3-a tail working condition detection device;

3-31-a third deviation sensor; 3-32-tear sensor;

3-4, a motor working condition detection device; 3-41-casing temperature detecting unit;

3-42-three-phase current detection unit; 3-43-three-phase winding temperature detecting unit;

3-44-motor bearing temperature detecting unit; 4-a timing circuit;

5-a data acquisition device; 6-data transmitter.

Detailed Description

As shown in fig. 1, a fault monitoring and early warning system for a mine belt conveyor comprises an upper monitor 1, a conveyor working condition detection device for detecting the working condition of a monitored belt conveyor in real time, a data acquisition device 5 connected with the conveyor working condition detection device, an early warning prompting device 2 controlled by the upper monitor 1, and a timing circuit 4 connected with the upper monitor 1, wherein the early warning prompting device 2 and the data acquisition device 5 are both connected with the upper monitor 1; the monitored belt conveyor is a belt conveyor arranged in a coal mine underground roadway.

The conveyor working condition detection device comprises a motor working condition detection device 3-4, a machine head working condition detection device 3-1 arranged at the machine head of the monitored belt conveyor and a machine tail working condition detection device 3-3 arranged at the machine tail of the monitored belt conveyor; the machine head working condition detection device 3-1 comprises a smoke concentration detection unit 3-14, a belt speed detection unit 3-15 for detecting the belt speed of the monitored belt conveyor in real time, a driving roller rotating speed detection unit 3-12 for detecting the rotating speed of a driving roller arranged on the machine head of the monitored belt conveyor in real time, a guide roller rotating speed detection unit 3-13 for detecting the rotating speed of a guide roller arranged on the machine head of the monitored belt conveyor in real time and a roller bearing temperature detection unit 3-16 for detecting the surface temperature of a roller bearing of the driving roller in real time; the tail working condition detection device 3-3 comprises a tearing sensor 3-32; the motor working condition detection device 3-4 comprises a three-phase current detection unit 3-42 for respectively detecting three-phase currents of a driving motor of the driving roller in real time, a three-phase winding temperature detection unit 3-43 for respectively detecting temperatures of three-phase windings of the driving motor in real time, a motor bearing temperature detection unit 3-44 for detecting temperatures of a motor bearing of the driving motor in real time, and a shell temperature detection unit 3-41 for detecting shell temperatures of the driving motor in real time, wherein the driving roller rotating speed detection unit 3-12, the guide roller rotating speed detection unit 3-13, the smoke concentration detection unit 3-14, the belt speed detection unit 3-15, the roller bearing temperature detection unit 3-16, the tearing sensor 3-32, the three-phase current detection unit 3-42, the smoke concentration detection unit 3-14, the belt speed detection unit 3-15, the roller bearing temperature detection, The three-phase winding temperature detection unit 3-43, the motor bearing temperature detection unit 3-44 and the machine shell temperature detection unit 3-41 are all connected with the data acquisition device 5.

In this embodiment, the fault monitoring and early warning system for the mine belt conveyor further comprises a data transmitter 6 connected with the data acquisition device 5, and the data transmitter 6 is connected with the upper monitor 1 through an optical fiber.

In actual use, the data acquisition device 5 communicates with the upper monitor 1 through the data transmitter 6.

In this embodiment, the number of the conveyor working condition detection devices and the number of the data acquisition devices 5 are both the same as the number of the monitored belt conveyors, and the number of the conveyor working condition detection devices and the number of the data acquisition devices 5 are all multiple, the plurality of conveyor working condition detection devices respectively detect the working conditions of the monitored belt conveyors in real time, the plurality of conveyor working condition detection devices are respectively connected with the plurality of data acquisition devices 5, and the plurality of data acquisition devices 5 are all connected with the upper monitor 1; the monitored belt conveyors are respectively installed in the coal mine underground roadways, the monitored belt conveyors are connected to form a coal mine underground conveying system, and the coal mine underground roadways are development roadways, preparation roadways or stoping roadways.

Meanwhile, the conveyor working condition detection device also comprises a middle working condition detection device 3-2 arranged at the middle position of the monitored belt conveyor, and the middle working condition detection device 3-2 comprises a second deviation sensor 3-21; the machine head working condition detection device 3-1 further comprises a first deviation sensor 3-11, and the machine tail working condition detection device 3-3 further comprises a third deviation sensor 3-31; the first deviation sensor 3-11, the second deviation sensor 3-21 and the third deviation sensor 3-31 are all connected with the data acquisition device 5.

In this embodiment, the first deviation sensor 3-11, the second deviation sensor 3-21, and the third deviation sensor 3-31 are all conventional deviation sensors, and all of the sensors detect whether the conveying belt of the monitored belt conveyor deviates or not and perform deviation alarm. The tearing sensors 3-32 are conventional tearing sensors and detect whether the conveying belt of the monitored belt conveyor is torn or not and carry out tearing alarm.

