CN110040468B - Fault diagnosis method and device for belt conveyor - Google Patents
Fault diagnosis method and device for belt conveyor Download PDFInfo
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- CN110040468B CN110040468B CN201810035164.6A CN201810035164A CN110040468B CN 110040468 B CN110040468 B CN 110040468B CN 201810035164 A CN201810035164 A CN 201810035164A CN 110040468 B CN110040468 B CN 110040468B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
- B65G43/02—Control devices, e.g. for safety, warning or fault-correcting detecting dangerous physical condition of load carriers, e.g. for interrupting the drive in the event of overheating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
- B65G43/04—Control devices, e.g. for safety, warning or fault-correcting detecting slip between driving element and load-carrier, e.g. for interrupting the drive
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Abstract
The invention provides a fault diagnosis method and a fault diagnosis device for a belt conveyor, which are characterized in that a first linear speed of the surface of the belt conveyor is calculated according to a first running image of the surface of the belt conveyor, which is acquired by a first image acquisition device; and then diagnosing various faults of the belt conveyor according to the first linear speed, the driving line speed, the bend linear speed and the normal working speed of the belt conveyor. The first linear speed of the surface of the belt conveyor is calculated by acquiring the first running image through the first image acquisition device, and a sensor is not required to be installed at certain specific positions on the belt conveyor, so that the structure of the belt conveyor is not required to be modified, and the difficulty in disassembly and maintenance can be reduced; and the overload fault, the belt tearing fault, the slipping fault, the dead-locking fault of the turnabout drum and the failure reversing fault of the coupling of the belt conveyor can be diagnosed through the first linear speed, the driving line speed, the turnabout linear speed and the normal working speed of the belt conveyor, so that the fault of the belt conveyor can be fully diagnosed.
Description
Technical Field
The application relates to the technical field of fault diagnosis, in particular to a fault diagnosis method and device for a belt conveyor.
Background
The belt conveyor is an important continuous conveying machine and plays an important role in the transportation of bulk materials. The belt conveyor usually has a severe working environment and needs to operate for a long time, so that faults often occur, and the faults need to be detected and eliminated in time so as to avoid accidents. However, the belt conveyor needs to detect a plurality of fault points, has a large workload, and requires high detection precision, so that it is generally difficult to detect and remove faults through human sense organs and engineering experience, and particularly, a long-distance large-capacity belt conveyor is inconvenient to make accurate diagnosis of faults, and in addition, the defects in the aspects of technology and production management cause belt conveyor accidents to occur frequently.
In the prior art, the fault of the belt conveyor is mainly detected by using speed information of the belt conveyor, generally, the speed information of the belt conveyor is detected by using a sensor arranged at some specific position of the belt conveyor, for example, the rotation speed of a pinch roller is measured by the sensor, then the belt speed is calculated according to the rotation speed and the outer diameter of the pinch roller (or the rotation speed of a roller is measured and then the belt speed is calculated), and then the fault is diagnosed according to the detected speed information.
However, the prior art adopts a sensor detection mode to have many disadvantages, firstly, the structure of the belt conveyor needs to be modified (opening, punching and the like) to install the sensor on the belt conveyor, and once the sensor fails, the disassembly and the maintenance consume time and labor; secondly, the belt conveyor faults detected by the speed information detected by the sensors at certain specific positions are less and cannot be fully diagnosed, for example, the sensor for measuring the rotating speed of the pinch roller may not be able to diagnose the coupler failure reversal faults, the belt breakage faults, the belt conveyor overload faults, the bend pulley blocking faults, the belt slip faults caused by the loosening of the belt and the like.
Disclosure of Invention
In view of the above, the present invention provides a method and an apparatus for diagnosing a fault of a belt conveyor, which are used to reduce maintenance difficulty and fully diagnose a fault of a belt conveyor.
The technical scheme provided by the invention is as follows:
a fault diagnosis method of a belt conveyor comprises the following steps:
acquiring a first running image of the surface of the belt conveyor, acquired by a first image acquisition device, and calculating a first linear speed of the surface of the belt conveyor according to the first running image;
acquiring a driving rotating speed of a driving roller of the belt conveyor and a redirection rotating speed of a redirection roller, which are acquired by a speed measuring device, calculating the driving wire speed of the driving roller according to the driving rotating speed and the diameter of the driving roller, and calculating the redirection linear speed of the redirection roller according to the redirection rotating speed and the diameter of the redirection roller;
and diagnosing overload faults, belt tearing faults, slipping faults, dead-locking faults of the turnabout drum and failure and reversal faults of a coupler of the belt conveyor according to the first linear speed, the driving linear speed, the turnabout linear speed and the normal working speed of the belt conveyor.
Preferably, first color blocks and second color blocks which are arranged alternately are arranged on the surface of the belt conveyor, and the length of each first color block is equal;
then, the acquiring a first operation image of the surface of the belt conveyor, which is acquired by a first image acquisition device, and calculating a first linear velocity of the surface of the belt conveyor according to the first operation image includes:
acquiring the first running image of the surface of the belt conveyor, acquired by the first image acquisition device, and calculating first passing time of the first color block passing through the first image acquisition device according to the first running image;
and calculating a first passing speed of the first color block passing through the first image acquisition device according to the first passing time and the length of the first color block, and determining the first passing speed as a first linear speed of the surface of the belt conveyor.
