CN111891689B - Belt deviation detection system for belt conveyor - Google Patents
Belt deviation detection system for belt conveyor Download PDFInfo
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- CN111891689B CN111891689B CN202010784449.7A CN202010784449A CN111891689B CN 111891689 B CN111891689 B CN 111891689B CN 202010784449 A CN202010784449 A CN 202010784449A CN 111891689 B CN111891689 B CN 111891689B
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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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Abstract
The invention discloses a belt deviation detection system for a belt conveyor, and mainly relates to the related technical field of detection devices matched with intelligent detection equipment of the belt conveyor; comprises a hardware system and a software system; the hardware system comprises: an internet of things deviation sensor; an alarm; a wireless base station; a conveyor power switch; a data interaction server; the software system comprises: a state database; a deviation inference service; a mobile client; an operation platform; the data interaction server performs data interaction with the operation platform, the mobile client and all the deviation sensors of the Internet of things through a network; the invention is an intelligent detection system which can reduce the manual inspection requirement, has low cost, is simple and convenient to deploy and has high detection efficiency and accuracy.
Description
Technical Field
The invention mainly relates to the related technical field of detection devices matched with intelligent detection equipment of a belt conveyor, in particular to a belt deviation detection system for the belt conveyor.
Background
The belt deviation is a common fault of the belt conveyor, and timely and accurate detection and treatment of the deviation are guarantee for safe and stable operation of the conveying belt. The existing belt deviation detection method mainly comprises three types, the first type is a manual inspection mode, the real-time problem exists in regular inspection, the detection is delayed, the efficiency is low, and the risk is large; the second type is a mode of installing a contact type deviation switch, when deviation occurs, a switch signal is triggered, the belt conveyor can be directly stopped, the real-time problem is solved, however, in order to avoid frequent triggering, generally set triggering conditions are harsh, extra safety risks can be brought by long-term contact of the belt and a sensor, the state is still checked in a manual inspection mode, and detection hysteresis is still provided; the third type is based on machine vision's detection mode, but has solved the safety risk problem that the contact brought and have long-range real time monitoring advantage, has reduced the artifical demand of patrolling and examining, but the operational environment of conveyer belt is abominable usually, and waterproof dustproof jam-proof problem must be solved to the vision, and stability hardly guarantees, greatly increased the cost and the degree of difficulty of deploying.
Disclosure of Invention
The invention aims to solve the problems in the prior art and provides a belt deviation detection system for a belt conveyor, so as to realize an intelligent detection system which is low in cost, simple and convenient to deploy and high in detection efficiency and accuracy and can reduce the manual inspection requirement.
In order to achieve the purpose, the invention is realized by the following technical scheme:
a belt deviation detection system for a belt conveyor comprises a hardware system and a software system;
the hardware system includes:
the deviation sensor is additionally provided with an Internet of things function on the basis of a two-stage deviation switch, adopts the same installation mode as the two-stage deviation switch, is arranged on two sides of a roller carrier of the belt conveyor and is used for acquiring the belt deviation state at the installation position;
the alarm is matched with the internet of things deviation sensor for use and installation, and the alarm is triggered when the belt is obviously deviated and used for on-site warning;
the wireless base station is used for building a WIFI network environment along the belt conveyor;
the conveyor power switch is connected with all the internet of things deviation sensors, and the conveyor power switch can be used for turning off the conveyor power when any one position of the belt is seriously deviated;
a data interaction server;
the software system includes:
the state database comprises an internet of things deviation sensor data table, a belt deviation historical data table and a line table;
the deviation inference service is used for logic judgment of deviation states and calculation of prediction results of the deviation prediction model;
the mobile client is used for checking the belt deviation state and the running states of all the internet of things deviation sensors in real time;
the operation platform is used for checking the belt deviation state and the operation states of all the internet of things deviation sensors in real time;
the data interaction server performs data interaction with the operation platform, the mobile client and all the deviation sensors of the Internet of things through a network; the data interaction means receiving and storing real-time data and historical data acquired by all the deviation sensors of the internet of things, sending the data of the deviation sensors of the internet of things to the mobile client and the operation platform and receiving function requests of the mobile client and the operation platform; meanwhile, the system is also a data processing terminal used for deploying the belt deviation prediction model and calculating the prediction result in real time.
Preferably, the internet of things deviation sensors are installed in pairs and are respectively installed on two sides of the roller carrier of the belt conveyor.
Preferably, each internet of things deviation sensor has a unique equipment number.