In this embodiment, the upper monitor 1 is a PC.

In actual use, the upper monitor 1 may also adopt other types of data processing devices.

In this embodiment, the three-phase current detection devices 3 to 42 include three current detection units that respectively detect the three-phase currents of the motor in real time; the three-phase winding temperature detection devices 3 to 43 comprise three temperature sensors for respectively detecting the temperature of the three-phase winding of the motor in real time, and the motor bearing temperature detection devices 3 to 44 and the machine shell temperature detection devices 3 to 41 are all temperature sensors. The belt speed detection unit 3-15 is a speed sensor which detects the linear speed of the conveying belt of the monitored belt conveyor in real time, and the driving roller rotating speed detection unit 3-12 and the guide roller rotating speed detection unit 3-13 are both rotating speed sensors. The motor bearing temperature detection unit 3-44, the machine shell temperature detection unit 3-41 and the roller bearing temperature detection unit 3-16 are all temperature sensors.

In this embodiment, the three-phase currents detected by the three-phase current detection devices 3 to 42 are all line currents.

The guide roller is also called a direction-changing roller, is a common belt conveyor hardware fitting and is mainly used for changing the running direction of a conveying belt or pressing the conveying belt to increase the wrap angle of the conveying belt and a transmission roller. The machine head and the machine tail of the monitored belt conveyor are respectively provided with one guide roller.

As shown in fig. 2, the fault monitoring and early warning method for the mine belt conveyor comprises the following steps:

step one, conveyor working condition detection and synchronous uploading of detection information: the working condition of the monitored belt conveyor is detected in real time by the conveyor working condition detection device, the conveyor working condition information detected by the conveyor working condition detection device is collected by the data collection device 5 according to the preset sampling frequency f, and the collected conveyor working condition information is synchronously transmitted to the upper monitor 1; wherein, f is 1 Hz;

step two, analyzing and processing the working condition information of the conveyor: the upper monitoring machine 1 analyzes and processes the conveyor working condition information acquired at each sampling moment of the data acquisition device 5 according to the sampling time sequence, and performs fault diagnosis on the monitored belt conveyor according to the analysis and processing result to obtain a fault diagnosis result;

when the upper monitoring machine 1 analyzes and processes the conveyor working condition information acquired at any sampling moment of the data acquisition device 5, the process is as follows:

step 20111, slip fault preliminary diagnosis: according to the preset rated belt speed V of the monitored belt conveyor_SJudging the belt speed V detected by the belt speed detection units 3-15 in the current conveyor working condition information to be processed: when 0.3V_SIf V is less than 0.7Vs, the time is the time to be diagnosed, and the step 20112 is entered; otherwise, go to step 20113;

step 20112, further diagnosing the slip fault: for the time to be diagnosed in step 20111The belt speeds V detected by the belt speed detection units 3-15 in the conveyor working condition information collected by the data collection device 5 in the previous continuous P seconds are respectively diagnosed: when the belt speeds V detected by the belt speed detection units 3-15 in the conveyor working condition information collected by the data collection device 5 in continuous P seconds before the moment to be diagnosed are all larger than 0.3V_SAnd when the value is less than 0.7Vs, the slip fault of the monitored belt conveyor at the moment is diagnosed; otherwise, diagnosing that the monitored belt conveyor has no slip fault at the moment; wherein P is a positive integer and P is 10-20; the conveyor working condition information acquired by the data acquisition device 5 in the continuous P seconds before the time to be diagnosed is the conveyor working condition information acquired by the data acquisition device 5 in the continuous P seconds before the time to be diagnosed;

step 20113, further diagnosing the slip fault: according to a preset roller rotation speed difference value V₀And diagnosing the rotating speed value V1 detected by the driving roller rotating speed detection unit 3-12 and the rotating speed value V2 detected by the guide roller rotating speed detection unit 3-13 in the current working condition information of the conveyor to be processed: when | V1-V2| ≧ V₀When the monitored belt conveyor has the slip fault, the slip fault is diagnosed to exist in the monitored belt conveyor; otherwise, diagnosing that the monitored belt conveyor has no slip fault at the moment; wherein, V₀＝0.25m/s～0.35m/s；

When the monitored belt conveyor is diagnosed whether the tearing fault exists or not, the diagnosis is carried out according to the information detected by the tearing sensors 3-32 in the current working condition information of the conveyor to be processed: when the tearing sensors 3-32 in the current working condition information of the conveyor to be processed detect that the conveyor belt of the monitored belt conveyor is torn, the monitored belt conveyor is diagnosed to have tearing faults; otherwise, diagnosing that the monitored belt conveyor has no tearing fault at the moment;

when diagnosing whether the monitored belt conveyor has roller faults or not, diagnosing according to the temperature value T1 detected by the roller bearing temperature detection unit 3-16 in the current working condition information of the conveyor to be processed: when T1 > T1₀When the presence of the roller of the belt conveyor to be monitored at that time is diagnosedA failure; otherwise, diagnosing that the monitored belt conveyor has no roller fault at the moment; wherein, T1₀Threshold value for preset roller bearing temperature determination and T1₀＝70℃～80℃；