Preferably, the diagnosing the overload fault, the belt tearing fault, the slipping fault, the dead-locking fault of the bend pulley and the failure and reversal fault of the coupling of the belt conveyor according to the first linear speed, the driving linear speed and the bend linear speed includes:
when the first linear speed, the driving linear speed, the redirection linear speed and the normal working speed are equal, determining that the belt conveyor is in a normal working state;
when the first linear speed, the driving linear speed and the direction-changing linear speed are equal and the first linear speed, the driving linear speed and the direction-changing linear speed are all smaller than the normal working speed, determining that the belt conveyor has an overload fault;
when the first linear speed is equal to the redirection linear speed, the driving linear speed is equal to the normal working speed, and the first linear speed is lower than the driving linear speed, determining that a belt tearing fault occurs in the belt conveyor;
when the first linear speed is equal to the redirection linear speed and the first linear speed is not equal to the driving line speed, determining that the belt conveyor has a slip fault;
when the bend line speed is 0, determining that the bend roller of the belt conveyor is blocked;
and when the linear driving speed is equal to the linear redirecting speed in magnitude and the linear driving speed is opposite to the linear redirecting speed in direction, determining that a coupler failure reversal fault occurs in the belt conveyor.
Preferably, the method further comprises the following steps:
acquiring a second running image of the surface of the belt conveyor, acquired by a second image acquisition device, and calculating a second linear speed of the surface of the belt conveyor according to the second running image; the first image acquisition device is arranged above a first area on the surface of the belt conveyor, the second image acquisition device is arranged above a second area on the surface of the belt conveyor, and the first area is different from the second area;
and diagnosing the belt breakage fault of the belt conveyor according to the first linear speed, the second linear speed, the driving linear speed and the redirection linear speed.
Preferably, the diagnosing the belt breakage fault of the belt conveyor according to the first linear speed, the second linear speed, the driving linear speed and the bend linear speed includes:
when the first linear speed and the second linear speed are changed from the same direction as the linear driving speed to the opposite direction of the linear driving speed, determining that the first area of the surface of the belt conveyor has a belt breakage fault;
when the first linear speed is continuously increased and the second linear speed and the redirection linear speed are continuously reduced to 0, determining that the second area of the surface of the belt conveyor has a belt breakage fault;
when the first linear speed and the second linear speed are both continuously increased, the direction of the driving linear speed is unchanged, and the direction change linear speed is continuously reduced to 0, determining that a third area on the surface of the belt conveyor has a belt breakage fault; the third region is a region on the surface of the belt that is different from both the first region and the second region.
A failure diagnosis device of a belt conveyor includes:
the first calculation module is used for acquiring a first running image of the surface of the belt conveyor, acquired by a first image acquisition device, and calculating a first linear speed of the surface of the belt conveyor according to the first running image;
the second calculation module is used for acquiring the driving rotating speed of a driving roller of the belt conveyor and the direction-changing rotating speed of a direction-changing roller, which are acquired by the speed measuring device, calculating the driving wire speed of the driving roller according to the driving rotating speed and the diameter of the driving roller, and calculating the direction-changing linear speed of the direction-changing roller according to the direction-changing rotating speed and the diameter of the direction-changing roller;
and the first fault diagnosis module is used for diagnosing overload faults, belt tearing faults, slipping faults, bend drum blocking faults and coupling failure reversal faults of the belt conveyor according to the first linear speed, the driving linear speed, the bend linear speed and the normal working speed of the belt conveyor.
Preferably, first color blocks and second color blocks which are arranged alternately are arranged on the surface of the belt conveyor, and the length of each first color block is equal;
then, the first computing module includes:
the first calculation unit is used for acquiring the first running image of the surface of the belt conveyor, acquired by the first image acquisition device, and calculating first passing time of the first color block passing through the first image acquisition device according to the first running image;
and the second calculating unit is used for calculating a first passing speed of the first color block passing through the first image acquisition device according to the first passing time and the length of the first color block, and determining the first passing speed as a first linear speed of the surface of the belt conveyor.
Preferably, the first fault diagnosis module includes:
the normal state diagnosis unit is used for determining that the belt conveyor is in a normal working state when the first linear speed, the driving linear speed, the redirection linear speed and the normal working speed are equal;
the overload fault diagnosis unit is used for determining that the belt conveyor has overload faults when the first linear speed, the driving linear speed and the bend linear speed are equal and are all smaller than the normal working speed;
the tearing fault diagnosis unit is used for determining that a belt tearing fault occurs in the belt conveyor when the first linear speed is equal to the redirection linear speed, the driving linear speed is equal to the normal working speed, and the first linear speed is smaller than the driving linear speed;
the slip fault diagnosis unit is used for determining that the belt conveyor has a slip fault when the first linear speed is equal to the bend linear speed and the first linear speed is not equal to the driving line speed;
the dead-locking fault diagnosis unit is used for determining that the dead-locking fault of the turnabout drum occurs in the belt conveyor when the turnabout linear velocity is 0;
and the coupling fault diagnosis unit is used for determining that the belt conveyor has a coupling failure reversal fault when the linear driving speed is equal to the linear redirecting speed and the linear driving speed is opposite to the linear redirecting speed.