Preferably, the deviation state comprises a switching signal of a two-stage deviation switch and initial angle and real-time angle data output by the deviation sensor of the internet of things; the deviation state and the sensor equipment state are actively and continuously sent in a timed mode when the deviation sensor of the Internet of things works normally; the angle data refers to the inclination angle of the vertical rod of the two-stage deviation switch.
Preferably, the data interaction is completed by a data transmission interface defined by an HTTP Server in the data interaction Server, and the interface functions include equipment registration, equipment binding, equipment unbinding, equipment query, equipment state query and equipment state update;
preferably, the equipment state comprises a deviation switch signal, an initial inclination angle of a vertical rod, a deviation angle of the vertical rod, equipment abnormity, equipment online/offline and data updating time, and the deviation angle of the vertical rod is a real-time inclination angle of the vertical rod of the two-stage deviation switch and an initial inclination angle difference during installation.
Preferably, the data table of the deviation sensor of the internet of things comprises a unique ID, a name, an installation distance, a binding line ID, a paired sensor ID, an IP address, a deviation switch signal, an installation initial inclination angle, a real-time inclination angle, a deviation probability, an update time and an online state; the belt deviation historical data table comprises a sensor ID, a deviation switch signal, a deviation angle difference, a deviation probability, a belt running speed and uploading time.
Preferably, the logic judgment of the deviation state is that the belt is considered to be deviated when only one deviation response of two opposite internet of things deviation sensors occurs and the deviation response lasts for a certain time; and judging a response strategy according to the deviation grade.
Preferably, the deviation prediction model is a change trend simulated according to historical data of all internet of things deviation sensors on the current line, and is a combination of a time-dimension inclination angle change trend and a space-dimension inclination angle change trend related to the running speed of the belt.
Preferably, the functions of the mobile client and the operation platform comprise binding, naming and unbinding of the deviation sensors of the internet of things, pairing of the deviation sensors of the internet of things, arrangement of installation positions, state display of all the deviation sensors of the internet of things and belt state display; the state display of the deviation sensor of the Internet of things comprises online/offline of the sensor, and the state display of the belt comprises normal/deviation/severe deviation of the belt.
Compared with the prior art, the invention has the beneficial effects that:
1. the belt deviation detecting system is a complete real-time belt deviation detecting system, deviation faults and hidden dangers can be found in time and responded in time, and the running risk of a belt conveyor is greatly reduced;
2. the invention is a low-cost detection system which can be simply deployed and has high detection efficiency and high accuracy.
Drawings
FIG. 1 is a diagrammatic, schematic deployment of the basic elements of the present invention;
FIG. 2 is a simplified schematic diagram of a hardware system deployment framework of the present invention;
FIG. 3 is a simplified schematic diagram of a software system deployment framework of the present invention;
fig. 4 is a main flow chart of the off tracking detecting method of the present invention.
The reference numbers in the drawings: 1. an internet of things deviation sensor; 2. an alarm; 3. mounting a bracket; 4. a frame; 5. and (5) conveying the belt.
Detailed Description
The invention will be further illustrated with reference to the following specific examples. It should be understood that these examples are for illustrative purposes only and are not intended to limit the scope of the present invention. Further, it should be understood that various changes or modifications of the present invention may be made by those skilled in the art after reading the teaching of the present invention, and these equivalents also fall within the scope of the present application.
Example (b): as shown in fig. 1-4, the invention relates to a belt deviation detecting system for a belt conveyor, which comprises a hardware system and a software system;
the hardware system includes:
the system comprises an Internet of things deviation sensor 1, wherein the Internet of things deviation sensor 1 is a deviation sensor with an Internet of things function added on the basis of a two-stage deviation switch, is a deviation sensor for upgrading the Internet of things based on the two-stage deviation switch, adopts the same installation mode as the two-stage deviation switch, is arranged on two sides of a roller carrier of a belt conveyor, and is used for collecting a belt deviation state at an installation position;
the alarm 2 is matched with the internet of things deviation sensor 1 for use and installation, and is triggered when the belt deviates obviously and used for on-site warning;
the wireless base station is used for building a WIFI network environment along the belt conveyor;
the conveyor power switch is connected with all the internet of things deviation sensors 1, and when any one position of the belt is seriously deviated, the conveyor power switch can turn off the conveyor;
a data interaction server;
the software system includes:
the state database comprises an internet of things deviation sensor data table, a belt deviation historical data table and a line table;
the deviation inference service is used for logically judging the deviation state and calculating the prediction result of the deviation prediction model;
the mobile client is used for checking the belt deviation state and the running states of all the internet of things deviation sensors 1 in real time;
the operation platform is used for checking the belt deviation state and the operation states of all the internet of things deviation sensors 1 in real time;
the data interaction server performs data interaction with the operation platform, the mobile client and all the deviation sensors 1 of the Internet of things through a network; the data interaction is to receive and store real-time data and historical data acquired by all the internet of things deviation sensors 1, send the data of the internet of things deviation sensors 1 to the mobile client and the operation platform and receive function requests of the mobile client and the operation platform; meanwhile, the system is also a data processing terminal used for deploying the belt deviation prediction model and calculating the prediction result in real time.