When whether the monitored belt conveyor has smoke fault or not is diagnosed, diagnosing according to the concentration value n detected by the smoke concentration detection units 3-14 in the current conveyor condition information to be processed: when n > n₀When the smoke fault exists, the monitored belt conveyor is diagnosed to have the smoke fault; otherwise, diagnosing that the monitored belt conveyor has no smoke fault at the moment; wherein n is₀Determining a threshold value for a preset smoke concentration n₀＝0.08mg/m³～0.12mg/m³；

step 20121, initial diagnosis of belt breakage fault: according to the preset rated belt speed V of the monitored belt conveyor_SJudging the belt speed V detected by the belt speed detection units 3-15 in the current conveyor working condition information to be processed: when V is less than or equal to 0.3V_SIf so, the time to be diagnosed is indicated, and the step 20122 is carried out; otherwise, diagnosing that the belt breakage fault does not exist in the monitored belt conveyor at the moment, and completing the belt breakage fault diagnosis process of the monitored belt conveyor at the moment;

step 20122, further diagnosing belt breakage faults: respectively diagnosing the belt speeds V detected by the belt speed detection units 3-15 in the conveyor working condition information acquired by the data acquisition device 5 in continuous Q seconds before the time to be diagnosed in the step 20121: when the belt speed V detected by the belt speed detection units 3-15 in the conveyor working condition information collected by the data collection device 5 in continuous Q seconds before the moment to be diagnosed is not more than 0.3V_SWhen the belt is broken, the belt broken fault of the monitored belt conveyor is diagnosed; otherwise, diagnosing that the belt breakage fault does not exist in the monitored belt conveyor at the moment; wherein Q is a positive integer and Q is 3-10; wherein, the data acquisition within continuous Q seconds before the time to be diagnosedThe conveyor working condition information acquired by the device 5 is the conveyor working condition information acquired by the data acquisition device 5 in the previous Q seconds of the moment to be diagnosed;

when the monitored belt conveyor is diagnosed to determine whether a motor fault exists, respectively diagnosing whether the monitored belt conveyor has a motor bearing fault, a motor overload fault and a motor heat dissipation fault according to the information detected by the motor working condition detection device 3-4 in the current conveyor working condition information to be processed;

when diagnosing whether the motor bearing fault exists in the monitored belt conveyor at this time, diagnosing according to a temperature value T2 detected by the motor bearing temperature detection units 3-44 in the current conveyor condition information to be processed: when T2 > T2₀When the motor bearing fault exists, the motor bearing fault of the monitored belt conveyor is diagnosed; otherwise, diagnosing that no motor bearing fault exists in the monitored belt conveyor at the moment; wherein, T2₀Threshold value for predetermined motor bearing temperature determination and T2₀＝75℃～85℃；

When the monitored belt conveyor is diagnosed whether the motor overload fault exists or not, the diagnosis is carried out according to the information detected by the three-phase winding temperature detection unit 3-43 and the three-phase current detection unit 3-42 in the current conveyor condition information to be processed: when the temperatures of the three-phase windings detected by the three-phase winding temperature detection units 3-43 are all larger than T3₀And the three-phase currents detected by the three-phase current detection units 3-42 are all larger than I₀When the motor overload fault exists, the motor overload fault of the monitored belt conveyor is diagnosed; otherwise, diagnosing that the motor overload fault does not exist in the monitored belt conveyor at the moment; wherein, T3₀Threshold value for preset motor winding temperature determination and T3₀＝115℃～125℃；I₀Threshold value and I is judged for preset motor overload current₀＝A₁×I₁，A₁＝5～8；I₁The rated current of the driving motor is preset;

at this time, whether the motor exists in the monitored belt conveyor or notWhen the heat dissipation fault is diagnosed, diagnosing according to a temperature value T4 detected by the shell temperature detection units 3-41 in the current working condition information of the conveyor to be processed: when T4 > T4₀When the motor heat dissipation fault exists, the monitored belt conveyor is diagnosed to have the motor heat dissipation fault; otherwise, diagnosing that the monitored belt conveyor has no motor heat dissipation fault; wherein, T4₀Threshold value for predetermined motor case temperature determination and T4₀＝35℃～45℃；

step 204, early warning judgment: calling an early warning judgment module, and judging whether to perform early warning according to the fault diagnosis result of the monitored belt conveyor output in the step 203: when at least one fault exists in the monitored belt conveyor, judging that the monitored belt conveyor has the fault, and controlling the early warning prompting device 2 to give an alarm prompt; otherwise, judging that the monitored belt conveyor has no fault at the moment.