Preferably, the method further comprises the following steps:
the third calculation module is used for acquiring a second running image of the surface of the belt conveyor, acquired by the second image acquisition device, and calculating a second linear speed of the surface of the belt conveyor according to the second running image; the first image acquisition device is arranged above a first area on the surface of the belt conveyor, the second image acquisition device is arranged above a second area on the surface of the belt conveyor, and the first area is different from the second area;
and the second fault diagnosis module is used for diagnosing the belt breakage fault of the belt conveyor according to the first linear speed, the second linear speed, the driving linear speed and the redirection linear speed.
Preferably, the second fault diagnosis module includes:
the first diagnosis unit is used for determining that the belt breakage fault occurs in the first area of the surface of the belt conveyor when the first linear speed and the second linear speed change from the same direction as the driving linear speed to the opposite direction of the driving linear speed;
the second diagnosis unit is used for determining that the second area of the surface of the belt conveyor has a belt breakage fault when the first linear speed is continuously increased and the second linear speed and the direction changing linear speed are continuously reduced to 0;
the third diagnosis unit is used for determining that a belt breakage fault occurs in a third area on the surface of the belt conveyor when the first linear speed and the second linear speed are both continuously increased, the direction of the driving linear speed is unchanged, and the linear speed of the bend line is continuously reduced to 0; the third region is a region of the belt surface different from both the first region and the second region.
Compared with the prior art, the technical scheme provided by the invention has the following advantages:
the technical scheme provided by the invention includes the steps that a first running image of the surface of the belt conveyor, collected by a first image collecting device, is obtained, and a first linear speed of the surface of the belt conveyor is calculated according to the first running image; then acquiring the driving rotating speed of a driving roller of the belt conveyor and the redirection rotating speed of a redirection roller, which are acquired by a speed measuring device, calculating the driving wire speed of the driving roller according to the driving rotating speed and the diameter of the driving roller, and calculating the redirection linear speed of the redirection roller according to the redirection rotating speed and the diameter of the redirection roller; and diagnosing overload faults, belt tearing faults, slipping faults, dead-locking faults of the turnabout drum and failure and reversal faults of a coupler of the belt conveyor according to the first linear speed, the driving linear speed, the turnabout linear speed and the normal working speed of the belt conveyor. The first linear speed of the surface of the belt conveyor is calculated by acquiring the first running image through the first image acquisition device, and a sensor is not required to be installed at certain specific positions on the belt conveyor, so that the structure of the belt conveyor is not required to be modified (opening, punching and the like), and the difficulty in disassembly and maintenance can be reduced; moreover, through the first linear speed, the driving line speed, the bend linear speed and the normal working speed of the belt conveyor calculated by the method, the overload fault, the belt tearing fault, the slipping fault, the bend pulley blocking fault and the coupling failure reversing fault of the belt conveyor can be diagnosed, so that the fault of the belt conveyor can be fully diagnosed.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
Fig. 1 is a schematic flow chart of a method for diagnosing a fault of a belt conveyor according to an embodiment of the present invention;
FIG. 2 is a top view of a belt surface provided by an embodiment of the present invention;
fig. 3 is a schematic view of an application scenario of the belt conveyor fault diagnosis method provided in the embodiment of the present invention;
fig. 4 is a schematic structural diagram of a fault diagnosis device of a belt conveyor provided in an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, a schematic flow chart of a method for diagnosing a fault of a belt conveyor according to an embodiment of the present invention is shown, where the method may include the following steps:
s101: acquiring a first running image of the surface of the belt conveyor, acquired by a first image acquisition device, and calculating a first linear speed of the surface of the belt conveyor according to the first running image;
in the embodiment of the application, in order to ensure the calculation accuracy and prevent misdiagnosis, besides acquiring a first running image of the surface of the belt conveyor, which is acquired by a first image acquisition device, and calculating a first linear velocity of the surface of the belt conveyor according to the first running image, a second running image of the surface of the belt conveyor, which is acquired by a second image acquisition device, can be acquired, and a second linear velocity of the surface of the belt conveyor is calculated according to the second running image; then, the failure diagnosis is simultaneously performed based on the first linear velocity and the second linear velocity.
The first image acquisition device is arranged above a first area on the surface of the belt conveyor, the second image acquisition device is arranged above a second area on the surface of the belt conveyor, and the first area is different from the second area.
In the embodiment of the application, first color blocks and second color blocks which are arranged alternately are arranged on the surface of the belt conveyor, and the lengths of the first color blocks are equal;
then, the acquiring a first operation image of the surface of the belt conveyor, which is acquired by a first image acquisition device, and calculating a first linear velocity of the surface of the belt conveyor according to the first operation image includes:
acquiring the first running image of the surface of the belt conveyor, acquired by the first image acquisition device, and calculating first passing time of the first color block passing through the first image acquisition device according to the first running image;
and calculating a first passing speed of the first color block passing through the first image acquisition device according to the first passing time and the length of the first color block, and determining the first passing speed as a first linear speed of the surface of the belt conveyor.
