CN106429301A - Belt monitoring early warning device based on ultrasonic waves - Google Patents

Abstract

The invention discloses an ultrasonic-based belt monitoring and alarm device, which adopts the principle of non-contact ultrasonic measurement, and effectively avoids failures such as missed and false alarms caused by travel switch measurement affected by the contact environment. The monitoring and alarming device measures and obtains the distance value from the ultrasonic rangefinder to the two edges of the belt through the ultrasonic distance measuring sensor, and compares the two sets of distance data to determine whether the belt deviates and the direction of the deviation. Send alerts in time to protect belt equipment from damage. The system uses very few equipment and original parts, simple structure, high detection reliability, low system maintenance cost, and is convenient for popularization and application in various transport belt use industries.

Description

Belt Monitoring and Alarming Device Based on Ultrasonic

technical field

The invention relates to an ultrasonic-based belt monitoring and alarm device, which relates to the fields of ultrasonic distance measurement and communication.

Background technique

Conveyor belts are important equipment for short-distance transportation of materials, and are widely used in mining, agriculture, food, tobacco and other production industries. Belt deviation is a common fault in the operation of the conveyor belt, but it is easy to cause great harm. Generally, the deviation of the belt will cause material spreading and belt wear; in the case of serious deviation, it is easy to cause severe friction between the belt and the frame, which will cause the belt to soften, burn and even cause a fire, causing the entire production line to stop production, replace the belt and repair it. The equipment takes a long time, which directly affects the normal production. Therefore, timely and accurate detection of belt deviation is of great significance. At present, the main method of belt deviation detection is to use the deviation detection switch, that is, the travel switch. When in use, the limit switches are installed in pairs at the head or tail of the conveyor. When the belt deviates, the edge of the belt contacts and presses the contact of the limit switch to generate a movement and trigger an alarm. The deviation detection switch is a mechanical switch that adopts a contact detection method. When it is used in a relatively harsh production environment such as a coal mine, it is easily affected by coal dust, mud, oil sludge, etc., and it is prone to false alarms and false alarms. Wait for failure. Therefore, the failure rate of the deviation detection switch is relatively high. In order to ensure the normal operation of the deviation detection switch, full-time personnel are required to manually maintain the switch regularly, and the labor cost is relatively high.

Therefore, there is a need for a new method and new equipment for detecting the deviation of the transport belt that uses the principle of non-contact detection, is reliable in operation, is easy to implement, and has low maintenance costs.

Contents of the invention

The object of the present invention is to provide a belt monitoring and alarming device based on ultrasonic waves, which adopts the principle of non-contact detection, and is reliable in operation and low in maintenance cost. The monitoring and alarm device mainly includes an ultrasonic distance measuring unit, a human-computer interaction unit, a data processing unit, a communication unit and an alarm unit; the specific functions of each unit of the monitoring and alarm device are as follows:

1. The ultrasonic distance measuring unit is used to collect the distance data from the ultrasonic sensor to the two edges of the belt, including two ultrasonic distance measuring sensors, which are respectively installed above the two edges of the transport belt, and the installation height is the same, and the installation height is higher than the height of the material; The line connecting the center positions of the two ultrasonic ranging sensors is perpendicular to the running direction of the belt.

2. The human-computer interaction unit includes buttons and a display screen. The buttons are used to set and operate detection-related parameters, and the display screen is used for data display.

3. The communication unit includes an input port and an output port; the input port is used to receive the distance data sent by the ultrasonic ranging sensor; the output port is used to send the deviation alarm data of the data processing unit to the alarm unit and the belt control device, and the alarm unit performs Sound and light alarm, control the belt to stop running through the belt control device.

4. The data processing unit compares the difference between the distance data measured by the two ultrasonic distance measuring sensors. When the absolute value of the difference exceeds the set threshold, the deviation direction is determined according to the positive or negative of the difference, and is sent through the communication unit. Belt deviation alarm data; the threshold value is obtained through on-site measurement setting or artificial setting.

5. The alarm unit is used for sound and light alarm.

Description of drawings

Figure 1 is a schematic diagram of an ultrasonic-based belt monitoring and alarming device.

Figure 2 is a schematic diagram of the installation of an ultrasonic-based belt monitoring and alarm device.

Fig. 3 is a schematic diagram of the monitoring and alarming implementation process of the ultrasonic-based belt monitoring and alarming device.

Figure 4. Schematic diagram of comparison of distance data on both sides when the belt does not deviate.

Figure 5. Schematic diagram of comparison of distance data on both sides when the belt deviates.

detailed description

In the embodiment shown in Figure 1, the monitoring and alarming device includes:

1. Ultrasonic ranging unit (101), which adopts a small beam angle transmitting and receiving integrated ultrasonic ranging sensor (102) with a ranging distance greater than 3 meters, and can use the KS109 ultrasonic ranging module of Shenzhen Guidance Electromechanical Technology Co., Ltd.