In this embodiment, when the fault diagnosis result is output in step 203, the upper monitor 1 further needs to synchronously display the fault generation reasons of all fault types existing in the monitored belt conveyor and the recommended processing measures according to a fault diagnosis database established in advance;

In this embodiment, the fault diagnosis result in the second step further includes a deviation correlation diagnosis result, where the deviation correlation diagnosis result includes a deviation correlation diagnosis result of a tearing fault, a deviation correlation diagnosis result of a drum fault, and a deviation correlation diagnosis result of a smoking fault;

after diagnosing whether the monitored belt conveyor has the tearing fault or not in the second step, when the monitored belt conveyor has the tearing fault, the upper monitor 1 further needs to judge a deviation correlation diagnosis result of the tearing fault according to information detected by the first deviation sensor 3-11, the second deviation sensor 3-21 and the third deviation sensor 3-31 in the current to-be-processed conveyor working condition information: when the first deviation sensor 3-11, the second deviation sensor 3-21 or the third deviation sensor 3-31 detects that the conveying belt of the monitored belt conveyor deviates, judging that the deviation correlation diagnosis result of the tearing fault at the moment is that the conveying belt deviates to cause the tearing fault; otherwise, judging that the deviation correlation diagnosis result of the tearing fault is that the tearing fault is irrelevant to the deviation of the conveying belt;

in the second step, after diagnosing whether a roller fault exists in the monitored belt conveyor, when the roller fault exists in the monitored belt conveyor, the upper monitor 1 further needs to judge a deviation correlation diagnosis result of the roller fault according to information detected by the first deviation sensor 3-11, the second deviation sensor 3-21 and the third deviation sensor 3-31 in the current information of the working condition of the conveyor to be processed: when the first deviation sensor 3-11, the second deviation sensor 3-21 or the third deviation sensor 3-31 detects that the conveyer belt of the monitored belt conveyor deviates, judging that the deviation correlation diagnosis result of the roller fault at the moment is that the conveyer belt deviates to cause the roller fault; otherwise, judging that the deviation correlation diagnosis result of the roller fault is that the roller fault is irrelevant to the deviation of the conveying belt;

after diagnosing whether the monitored belt conveyor has a smoke fault or not in the second step, when the monitored belt conveyor has a smoke fault, the upper monitor 1 further needs to judge a deviation correlation diagnosis result of the smoke fault according to information detected by the first deviation sensor 3-11, the second deviation sensor 3-21 and the third deviation sensor 3-31 in the current to-be-processed conveyor working condition information: when the first deviation sensor 3-11, the second deviation sensor 3-21 or the third deviation sensor 3-31 detects that the conveying belt of the monitored belt conveyor deviates, judging that the deviation correlation diagnosis result of the smoke fault at the moment is that the conveying belt deviates to cause the smoke fault; otherwise, judging that the deviation correlation diagnosis result of the smoking fault is that the smoking fault is irrelevant to the deviation of the conveying belt.

In this embodiment, the fault diagnosis result in the second step further includes a slip fault severity diagnosis result;

when diagnosing whether the monitored belt conveyor has a slip fault in this time in step two, and when diagnosing that the monitored belt conveyor has a slip fault in this time in step 20113, the upper monitor 1 further needs to determine a severity diagnosis result of the slip fault in this time according to the concentration value n detected by the smoke concentration detection units 3 to 14 in the current conveyor condition information to be processed: when n > n₀Judging that the severity diagnosis result of the slip fault is a severe slip fault at the moment; otherwise, judging that the severity diagnosis result of the slip fault is the common slip fault.

In this embodiment, step 202 is T1₀＝75℃；n₀＝0.1mg/m³，T2₀＝80℃，T3₀＝120℃，T4₀The temperature is higher than 40 ℃; p-15 in step 20112, Q-4 in step 20122; v described in step 20113₀＝0.3m/s。

In actual use, the T1 can be used according to specific requirements₀、n₀、T2₀、T3₀、T4₀P, Q and V₀The values of the two are respectively adjusted correspondingly.

In this embodiment, when the conveyor condition information is analyzed and processed in the second step, the upper monitor 1 synchronously analyzes and processes the conveyor condition information acquired by the data acquisition devices 5 respectively; moreover, the analysis and processing methods of the conveyor working condition information acquired by all the data acquisition devices 5 are the same;

when the conveyor working condition information acquired by any one data acquisition device 5 is analyzed, the conveyor working condition information acquired at each sampling moment of the data acquisition device 5 is respectively analyzed according to the sampling time sequence, and the monitored belt conveyor is subjected to fault diagnosis according to the analysis processing result to obtain a fault diagnosis result; when analyzing the conveyor working condition information acquired at any sampling time of the data acquisition device 5, the analysis is performed according to the method described in step 201 to step 204.

In this embodiment, the cause of the slip fault stored in the fault diagnosis database is that the wear of the conveyor belt is severe due to aging after long-term use, and the friction force of the driving roller is insufficient or the monitored belt conveyor bears an excessive load.