Then, the obtaining a second operation image of the surface of the belt conveyor, which is acquired by a second image acquisition device, and calculating a second linear velocity of the surface of the belt conveyor according to the second operation image includes:
acquiring a second running image of the surface of the belt conveyor, acquired by the second image acquisition device, and calculating second passing time of the first color block passing through the second image acquisition device according to the second running image;
and calculating a second passing speed of the first color block passing through the second image acquisition device according to the second passing time and the length of the first color block, and determining the second passing speed as a second linear speed of the surface of the belt conveyor.
As shown in fig. 2, in a top view of the surface of the belt conveyor provided by the present invention, the edge of the belt is coated with a white block (a first color block) and a black block (a second color block) which are equidistant, wherein the white block is required to have a smooth surface, and the black block is required to have a rough surface, so as to facilitate the acquisition of images by the camera. The lengths of accurately dividing the white color blocks and the black color blocks are both 10-20 CM. Of course, the first and second patch colors may be replaced by other easily distinguishable colors, respectively.
As shown in fig. 3, it is a schematic view of an application scenario of the belt conveyor fault diagnosis method provided by the present invention. When the belt conveyor normally works, the belt basically moves at a constant speed, black and white color blocks alternately appear under a camera 1 (a first image acquisition device) and a camera 2 (a second image acquisition device), images acquired by the camera 1 (the first image acquisition device) and the camera 2 (the second image acquisition device) are subjected to gray scale processing, the gray scale of the acquired images is 255 (or close to 255) when the white blocks pass under the camera 1 (the first image acquisition device) and the camera 2 (the second image acquisition device), and the gray scale of the images is 0 (or close to 0) when the black blocks pass under the camera. The lengths of the black and white blocks are known, and the time to collect the white block is known, based on
Each white block can be calculatedA velocity V1 (first linear velocity) passing directly below the camera 1 (first image pickup device) and a velocity V2 (second linear velocity) passing directly below the camera 2 (second image pickup device). Because the length of the color block is small relative to the overall length of the belt, the instantaneous velocity of each point on the color block can be replaced by the average velocity on the color block.
S102: acquiring a driving rotating speed of a driving roller of the belt conveyor and a redirection rotating speed of a redirection roller, which are acquired by a speed measuring device, calculating the driving wire speed of the driving roller according to the driving rotating speed and the diameter of the driving roller, and calculating the redirection linear speed of the redirection roller according to the redirection rotating speed and the diameter of the redirection roller;
as shown in fig. 3, speed measuring motors (speed measuring devices) are respectively installed on the shaft portions of the head and the tail of the belt conveyor to measure the rotating speeds of the driving roller and the direction-changing roller of the belt conveyor.
Because the diameters of the drive pulley and the direction-changing pulley are known according to the formula
The drive line speed V3 for the drive drum surface and the line speed V4 for the direction-changing drum surface can be calculated.
In the formula: n is the rotating speed (r/min) of the corresponding shaft measured by the speed measuring motor;
d is the diameter (m) of the driving roller or the direction-changing roller.
S103: and diagnosing overload faults, belt tearing faults, slipping faults, dead-locking faults of the turnabout drum and failure and reversal faults of a coupler of the belt conveyor according to the first linear speed, the driving linear speed, the turnabout linear speed and the normal working speed of the belt conveyor.
In the embodiment of the application, the speed of the belt conveyor is set as V0 when the belt conveyor works normally; when the belt conveyor does not have a belt breakage fault, the speeds V1 and V2 measured by the cameras 1 and 2 are equal, so that the overload fault, the belt tearing fault, the slipping fault, the dead-locking fault of the turnabout drum and the failure and reversal fault of the coupling of the belt conveyor can be diagnosed only according to the first linear speed, the driving linear speed, the turnabout linear speed and the normal working speed of the belt conveyor, and the method comprises the following steps:
firstly, when the first linear speed, the driving linear speed, the redirection linear speed and the normal working speed are equal, determining that the belt conveyor is in a normal working state;
when the belt conveyor normally works, the speed of the belt surface is the same as the speed of the turnabout drum of the driving roller;
namely: v1 ═ V2 ═ V3 ═ V4 ═ V0;
determining that the belt conveyor has an overload fault when the first linear speed, the driving linear speed and the redirection linear speed are equal and the first linear speed, the driving linear speed and the redirection linear speed are all smaller than the normal working speed;
when the belt conveyor is overloaded, the speed of the surface of the belt, the speed of the driving rollers and the speed of the direction-changing rollers are all positive directions and have the same speed but are lower than the normal running speed V0 of the belt conveyor;
namely, V1 ═ V2 ═ V3 ═ V4 < V0;
when the first linear speed is equal to the redirection linear speed, the driving linear speed is equal to the normal working speed, and the first linear speed is lower than the driving linear speed, determining that the belt tearing fault occurs in the belt conveyor;
when the belt conveyor has a tearing fault, the belt is longitudinally stretched due to tearing, so that the speed of the surface of the belt is equal to that of the bend pulley but less than that of the driving pulley;
namely, V1 ═ V2 ═ V4 < V3 ═ V0;
when the first linear speed is equal to the redirection linear speed and the first linear speed is not equal to the driving line speed, determining that the belt conveyor has a slip fault;
when the belt conveyor has a serious slip fault (slip reversal), the speed of the belt surface is the same as that of the bend pulley and the direction is the reverse direction, and the linear speed direction of the driving pulley is the positive direction;
that is, V1-V2-V4 is a negative value, and V3 is a positive value;
when the belt conveyor has slight slip fault, the linear speed of the surface of the belt conveyor and the linear speed of the turnabout drum are in the same direction, namely the positive direction; meanwhile, the linear velocity direction of the driving roller is also a positive direction, and the difference between the linear velocity direction and the speed of the driving roller is not large, namely the linear velocity direction is smaller than K;
when the belt conveyor has a slip fault, the linear speed of the surface of the belt conveyor is in the same direction as the linear speed of the turnabout drum and is in the positive direction; meanwhile, the linear velocity direction of the driving roller is also a positive direction, and the speed difference between the driving roller and the linear velocity direction is larger than K;
in the embodiment of the application, K is 0.79;
determining that the bend pulley of the belt conveyor is blocked when the bend linear velocity is 0;
when the belt conveyor is blocked, the bend pulley is locked and does not rotate, and the linear speed is 0.