Preferably, the deviation sensors 1 of the internet of things are installed in pairs and are respectively installed on two sides of a roller carrier of the belt conveyor, so that the deviation direction of the belt can be determined, the condition that the functions of the sensors are triggered due to other reasons can be sensed, for example, when one sensor is abnormal or two sensors are triggered simultaneously due to artificial force, the condition that the functions of the sensors are triggered due to external force other than belt deviation can be reduced.
Preferably, each internet of things deviation sensor 1 has a unique equipment number, can be provided with a binding belt conveyor line, and corresponds to an installation position, so that the internet of things deviation sensor supports fault location when a fault occurs.
Preferably, the deviation state comprises a switching signal of a two-stage deviation switch and initial angle and real-time angle data output by the deviation sensor 1 of the internet of things; the deviation sensor 1 of the internet of things actively continuously sends a deviation state and a sensor equipment state at regular time when working normally; the angle data refers to the inclination angle of a vertical rod of the two-stage deviation switch.
Preferably, the data interaction is completed by a data transmission interface defined by an HTTP Server in the data interaction Server, and the interface functions include device registration, device binding, device unbinding, device query, device status query, and device status update.
Preferably, the equipment state comprises a deviation switch signal, an initial inclination angle of a vertical rod, a deviation angle of the vertical rod, equipment abnormity, equipment online/offline and data updating time, and the deviation angle of the vertical rod is a real-time inclination angle of the vertical rod of the two-stage deviation switch and an initial inclination angle difference during installation.
Preferably, the data table of the deviation sensor of the internet of things comprises a unique ID, a name, an installation distance, a binding line ID, a paired sensor ID, an IP address, a deviation switch signal, an installation initial inclination angle, a real-time inclination angle, a deviation probability, an update time and an online state; the belt deviation historical data table comprises a sensor ID, a deviation switch signal, a deviation angle difference, a deviation probability, a belt running speed and uploading time.
Preferably, the logic judgment of the deviation state is that when only one of the two opposite internet-of-things deviation sensors 1 generates deviation response and the deviation response lasts for a certain time, the belt is considered to be deviated; and judging a response strategy according to the deviation grade.
Preferably, the deviation prediction model is a change trend simulated according to historical data of all internet of things deviation sensors 1 on the current line, and is a combination of a time-dimension inclination angle change trend and a space-dimension inclination angle change trend related to the running speed of the belt.
Preferably, the functions of the mobile client and the operation platform comprise binding, naming and unbinding of the internet of things deviation sensors 1, pairing of the internet of things deviation sensors 1, setting of installation positions, state display of all the internet of things deviation sensors and belt state display; the state display of the deviation sensor of the Internet of things comprises online/offline of the sensor, and the state display of the belt comprises normal/deviation/severe deviation of the belt.