The tearing fault generation reasons stored in the fault diagnosis database are that sundries such as large coal gangue rolled into a coal flow line cut the belt surface of the monitored belt conveyor, and coal blocks scattered at the bottom of the monitored belt conveyor cut the lower belt or the monitored belt conveyor is seriously deviated.

The failure generation reason of the roller failure stored in the failure diagnosis database is that the roller inner bearing is damaged, the oil is lacked, the main shaft is damaged or the winding drum is abraded and deformed due to the deviation of the conveying belt of the monitored belt conveyor.

The failure generation reason of the smoking failure stored in the failure diagnosis database is friction heat generation smoking caused by abnormal contact of the deviation of the conveying belt of the monitored belt conveyor with the roller and the rack, and fire is caused when the friction heat generation smoking is serious.

The failure cause of the belt breakage failure stored in the failure diagnosis database is that the conveyor belt is aged due to a joint or the tension of the conveyor belt is large or the belt conveyor is stuck by large coal or gangue.

The fault generation reason of the motor fault stored in the fault diagnosis database is short circuit caused by breakdown due to the fact that the motor heats to promote insulation aging and cracking of the enameled wire and reduction of insulation performance due to long-time overload operation; or the internal speed reducer, the coupling and other parts of the motor lack oil, and the internal bearing is seriously abraded, so that abnormal noise and heating phenomena occur in the motor.

And the suggested processing measures stored in the fault diagnosis database correspond to the fault generation reasons one by one, and the suggested processing measures are measures which are summarized by technical personnel in the field according to experience and common knowledge and are suitable for processing the fault caused by the corresponding fault generation reasons.

The above description is only a preferred embodiment of the present invention, and is not intended to limit the present invention, and all simple modifications, changes and equivalent structural changes made to the above embodiment according to the technical spirit of the present invention still fall within the protection scope of the technical solution of the present invention.

Claims

1. The utility model provides a mine belt conveyor fault monitoring early warning system which characterized in that: the monitoring system comprises an upper monitoring machine (1), a conveyor working condition detection device for detecting the working condition of a monitored belt conveyor in real time, a data acquisition device (5) connected with the conveyor working condition detection device, an early warning prompting device (2) controlled by the upper monitoring machine (1) and a timing circuit (4) connected with the upper monitoring machine (1), wherein the early warning prompting device (2) and the data acquisition device (5) are both connected with the upper monitoring machine (1); the monitored belt conveyor is a belt conveyor arranged in an underground roadway of a coal mine;

the conveyor working condition detection device comprises a motor working condition detection device (3-4), a machine head working condition detection device (3-1) arranged at the machine head of the monitored belt conveyor and a machine tail working condition detection device (3-3) arranged at the machine tail of the monitored belt conveyor; the machine head working condition detection device (3-1) comprises a smoke concentration detection unit (3-14), a belt speed detection unit (3-15) for detecting the belt speed of the monitored belt conveyor in real time, a driving roller rotating speed detection unit (3-12) for detecting the rotating speed of a driving roller installed on the machine head of the monitored belt conveyor in real time, a guide roller rotating speed detection unit (3-13) for detecting the rotating speed of a guide roller installed on the machine head of the monitored belt conveyor in real time and a roller bearing temperature detection unit (3-16) for detecting the surface temperature of a roller bearing of the driving roller in real time; the tail working condition detection device (3-3) comprises a tearing sensor (3-32); the motor working condition detection device (3-4) comprises a three-phase current detection unit (3-42) for respectively detecting the three-phase current of the driving motor of the driving roller in real time, a three-phase winding temperature detection unit (3-43) for respectively detecting the temperature of the three-phase winding of the driving motor in real time, a motor bearing temperature detection unit (3-44) for detecting the temperature of the motor bearing of the driving motor in real time, and a casing temperature detection unit (3-41) for detecting the casing temperature of the driving motor in real time, wherein the driving roller rotating speed detection unit (3-12), the guide roller rotating speed detection unit (3-13), the smoke concentration detection unit (3-14), the belt speed detection unit (3-15), the roller bearing temperature detection unit (3-16), The tearing sensor (3-32), the three-phase current detection unit (3-42), the three-phase winding temperature detection unit (3-43), the motor bearing temperature detection unit (3-44) and the case temperature detection unit (3-41) are all connected with the data acquisition device (5).

2. The mine belt conveyor fault monitoring and early warning system of claim 1, wherein: the monitoring system is characterized by further comprising a data transmitter (6) connected with the data acquisition device (5), wherein the data transmitter (6) is connected with the upper monitoring machine (1) through an optical fiber.