Sixthly, when the linear driving speed is equal to the linear redirecting speed in size and the linear driving speed is opposite to the linear redirecting speed in direction, determining that the belt conveyor has a coupler failure reversion fault.
When the coupler of the belt conveyor fails and reverses, the linear speeds of all the pinch rollers, the driving rollers and the turnabout rollers are equal, but the running direction is opposite.
The diagnosis is respectively made on the overload fault, the belt tearing fault, the slipping fault, the dead-locking fault of the turnabout drum and the failure reversing fault of the coupling of the belt conveyor, and the types of various faults are analyzed according to the speed index. And then analyzing the belt breakage fault of the belt conveyor.
Because the belt of the belt conveyor has very small possibility of belt breakage at the lower belt, the invention only diagnoses the fault at the upper belt.
As shown in fig. 3, two cameras (if the length of the belt conveyor is too long, the number of cameras can be increased properly) divide the upper belt into three areas 1, 2 and 3, wherein 1, 2 and 3 correspond to a first area, a second area and a third area respectively, and the third area is an area on the surface of the belt conveyor different from the first area and the second area.
The diagnosing the belt breakage fault of the belt conveyor according to the first linear speed, the second linear speed, the driving linear speed and the bend linear speed comprises the following steps:
when the first linear speed and the second linear speed are changed from the same direction as the linear driving speed to the opposite direction of the linear driving speed, determining that the first area of the surface of the belt conveyor has a belt breakage fault;
when the belt breakage fault occurs in the area 1, the speeds V1 and V2 measured by the cameras 1 and 2 are equal, the speed is reduced to zero first, then the speed direction is changed to a reverse direction, and the linear speed direction of the driving roller is a positive direction.
Determining that the second area on the surface of the belt conveyor has a belt breakage fault when the first linear speed is continuously increased and the second linear speed and the bend linear speed are continuously reduced to 0;
when the belt breakage fault occurs in the 2 area, the speed V1 measured by the camera 1 continuously increases, and the speed V2 measured by the camera 2 and the speed V4 of the direction-changing drum continuously decrease to 0;
ninthly, when the first linear speed and the second linear speed are both continuously increased, the direction of the driving linear speed is unchanged, and the linear speed of the bend line is continuously reduced to 0, determining that a third area on the surface of the belt conveyor has a belt breakage fault;
when the belt breakage fault occurs in the 3-zone, the speeds V1, V2 measured by the cameras 1, 2 increase, the speed V3 of the driving drum is in the positive direction, and the speed V4 of the direction-changing drum is decelerated to 0.
To sum up, this application embodiment not only can make the diagnosis to the broken belt trouble according to speed information to can judge that the broken belt trouble takes place in which region on belt feeder surface.