2. The communication unit (103) includes an input port (104) and an input port (105), the data input port is connected to the measurement data sent by an ultrasonic distance measuring sensor (102), and adopts the I2C bus communication mode. The data output port sends the data to other equipment, and uses RS485 communication to connect with the alarm unit, belt control equipment (such as PLC) and other monitoring equipment. When the belt deviates, it sends an alarm signal to control the belt to stop running and protect related equipment.

3. The human-computer interaction unit (106), including a display screen (107) and buttons (108), the display screen adopts a two-line dot-matrix LCD liquid crystal display module, and the viewing area size: 60.5×18.0mm, 54.8×18.3m. The design uses 4 buttons, adopts an independent button-type keyboard, and combines with the display interface of the display screen to realize the function of setting and operating the detection-related parameters.

4. The alarm unit (109) adopts an audible and visual alarm (110) with a horn and an alarm lamp to realize the audible and visual alarm function, and communicates with the communication unit through the RS485 interface.

5. The data processing unit (111), and the processor (112) are used to perform data comparison processing work, which can be implemented using MCU or FPGA.

6. Auxiliary circuit (113), in addition to the above-mentioned unit equipment, the device also includes auxiliary circuits such as power supply circuits and related components to provide support for each unit equipment component. For example, all components and circuits used in coal mines should comply with Intrinsic safety requirements.

Refer to Figure 2 for the installation diagram of the monitoring and alarm device:

1. The ultrasonic distance measuring sensors (203) are respectively installed on the support (202), above the two edges of the transport belt (201), and the installation heights are the same, and the installation height is higher than the height of the material. In order to ensure the monitoring accuracy, the ultrasonic distance measuring sensors It should be as close as possible to the belt surface; the line connecting the centers of the two ultrasonic distance measuring sensors is perpendicular to the running direction of the belt.

2. Other unit elements except the ultrasonic distance measuring unit are concentrated in the device casing (204), and the device casing can be installed on the bracket.

The specific implementation steps of the device monitoring and alarm are shown in Figure 3:

1. (301) Determine whether the device has been calibrated, if not, perform position calibration (302), if calibrated, execute (303). Direct detection.

2. (302) Position calibration. During calibration, it is necessary to measure the belt with a normal position using an ultrasonic distance measuring device to obtain the distances A _L and A _R from the ultrasonic wave to the edge of the belt, and calculate A _L -A _R , such as |A _L -A _R |>G, then adjust the inclination of the support (202) to make |A _L -A _R |<G. G is the set threshold, which is obtained through on-site measurement settings or artificial settings.

3. (303) The communication unit receives the measurement by the ultrasonic range finder to obtain the distances _BL and _BR from the ultrasonic range finder to the edge of the belt.

4. (304) The comparator of the data processing unit compares the edge distance of the real-time belt, if |B _L -B _R | > F, then execute (305), otherwise return to (303). F is the set threshold, which is obtained through on-site measurement or artificial setting.

5. (305) Judging whether B _L -B _R is greater than zero, if greater than zero, the belt will deviate to the right, and if it is less than zero, then the belt will deviate to the left.

6. (306) The communication unit sends deviation and deviation direction alarm logic data to the human-computer interaction unit, the alarm unit and the belt control device, the alarm unit gives an audible and visual alarm, the display displays relevant information, and the belt control device controls the belt to stop running.

Claims (3)

1. A belt monitoring and alarming device based on ultrasonic waves, characterized in that: the device mainly includes ultrasonic ranging unit, human-computer interaction unit, data processing unit, communication unit and alarm unit; ultrasonic ranging unit is used to collect ultrasonic sensors to belt The distance data of the two edges, including two ultrasonic distance measuring sensors; the two ultrasonic distance measuring sensors are respectively installed above the two edges of the conveyor belt, the installation height is the same, and the installation height is higher than the height of the material; the center position of the two ultrasonic distance measuring sensors The connection line is perpendicular to the running direction of the belt; the data processing unit is responsible for processing the distance data collected by the ultrasonic distance measuring sensor, and obtains the data of whether the belt deviates and the direction of the deviation; the human-computer interaction unit includes buttons and a display screen, and the buttons are used for Set the detection-related parameters, and the display screen is used for data display; the communication unit is responsible for receiving data from the ultrasonic ranging sensor and sending alarm data; the alarm unit is used for sound and light alarms. 2. The monitoring and alarm device according to claim 1, characterized in that: the data processing unit compares the distance data obtained by the measurement of two ultrasonic distance measuring sensors, and when the absolute value of the difference exceeds the set threshold, then according to The difference is positive or negative to determine the deviation direction, and the belt deviation alarm data is sent through the communication unit; the threshold value is obtained by on-site measurement or artificial setting. 3. The monitoring and alarm device according to claim 1, characterized in that: the communication unit includes an input port and an output port; the input port is used to receive the distance data sent by the ultrasonic ranging sensor; the output port is used to use the running data of the data processing unit The partial alarm data is sent to the alarm unit and the belt control equipment, the alarm unit gives an audible and visual alarm, and the belt is controlled by the belt control equipment to stop running.