3. The mine belt conveyor fault monitoring and early warning system of claim 1 or 2, characterized in that: the number of the conveyor working condition detection devices and the number of the data acquisition devices (5) are the same as that of the monitored belt conveyors, the number of the conveyor working condition detection devices and the number of the data acquisition devices are multiple, the plurality of conveyor working condition detection devices respectively detect the working conditions of the monitored belt conveyors in real time, the plurality of conveyor working condition detection devices are respectively connected with the plurality of data acquisition devices (5), and the plurality of data acquisition devices (5) are all connected with an upper monitoring machine (1); the monitored belt conveyors are respectively installed in the coal mine underground roadways, the monitored belt conveyors are connected to form a coal mine underground conveying system, and the coal mine underground roadways are development roadways, preparation roadways or stoping roadways.

4. The mine belt conveyor fault monitoring and early warning system of claim 1 or 2, characterized in that: the conveyor working condition detection device also comprises a middle working condition detection device (3-2) arranged at the middle position of the monitored belt conveyor, and the middle working condition detection device (3-2) comprises a second deviation sensor (3-21); the machine head working condition detection device (3-1) further comprises a first deviation sensor (3-11), and the machine tail working condition detection device (3-3) further comprises a third deviation sensor (3-31); the first deviation sensor (3-11), the second deviation sensor (3-21) and the third deviation sensor (3-31) are all connected with the data acquisition device (5).

5. A method for monitoring and early warning of faults of a mine belt conveyor by using the system as claimed in claim 1, wherein the method comprises the following steps: the method comprises the following steps:

step one, conveyor working condition detection and synchronous uploading of detection information: the working condition of the monitored belt conveyor is detected in real time by the conveyor working condition detection device, the conveyor working condition information detected by the conveyor working condition detection device is collected by a data collection device (5) according to a preset sampling frequency f, and the collected conveyor working condition information is synchronously transmitted to an upper monitor (1); wherein, f is 1 Hz;

step two, analyzing and processing the working condition information of the conveyor: the upper monitoring machine (1) analyzes and processes the conveyor working condition information acquired at each sampling moment of the data acquisition device (5) according to the sampling time sequence, and performs fault diagnosis on the monitored belt conveyor according to the analysis and processing result to obtain a fault diagnosis result;

when the upper monitoring machine (1) analyzes and processes the conveyor working condition information acquired at any sampling moment of the data acquisition device (5), the process is as follows:

step 20111, slip fault preliminary diagnosis: according to the preset rated belt speed V of the monitored belt conveyor_SJudging the belt speed V detected by the belt speed detecting unit (3-15) in the current working condition information of the conveyor to be processed: when 0.3V_SIf V is less than 0.7Vs, the time is the time to be diagnosed, and the step 20112 is entered; otherwise, go to step 20113;

step 20112, further diagnosing the slip fault: respectively diagnosing the belt speeds V detected by the belt speed detection units (3-15) in the conveyor working condition information acquired by the data acquisition device (5) within continuous P seconds before the time to be diagnosed in the step 20111: when the belt speed V detected by the belt speed detecting units (3-15) in the conveyor working condition information collected by the data collecting device (5) in continuous P seconds before the moment to be diagnosed is greater than 0.3V_SAnd when the value is less than 0.7Vs, the slip fault of the monitored belt conveyor at the moment is diagnosed; otherwise, diagnosing that the monitored belt conveyor has no slip fault at the moment; wherein P is a positive integer and P is 10-20;

step 20113, further diagnosing the slip fault: according to a preset roller rotation speed difference value V₀And diagnosing a rotating speed value V1 detected by a driving roller rotating speed detection unit (3-12) and a rotating speed value V2 detected by a guide roller rotating speed detection unit (3-13) in the current to-be-processed conveyor condition information: when | V1-V2| ≧ V₀When the monitored belt conveyor has the slip fault, the slip fault is diagnosed to exist in the monitored belt conveyor; otherwise, diagnosing that the monitored belt conveyor has no slip fault at the moment; wherein, V₀＝0.25m/s～0.35m/s；

When the monitored belt conveyor is diagnosed whether tearing faults exist or not, the diagnosis is carried out according to the information detected by the tearing sensors (3-32) in the current condition information of the conveyor to be processed: when the tearing sensor (3-32) in the current to-be-processed conveyor condition information detects that the conveyor belt of the monitored belt conveyor is torn, the monitored belt conveyor is diagnosed to have tearing faults; otherwise, diagnosing that the monitored belt conveyor has no tearing fault at the moment;

when the monitored belt conveyor is diagnosed whether a roller fault exists or not, diagnosing according to a temperature value T1 detected by roller bearing temperature detection units (3-16) in the current working condition information of the conveyor to be processed: when T1 > T1₀When the monitored belt conveyor has a roller, the method diagnoses that the monitored belt conveyor has the rollerA barrier; otherwise, diagnosing that the monitored belt conveyor has no roller fault at the moment; wherein, T1₀Threshold value for preset roller bearing temperature determination and T1₀＝70℃～80℃；