By taking a belt conveyor with the speed of 2-4 m/s under the normal operation condition as a reference, the data obtained when the belt conveyor has overload, tearing, slipping, roller locking and coupler failure faults are shown in the following table:
| V1 | V2 | V3 | V4 | fault diagnosis |
| 2.22m/s | 2.25m/s | 2.25m/s | 2.23m/s | No load (Normal) |
| 0.75m/s | 0.73m/s | 0.79m/s | 0.71m/s | Overload fault |
| 1.61m/s | 1.56m/s | 2.24m/s | 1.52m/s | Tear failure |
| -0.81m/s | -0.81m/s | 2.24m/s | -0.84m/s | Slip reversal failure |
| 1.99m/s | 1.94m/s | 2.24m/s | 1.93m/s | Slight slip fault |
| 1.15m/s | 1.13m/s | 2.24m/s | 0.95m/s | Slip fault |
| 0m/s | 0m/s | 0m/s | 0m/s | Cylinder jam fault |
| -0.83m/s | -0.83m/s | -0.83m/s | -0.83m/s | Failure fault of coupling |
According to the technical scheme provided by the invention, a first running image of the surface of the belt conveyor, which is acquired by a first image acquisition device, is acquired, and a first linear speed of the surface of the belt conveyor is calculated according to the first running image; then acquiring the driving rotating speed of a driving roller of the belt conveyor and the redirection rotating speed of a redirection roller, which are acquired by a speed measuring device, calculating the driving wire speed of the driving roller according to the driving rotating speed and the diameter of the driving roller, and calculating the redirection linear speed of the redirection roller according to the redirection rotating speed and the diameter of the redirection roller; and diagnosing overload faults, belt tearing faults, slipping faults, dead-locking faults of the turnabout drum and failure and reversal faults of a coupler of the belt conveyor according to the first linear speed, the driving linear speed, the turnabout linear speed and the normal working speed of the belt conveyor. The first linear speed of the surface of the belt conveyor is calculated by acquiring the first running image through the first image acquisition device, and a sensor is not required to be installed at certain specific positions on the belt conveyor, so that the structure of the belt conveyor is not required to be modified (opening, punching and the like), and the difficulty in disassembly and maintenance can be reduced; moreover, through the first linear speed, the driving line speed, the bend linear speed and the normal working speed of the belt conveyor calculated by the method, the overload fault, the belt tearing fault, the slipping fault, the bend pulley blocking fault and the coupling failure reversing fault of the belt conveyor can be diagnosed, so that the fault of the belt conveyor can be fully diagnosed.
For simplicity of explanation, the foregoing method embodiments are described as a series of acts or combinations, but it should be understood by those skilled in the art that the present invention is not limited by the order of acts or acts described, as some steps may occur in other orders or concurrently with other steps in accordance with the invention. Further, those skilled in the art should also appreciate that the embodiments described in the specification are preferred embodiments and that the acts and modules referred to are not necessarily required by the invention.
Corresponding to the above method embodiment, an embodiment of the present invention further provides a fault diagnosis device for a belt conveyor, where an optional structure of the fault diagnosis device is shown in fig. 4, and the fault diagnosis device may include: a first calculation module 11, a second control module 12 and a first fault diagnosis module 13.
The first calculation module 11 is configured to obtain a first operation image of the surface of the belt conveyor, which is acquired by a first image acquisition device, and calculate a first linear velocity of the surface of the belt conveyor according to the first operation image;
preferably, first color blocks and second color blocks which are arranged alternately are arranged on the surface of the belt conveyor, and the length of each first color block is equal;
then, the first calculation module 11 may include:
the first calculation unit is used for acquiring the first running image of the surface of the belt conveyor, acquired by the first image acquisition device, and calculating first passing time of the first color block passing through the first image acquisition device according to the first running image;
and the second calculating unit is used for calculating a first passing speed of the first color block passing through the first image acquisition device according to the first passing time and the length of the first color block, and determining the first passing speed as a first linear speed of the surface of the belt conveyor.
The second calculating module 12 is configured to obtain a driving rotation speed of a driving drum of the belt conveyor and a direction-changing rotation speed of a direction-changing drum, which are acquired by a speed measuring device, calculate a driving line speed of the driving drum according to the driving rotation speed and a diameter of the driving drum, and calculate a direction-changing line speed of the direction-changing drum according to the direction-changing rotation speed and the diameter of the direction-changing drum;
and the first fault diagnosis module 13 is configured to diagnose an overload fault, a belt tearing fault, a slipping fault, a bend drum locking fault and a coupling failure reversal fault of the belt conveyor according to the first linear speed, the driving linear speed, the bend linear speed and the normal operating speed of the belt conveyor.
Preferably, the first fault diagnosis module 13 may include:
the normal state diagnosis unit is used for determining that the belt conveyor is in a normal working state when the first linear speed, the driving linear speed, the redirection linear speed and the normal working speed are equal;
the overload fault diagnosis unit is used for determining that the belt conveyor has overload faults when the first linear speed, the driving linear speed and the bend linear speed are equal and are all smaller than the normal working speed;
the tearing fault diagnosis unit is used for determining that a belt tearing fault occurs in the belt conveyor when the first linear speed is equal to the redirection linear speed, the driving linear speed is equal to the normal working speed, and the first linear speed is smaller than the driving linear speed;
the slip fault diagnosis unit is used for determining that the belt conveyor has a slip fault when the first linear speed is equal to the bend linear speed and the first linear speed is not equal to the driving line speed;
the dead-locking fault diagnosis unit is used for determining that the dead-locking fault of the turnabout drum occurs in the belt conveyor when the turnabout linear velocity is 0;
and the coupling fault diagnosis unit is used for determining that the belt conveyor has a coupling failure reversal fault when the linear driving speed is equal to the linear redirecting speed and the linear driving speed is opposite to the linear redirecting speed.