Specifically, as shown in fig. 1, fig. 1 is a schematic diagram of the deployment of a basic unit (off-tracking sensor) of a belt off-tracking detection system for a belt conveyor provided in this embodiment, basic data of the whole system comes from the basic unit, and the basic unit includes a pair of internet-of-things off-tracking sensors 1, a pair of alarms 2, and a mounting bracket 3 for fixing the internet-of-things off-tracking sensors 1 and the alarms 2; the mounting support 3 is fixed on the machine frame 4 on two sides of the belt conveyor, the distance between a vertical rod on the internet of things deviation sensor 1 and the conveying belt 5 is 50-100 mm due to the fixed position of the internet of things deviation sensor 1, 1 alarm 2 is correspondingly mounted on 1 internet of things deviation sensor 1, and the on-off of the alarm 2 can be controlled by the switching signal of the internet of things deviation sensor 1;
specifically, as shown in fig. 2, fig. 2 is a schematic diagram of a hardware deployment framework of a belt deviation detecting system for a belt conveyor according to this embodiment, a solid line in fig. 2 represents a cable, and a dashed line represents main hardware included in a network connection whole system, including: the system comprises an Internet of things deviation sensor 1, an alarm 2, a conveyor power supply, a data interaction server, an operation platform and a mobile client; the deviation sensors 1 of the internet of things are installed on two sides of the conveyer belt 5 in pairs, each deviation sensor 1 of the internet of things is provided with an alarm 2, and each deviation sensor 1 of the internet of things and each alarm 2 of the internet of things are installed at intervals of 50 meters; all the internet of things deviation sensors 1 are connected in series through cables and connected in series with a conveyor power supply, the alarm 2 is connected in parallel with the conveyor power supply, and the switching signals of the internet of things deviation sensors 1 can directly control the on-off of the conveyor power supply and the alarm; in the embodiment, the network environment is WIFI built through a wireless base station, and the deviation sensor 1 of the internet of things interacts with the data interaction server through a WIFI network; the operation platform and the mobile client can interact with the data interaction server through a local area network or a public network;
specifically, as shown in fig. 3, fig. 3 is a schematic diagram of a software deployment framework of the belt deviation detecting system for a belt conveyor provided in this embodiment, where the whole system includes main software including: the system comprises server side software, a deviation sensor development application program, a mobile phone side application program and an operation platform application program;
in this embodiment, when the system is deployed as a whole, the preferentially deploying the server includes: creating a database, wherein the database comprises a line table, a deviation sensor data table and a historical data table; deploying the http server according to a database, wherein the http server comprises interfaces of newly building (registering), inquiring and updating a line and sensor equipment, binding the line by a sensor, binding a paired sensor by the sensor, setting the installation position of the sensor, setting the installation initial inclination angle of the sensor, newly building and inquiring deviation historical data and the like; deploying a deviation detection service, inputting the acquired real-time data and historical data, and outputting a sensor state and a belt deviation state for function display of an operation platform and a mobile phone end application program.
In this embodiment, the application program functions in the deviation sensor development board include: registering equipment configured by a sensor in a factory; the method comprises the steps of line binding, paired sensor binding, installation distance setting and initial inclination angle setting during field installation, wherein the functions are realized in a mobile phone end application program; uploading a real-time inclination angle and uploading a deviation switch signal in formal operation; all functions are realized by calling an interface of the http server; the equipment registration adds a new piece of data in the offset sensor data table, and the updated data has the unique ID of the sensor, the IP address and the updating time when the registration is finished; the data updated when the field installation is completed comprises sensor naming, installation distance, binding line ID, paired sensor ID, IP address, deviation switch signal, installation initial inclination angle and update time; the updated data in the formal operation comprises a deviation switch signal, a real-time inclination angle and updating time in a deviation sensor data table; combining the deviation detection service, creating a piece of data in a historical data table at intervals: the sensor ID, the deviation switch signal, the inclination angle difference, the deviation probability and the uploading time are configured more perfectly, and the factors which are more likely to influence the belt operation, such as the operation speed, the ambient temperature and the humidity of the conveyer belt, are obtained;
specifically, as shown in fig. 4, fig. 4 is a main flow chart of a deviation detecting method of a belt deviation detecting system for a belt conveyor provided in this embodiment, and the system adopts a deviation probability calculating method based on a logistic regression model plus a stiffness constraint. Firstly, training a logistic regression model according to collected historical data, wherein the data comprises: the method comprises the following steps of (1) defining deviation degrees to form training and testing samples, wherein the deviation degrees comprise a deviation angle difference, a paired sensor deviation angle difference, ambient temperature, humidity, belt running speed, installation position, a deviation angle difference between front and rear adjacent sensors and deviation switching signals; after more new samples are accumulated continuously, the model can be iteratively trained; then, calculating the deviation probability for the data acquired by the system in real time by taking the current model and the deviation switch signal as hard constraints, directly determining the data as the deviation when one stage of the two-stage deviation switch is triggered, and directly determining the data as the serious deviation when the two stages of deviation switch are triggered; and when the inferred deviation result exceeds the threshold value, if the deviation is continuously judged for many times, executing deviation response (alarm, stop running of the belt conveyor, sending a message by a mobile phone end and the like).