When whether the monitored belt conveyor has smoke fault or not is diagnosed, diagnosing according to the concentration value n detected by the smoke concentration detection units (3-14) in the current conveyor condition information to be processed: when n > n₀When the smoke fault exists, the monitored belt conveyor is diagnosed to have the smoke fault; otherwise, diagnosing that the monitored belt conveyor has no smoke fault at the moment; wherein n is₀Determining a threshold value for a preset smoke concentration n₀＝0.08mg/m³～0.12mg/m³；

step 20121, initial diagnosis of belt breakage fault: according to the preset rated belt speed V of the monitored belt conveyor_SAnd judging the belt speed V detected by a belt speed detection unit (3-15) in the current conveyor condition information to be processed: when V is less than or equal to 0.3V_SIf so, the time to be diagnosed is indicated, and the step 20122 is carried out; otherwise, diagnosing that the belt breakage fault does not exist in the monitored belt conveyor at the moment, and completing the belt breakage fault diagnosis process of the monitored belt conveyor at the moment;

step 20122, further diagnosing belt breakage faults: respectively diagnosing the belt speeds V detected by the belt speed detection units (3-15) in the conveyor working condition information acquired by the data acquisition device (5) in continuous Q seconds before the time to be diagnosed in the step 20121: when the belt speed V detected by the belt speed detecting unit (3-15) in the conveyor working condition information collected by the data collecting device (5) in continuous Q seconds before the moment to be diagnosed is not more than 0.3V_SWhen the belt is broken, the belt broken fault of the monitored belt conveyor is diagnosed; otherwise, diagnosing that the belt breakage fault does not exist in the monitored belt conveyor at the moment; wherein Q is a positive integer and Q is 3-10;

when the monitored belt conveyor is diagnosed to determine whether a motor fault exists, respectively diagnosing whether the monitored belt conveyor has a motor bearing fault, a motor overload fault and a motor heat dissipation fault according to the information detected by the motor working condition detection device (3-4) in the current conveyor working condition information to be processed;

when the monitored belt conveyor is diagnosed whether a motor bearing fault exists or not, diagnosing according to a temperature value T2 detected by a motor bearing temperature detection unit (3-44) in the current conveyor condition information to be processed: when T2 > T2₀When the motor bearing fault exists, the motor bearing fault of the monitored belt conveyor is diagnosed; otherwise, diagnosing that no motor bearing fault exists in the monitored belt conveyor at the moment; wherein, T2₀Threshold value for predetermined motor bearing temperature determination and T2₀＝75℃～85℃；

When the motor overload fault of the monitored belt conveyor is diagnosed, diagnosing according to the information detected by the three-phase winding temperature detection unit (3-43) and the three-phase current detection unit (3-42) in the current conveyor condition information to be processed: when the temperature of the three-phase winding detected by the three-phase winding temperature detection units (3-43) is more than T3₀And the three-phase currents detected by the three-phase current detection units (3-42) are all larger than I₀When the motor overload fault exists, the motor overload fault of the monitored belt conveyor is diagnosed; otherwise, diagnosing that the motor overload fault does not exist in the monitored belt conveyor at the moment; wherein, T3₀Threshold value for preset motor winding temperature determination and T3₀＝115℃～125℃；I₀Threshold value and I is judged for preset motor overload current₀＝A₁×I₁，A₁＝5～8；I₁The rated current of the driving motor is preset;

when the monitored belt conveyor is diagnosed whether the motor heat dissipation fault exists or not, diagnosing according to a temperature value T4 detected by a shell temperature detection unit (3-41) in the current conveyor condition information to be processed: when T4 > T4₀When the motor heat dissipation fault exists, the monitored belt conveyor is diagnosed to have the motor heat dissipation fault; otherwise, diagnosing that the monitored belt conveyor has no motor heat dissipation fault; wherein, T4₀For preset electricityThreshold value for judging temperature of machine shell and T4₀＝35℃～45℃；

step 204, early warning judgment: calling an early warning judgment module, and judging whether to perform early warning according to the fault diagnosis result of the monitored belt conveyor output in the step 203: when at least one fault exists in the monitored belt conveyor, judging that the monitored belt conveyor has the fault, and controlling the early warning prompting device (2) to give an alarm prompt; otherwise, judging that the monitored belt conveyor has no fault at the moment.