Preferably, the method further comprises the following steps:
the third calculation module is used for acquiring a second running image of the surface of the belt conveyor, acquired by the second image acquisition device, and calculating a second linear speed of the surface of the belt conveyor according to the second running image; the first image acquisition device is arranged above a first area on the surface of the belt conveyor, the second image acquisition device is arranged above a second area on the surface of the belt conveyor, and the first area is different from the second area;
and the second fault diagnosis module is used for diagnosing the belt breakage fault of the belt conveyor according to the first linear speed, the second linear speed, the driving linear speed and the redirection linear speed.
Preferably, the second fault diagnosis module may include:
the first diagnosis unit is used for determining that the belt breakage fault occurs in the first area of the surface of the belt conveyor when the first linear speed and the second linear speed change from the same direction as the driving linear speed to the opposite direction of the driving linear speed;
the second diagnosis unit is used for determining that the second area of the surface of the belt conveyor has a belt breakage fault when the first linear speed is continuously increased and the second linear speed and the direction changing linear speed are continuously reduced to 0;
the third diagnosis unit is used for determining that a belt breakage fault occurs in a third area on the surface of the belt conveyor when the first linear speed and the second linear speed are both continuously increased, the direction of the driving linear speed is unchanged, and the linear speed of the bend line is continuously reduced to 0; the third region is a region of the belt surface different from both the first region and the second region.
The method in the above method embodiment is implemented by the fault diagnosis device for the belt conveyor provided in the embodiment of the present application, and for the implementation process, explanation, and the like of each step in the fault diagnosis device for the belt conveyor, reference is made to the relevant description in the above method embodiment, and the embodiment of the present invention is not further described.
It should be noted that, in the present specification, the embodiments are all described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments may be referred to each other. For the device-like embodiment, since it is basically similar to the method embodiment, the description is simple, and for the relevant points, reference may be made to the partial description of the method embodiment.
Finally, it should also be noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other identical elements in a process, method, article, or apparatus that comprises the element.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.
Claims (8)
1. A fault diagnosis method of a belt conveyor is characterized by comprising the following steps:
acquiring a first running image of the surface of the belt conveyor, acquired by a first image acquisition device, and calculating a first linear speed of the surface of the belt conveyor according to the first running image;
acquiring a driving rotating speed of a driving roller of the belt conveyor and a redirection rotating speed of a redirection roller, which are acquired by a speed measuring device, calculating the driving wire speed of the driving roller according to the driving rotating speed and the diameter of the driving roller, and calculating the redirection linear speed of the redirection roller according to the redirection rotating speed and the diameter of the redirection roller;
according to the first linear speed, the driving linear speed, the bend linear speed and the normal working speed of the belt conveyor, diagnosing overload faults, belt tearing faults, slipping faults, bend pulley blocking faults and coupler failure reverse faults of the belt conveyor;
the method comprises the following steps of diagnosing overload faults, belt tearing faults, slipping faults, dead-locking faults of a turnabout drum and failure reversing faults of a coupler of the belt conveyor according to the first linear speed, the driving linear speed and the turnabout linear speed, and comprises the following steps:
when the first linear speed, the driving linear speed, the redirection linear speed and the normal working speed are equal, determining that the belt conveyor is in a normal working state;
when the first linear speed, the driving linear speed and the direction-changing linear speed are equal and the first linear speed, the driving linear speed and the direction-changing linear speed are all smaller than the normal working speed, determining that the belt conveyor has an overload fault;
when the first linear speed is equal to the redirection linear speed, the driving linear speed is equal to the normal working speed, and the first linear speed is lower than the driving linear speed, determining that a belt tearing fault occurs in the belt conveyor;
when the first linear speed is equal to the redirection linear speed and the first linear speed is not equal to the driving line speed, determining that the belt conveyor has a slip fault;
when the bend line speed is 0, determining that the bend roller of the belt conveyor is blocked;
and when the linear driving speed is equal to the linear redirecting speed in magnitude and the linear driving speed is opposite to the linear redirecting speed in direction, determining that a coupler failure reversal fault occurs in the belt conveyor.
2. The method of claim 1, wherein the belt surface is provided with alternating first and second color patches, each of the first color patches being of equal length;
then, the acquiring a first operation image of the surface of the belt conveyor, which is acquired by a first image acquisition device, and calculating a first linear velocity of the surface of the belt conveyor according to the first operation image includes:
acquiring the first running image of the surface of the belt conveyor, acquired by the first image acquisition device, and calculating first passing time of the first color block passing through the first image acquisition device according to the first running image;
and calculating a first passing speed of the first color block passing through the first image acquisition device according to the first passing time and the length of the first color block, and determining the first passing speed as a first linear speed of the surface of the belt conveyor.
3. The method of claim 1, further comprising:
acquiring a second running image of the surface of the belt conveyor, acquired by a second image acquisition device, and calculating a second linear speed of the surface of the belt conveyor according to the second running image; the first image acquisition device is arranged above a first area on the surface of the belt conveyor, the second image acquisition device is arranged above a second area on the surface of the belt conveyor, and the first area is different from the second area;
and diagnosing the belt breakage fault of the belt conveyor according to the first linear speed, the second linear speed, the driving linear speed and the redirection linear speed.