Claims (8)
1. A belt deviation detection system for a belt conveyor is characterized by comprising a hardware system and a software system;
the hardware system includes:
the deviation sensor (1) of the Internet of things is a deviation sensor for adding the function of the Internet of things on the basis of two-stage deviation switches, adopts the same installation mode as the two-stage deviation switches, is arranged on two sides of a roller carrier of a belt conveyor and is used for acquiring the belt deviation state at the installation position;
the alarm (2) is matched with the internet of things deviation sensor (1) for use and installation, and the alarm (2) is triggered when the belt deviates obviously and is used for on-site warning;
the wireless base station is used for building a WIFI network environment along the belt conveyor;
the conveyor power switch is connected with all the internet of things deviation sensors (1), and when any one position of the belt is seriously deviated, the conveyor power switch can turn off the conveyor;
a data interaction server;
the software system comprises:
the state database comprises an internet of things deviation sensor data table, a belt deviation historical data table and a line table;
the deviation inference service is used for logic judgment of deviation states and calculation of prediction results of the deviation prediction model;
the logic judgment of the deviation state is that when only one of two opposite internet-of-things deviation sensors (1) generates deviation response and the deviation response lasts for a certain time, the belt is considered to be deviated; judging a response strategy according to the deviation grade;
the mobile client is used for checking the belt deviation state and the running states of all the internet of things deviation sensors (1) in real time;
the operation platform is used for checking the belt deviation state and the running states of all the internet of things deviation sensors (1) in real time;
the data interaction server performs data interaction with the operation platform, the mobile client and all the deviation sensors (1) of the Internet of things through a network; the data interaction means receiving and storing real-time data and historical data collected by all the internet of things deviation sensors (1), sending the data of the internet of things deviation sensors (1) to the mobile client and the operation platform and receiving function requests of the mobile client and the operation platform; meanwhile, the system is also a data processing terminal which is used for deploying a belt deviation prediction model and calculating a prediction result in real time;
the deviation state comprises a switching signal of a two-stage deviation switch and initial angle and real-time angle data output by the deviation sensor (1) of the Internet of things; the deviation sensor (1) of the Internet of things actively and continuously sends a deviation state and a sensor equipment state at regular time when working normally; the angle data refers to the inclination angle of the vertical rod of the two-stage deviation switch.
2. The belt off-tracking detection system for the belt conveyor according to claim 1, characterized in that: the deviation sensors (1) of the Internet of things are installed in pairs and are respectively installed on two sides of a roller carrier of the belt conveyor.
3. The belt deviation detecting system for the belt conveyor according to claim 1, wherein: each internet of things deviation sensor (1) is provided with a unique equipment number.
4. The belt off-tracking detection system for the belt conveyor according to claim 1, characterized in that: the data interaction is completed by a data transmission interface defined by an HTTP Server in the data interaction Server, and the interface functions comprise equipment registration, equipment binding, equipment unbinding, equipment query, equipment state query and equipment state update.
5. The belt off-tracking detection system for the belt conveyor according to claim 4, characterized in that: the equipment state comprises a deviation switch signal, an initial inclination angle of a vertical rod, a deviation angle difference of the vertical rod, equipment abnormity, online/offline of the equipment and data updating time, wherein the deviation angle difference of the vertical rod is the difference between the real-time inclination angle of the vertical rod of the two-stage deviation switch and the initial inclination angle during installation.
6. The belt off-tracking detection system for the belt conveyor according to claim 1, characterized in that: the data table of the deviation sensor of the Internet of things comprises a unique ID, a name, an installation distance, a binding line ID, a paired sensor ID, an IP address, a deviation switch signal, an installation initial inclination angle, a real-time inclination angle, a deviation probability, an updating time and an online state; the belt deviation historical data table comprises a sensor ID, a deviation switch signal, a deviation angle difference, a deviation probability, a belt running speed and uploading time.
7. The belt off-tracking detection system for the belt conveyor according to claim 1, characterized in that: the deviation prediction model is a change trend simulated according to historical data of all internet of things deviation sensors (1) on a current line, and is a combination of a time-dimension inclination angle change trend and a space-dimension inclination angle change trend related to the running speed of a belt.
8. The belt off-tracking detection system for the belt conveyor according to claim 1, characterized in that: the functions of the mobile client and the operation platform comprise binding, naming and unbinding of the internet of things deviation sensors (1), pairing of the internet of things deviation sensors (1), setting of installation positions, state display of all the internet of things deviation sensors and belt state display; the state display of the deviation sensor of the Internet of things comprises online/offline of the sensor, and the state display of the belt comprises normal/deviation/severe deviation of the belt.
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Address after: 510760 room 402, building J, No. 2, Jingye Third Street, Yushu Industrial Park, Science City, Huangpu District, Guangzhou, Guangdong Province Applicant after: Guangzhou Huafang Intelligent Technology Co.,Ltd. Address before: 510760 Room 203, 2817 Chuang Chuang Avenue, Huangpu District, Guangzhou, Guangdong Applicant before: Guangzhou Guanli Technology Co.,Ltd. |
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