6. The method of claim 5, wherein: when the fault diagnosis result is output in step 203, the upper monitor (1) further needs to synchronously display the fault generation reasons of all fault types existing in the monitored belt conveyor and the processing measures suggested to be adopted according to a fault diagnosis database established in advance;

7. The method of claim 5 or 6, wherein: the conveyor working condition detection device in the first step further comprises a middle working condition detection device (3-2) arranged at the middle position of the monitored belt conveyor, and the middle working condition detection device (3-2) comprises a second deviation sensor (3-21); the machine head working condition detection device (3-1) further comprises a first deviation sensor (3-11), and the machine tail working condition detection device (3-3) further comprises a third deviation sensor (3-31); the first deviation sensor (3-11), the second deviation sensor (3-21) and the third deviation sensor (3-31) are all connected with the data acquisition device (5);

after whether the monitored belt conveyor has the tearing fault or not is diagnosed in the second step, when the monitored belt conveyor has the tearing fault, the upper monitoring machine (1) also needs to judge a deviation correlation diagnosis result of the tearing fault according to information detected by a first deviation sensor (3-11), a second deviation sensor (3-21) and a third deviation sensor (3-31) in the current to-be-processed conveyor working condition information: when the first deviation sensor (3-11), the second deviation sensor (3-21) or the third deviation sensor (3-31) detects that the conveyer belt of the monitored belt conveyor deviates, judging that the deviation correlation diagnosis result of the tearing fault is that the conveyer belt deviates to cause the tearing fault; otherwise, judging that the deviation correlation diagnosis result of the tearing fault is that the tearing fault is irrelevant to the deviation of the conveying belt;

in the second step, after diagnosing whether a roller fault exists in the monitored belt conveyor, when the roller fault exists in the monitored belt conveyor, the upper monitoring machine (1) further needs to judge a deviation correlation diagnosis result of the roller fault at the moment according to information detected by a first deviation sensor (3-11), a second deviation sensor (3-21) and a third deviation sensor (3-31) in the current to-be-processed conveyor working condition information: when the first deviation sensor (3-11), the second deviation sensor (3-21) or the third deviation sensor (3-31) detects that the conveyer belt of the monitored belt conveyor deviates, judging that the deviation correlation diagnosis result of the roller fault is that the conveyer belt deviates to cause the roller fault; otherwise, judging that the deviation correlation diagnosis result of the roller fault is that the roller fault is irrelevant to the deviation of the conveying belt;

after diagnosing whether the monitored belt conveyor has a smoke fault or not in the second step, when the monitored belt conveyor has the smoke fault, the upper monitor (1) further needs to judge a deviation correlation diagnosis result of the smoke fault at the moment according to information detected by a first deviation sensor (3-11), a second deviation sensor (3-21) and a third deviation sensor (3-31) in the current condition information of the conveyor to be processed: when the first deviation sensor (3-11), the second deviation sensor (3-21) or the third deviation sensor (3-31) detects that the conveying belt of the monitored belt conveyor deviates, judging that the deviation correlation diagnosis result of the smoking fault is that the conveying belt deviates to cause the smoking fault; otherwise, judging that the deviation correlation diagnosis result of the smoking fault is that the smoking fault is irrelevant to the deviation of the conveying belt.

8. The method of claim 5 or 6, wherein: the fault diagnosis result in the second step further comprises a slip fault severity diagnosis result;

when diagnosing whether the monitored belt conveyor has a slip fault in this time in step two, and when diagnosing that the monitored belt conveyor has a slip fault in this time in step 20113, the upper monitor (1) further needs to judge a severity diagnosis result of the slip fault according to a concentration value n detected by the smoke concentration detection unit (3-14) in the current condition information of the conveyor to be processed: when n > n₀Judging that the severity diagnosis result of the slip fault is a severe slip fault at the moment; otherwise, judging that the severity diagnosis result of the slip fault is the common slip fault.

9. The method of claim 5 or 6, wherein: t1 stated in step 202₀＝75℃；n₀＝0.1mg/m³，T2₀＝80℃，T3₀＝120℃，T4₀The temperature is higher than 40 ℃; p-15 in step 20112, Q-4 in step 20122; v described in step 20113₀＝0.3m/s。

10. The method of claim 5 or 6, wherein: in the first step, the number of the conveyor working condition detection devices and the number of the data acquisition devices (5) are the same as that of the monitored belt conveyors, the number of the conveyor working condition detection devices is multiple, the plurality of conveyor working condition detection devices respectively detect the working conditions of the monitored belt conveyors in real time, the plurality of conveyor working condition detection devices are respectively connected with the plurality of data acquisition devices (5), and the plurality of data acquisition devices (5) are connected with an upper monitoring machine (1);

when the conveyor working condition information is analyzed and processed in the second step, the upper monitor (1) synchronously analyzes and processes the conveyor working condition information acquired by the data acquisition devices (5) respectively; besides, the analysis and processing methods of the conveyor working condition information acquired by all the data acquisition devices (5) are the same;

when the conveyor working condition information acquired by any one data acquisition device (5) is analyzed, the conveyor working condition information acquired at each sampling moment of the data acquisition device (5) is respectively analyzed according to the sampling time sequence, and the monitored belt conveyor is subjected to fault diagnosis according to the analysis processing result to obtain a fault diagnosis result; when the conveyor working condition information acquired at any sampling time of the data acquisition device (5) is analyzed, the analysis is performed according to the method from step 201 to step 204.