4. The method of claim 3, wherein diagnosing a belt breakage fault of the belt conveyor based on the first linear speed, the second linear speed, the drive linear speed, and the bend linear speed comprises:
when the first linear speed and the second linear speed are changed from the same direction as the linear driving speed to the opposite direction of the linear driving speed, determining that the first area of the surface of the belt conveyor has a belt breakage fault;
when the first linear speed is continuously increased and the second linear speed and the redirection linear speed are continuously reduced to 0, determining that the second area of the surface of the belt conveyor has a belt breakage fault;
when the first linear speed and the second linear speed are both continuously increased, the direction of the driving linear speed is unchanged, and the direction change linear speed is continuously reduced to 0, determining that a third area on the surface of the belt conveyor has a belt breakage fault; the third region is a region on the surface of the belt that is different from both the first region and the second region.
5. A failure diagnosis device of a belt conveyor, comprising:
the first calculation module is used for acquiring a first running image of the surface of the belt conveyor, acquired by a first image acquisition device, and calculating a first linear speed of the surface of the belt conveyor according to the first running image;
the second calculation module is used for acquiring the driving rotating speed of a driving roller of the belt conveyor and the direction-changing rotating speed of a direction-changing roller, which are acquired by the speed measuring device, calculating the driving wire speed of the driving roller according to the driving rotating speed and the diameter of the driving roller, and calculating the direction-changing linear speed of the direction-changing roller according to the direction-changing rotating speed and the diameter of the direction-changing roller;
the first fault diagnosis module is used for diagnosing overload faults, belt tearing faults, slipping faults, bend drum blocking faults and coupling failure reversal faults of the belt conveyor according to the first linear speed, the driving linear speed, the bend linear speed and the normal working speed of the belt conveyor;
the first fault diagnosis module includes:
the normal state diagnosis unit is used for determining that the belt conveyor is in a normal working state when the first linear speed, the driving linear speed, the redirection linear speed and the normal working speed are equal;
the overload fault diagnosis unit is used for determining that the belt conveyor has overload faults when the first linear speed, the driving linear speed and the bend linear speed are equal and are all smaller than the normal working speed;
the tearing fault diagnosis unit is used for determining that a belt tearing fault occurs in the belt conveyor when the first linear speed is equal to the redirection linear speed, the driving linear speed is equal to the normal working speed, and the first linear speed is smaller than the driving linear speed;
the slip fault diagnosis unit is used for determining that the belt conveyor has a slip fault when the first linear speed is equal to the bend linear speed and the first linear speed is not equal to the driving line speed;
the dead-locking fault diagnosis unit is used for determining that the dead-locking fault of the turnabout drum occurs in the belt conveyor when the turnabout linear velocity is 0;
and the coupling fault diagnosis unit is used for determining that the belt conveyor has a coupling failure reversal fault when the linear driving speed is equal to the linear redirecting speed and the linear driving speed is opposite to the linear redirecting speed.
6. The apparatus of claim 5, wherein the belt surface is provided with first and second alternating color patches, each of the first color patches being of equal length;
then, the first computing module includes:
the first calculation unit is used for acquiring the first running image of the surface of the belt conveyor, acquired by the first image acquisition device, and calculating first passing time of the first color block passing through the first image acquisition device according to the first running image;
and the second calculating unit is used for calculating a first passing speed of the first color block passing through the first image acquisition device according to the first passing time and the length of the first color block, and determining the first passing speed as a first linear speed of the surface of the belt conveyor.
7. The apparatus of claim 5, further comprising:
the third calculation module is used for acquiring a second running image of the surface of the belt conveyor, acquired by the second image acquisition device, and calculating a second linear speed of the surface of the belt conveyor according to the second running image; the first image acquisition device is arranged above a first area on the surface of the belt conveyor, the second image acquisition device is arranged above a second area on the surface of the belt conveyor, and the first area is different from the second area;
and the second fault diagnosis module is used for diagnosing the belt breakage fault of the belt conveyor according to the first linear speed, the second linear speed, the driving linear speed and the redirection linear speed.
8. The apparatus of claim 7, wherein the second fault diagnosis module comprises:
the first diagnosis unit is used for determining that the belt breakage fault occurs in the first area of the surface of the belt conveyor when the first linear speed and the second linear speed change from the same direction as the driving linear speed to the opposite direction of the driving linear speed;
the second diagnosis unit is used for determining that the second area of the surface of the belt conveyor has a belt breakage fault when the first linear speed is continuously increased and the second linear speed and the direction changing linear speed are continuously reduced to 0;
the third diagnosis unit is used for determining that a belt breakage fault occurs in a third area on the surface of the belt conveyor when the first linear speed and the second linear speed are both continuously increased, the direction of the driving linear speed is unchanged, and the linear speed of the bend line is continuously reduced to 0; the third region is a region of the belt surface different from both the first region and the second region.
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| CN112229461B (en) * | 2020-11-03 | 2024-06-04 | 浙江工业大学 | Device and method for detecting real-time flow in tea processing process |
| CN113401615A (en) * | 2021-06-29 | 2021-09-17 | 攀钢集团西昌钢钒有限公司 | Method and device for diagnosing belt fault of belt conveyor, electronic equipment and medium |
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