CN116755162A - Matrix type metal detection method and device applied to tubular belt conveyor - Google Patents
Matrix type metal detection method and device applied to tubular belt conveyor Download PDFInfo
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- 239000002184 metal Substances 0.000 title claims abstract description 247
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 247
- 238000001514 detection method Methods 0.000 title claims abstract description 141
- 239000011159 matrix material Substances 0.000 title claims abstract description 81
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
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- G01V3/08—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation operating with magnetic or electric fields produced or modified by objects or geological structures or by detecting devices
- G01V3/10—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation operating with magnetic or electric fields produced or modified by objects or geological structures or by detecting devices using induction coils
- G01V3/104—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation operating with magnetic or electric fields produced or modified by objects or geological structures or by detecting devices using induction coils using several coupled or uncoupled coils
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Abstract
The application particularly relates to a matrix type metal detection method and a matrix type metal detection device applied to a tubular belt conveyor, wherein the method comprises the following steps: the belt runs, after the upper matrix metal detector detects the metal foreign matters, the signal and the data recorded by the encoder are transmitted to the metal detection controller for filtering treatment, and then transmitted to the main controller for length, position, angle and width calculation, and whether the placement position and the placement state can safely pass through the running section is judged; the device comprises an upper matrix metal detector and an encoder, wherein the upper matrix metal detector is provided with two rows of upper metal detection sensors along the length direction of the belt, and the encoder is connected with the unfolding section of the belt. The application can accurately evaluate whether the metal foreign matters safely pass through the belt running section, reduce the false alarm shutdown times, effectively prevent the oversized and overlong metal foreign matters from entering the belt running section to damage the belt and prolong the service life of the belt.
Description
Technical Field
The application belongs to the technical field of metal detection and identification, and particularly relates to a matrix type metal detection method and device applied to a tubular belt conveyor.
Background
The tubular belt conveyer (pipe belt conveyer) is a new type conveyer with both pipeline conveying and belt conveying, its belt can be closed into circular pipe form (running section) by itself in running zone, and can be unfolded into plane form (unfolded section) only in receiving zone and unloading zone, so that the tubular belt conveyer can be used for conveying various block and powder materials of coal, ore, grain, cement, pulp and concrete, etc..
When the belt is provided with metal foreign matters, especially the metal foreign matters exceeding a certain width are easy to pierce the belt in a running area, so that the belt is torn longitudinally in a large range. In order to solve the problem, a person skilled in the art uses a metal detector to detect the material on the belt, but the current metal detector can only detect whether the metal foreign matter exists, and an alarm can be given out no matter how large the metal detector exists, in fact, in certain fields, the metal foreign matter is allowed to appear in the material as long as the metal foreign matter cannot damage the belt, the metal detector in the prior art cannot distinguish the size of the metal foreign matter, and frequent alarm shutdown seriously affects the working efficiency.
Disclosure of Invention
The application aims to provide a matrix metal detection method and a matrix metal detection device applied to a tubular belt conveyor, wherein a matrix metal detector is arranged at an unfolding section before a running section, and a plurality of metal detection sensors are used for cooperatively detecting the length, the width and the angle of metal foreign matters on a belt to judge whether the belt is damaged and pierced or not when the belt enters the running section, so that the false alarm times are reduced, and the working efficiency is improved.
The application is realized by the following technical scheme:
namely a matrix metal detection method applied to a tubular belt conveyor, which is characterized by comprising the following steps:
1) An upper matrix metal detector pointing to the belt is arranged above the part of the expansion section before the operation section, which is in transition from tiling to crimping, the upper matrix metal detector comprises a plurality of upper metal detection sensors which are arranged in a matrix, the detection diameters of the upper metal detection sensors are not overlapped with each other, an encoder is arranged on the belt, and the upper matrix metal detector and the encoder are connected with a metal detection controller through signals;
2) The belt runs, the upper matrix metal detector transmits signals to the metal detection controller after detecting the metal foreign matters, and meanwhile, the data recorded by the encoder at the moment are transmitted to the metal detection controller;
3) The metal detection controller carries out filtering processing on the signals detected by the upper matrix metal detector;
4) And transmitting the signals subjected to filtering pretreatment to a main controller for length, position, angle and width calculation:
and (3) calculating the length: the filtered signals are input into a main controller to obtain metal foreign matter signals, the metal foreign matter signals are recorded as C1 by combining an encoder, the metal foreign matter signals are recorded as C2 after the metal foreign matter signals are not detected, the length C=C2-C1 of the metal foreign matter is equal to or more than one data detected by an upper metal detection sensor, the upper matrix metal detector is provided with a plurality of upper metal detection sensors, after a plurality of groups of data are obtained, the data are subjected to length calculation by adopting a median average filtering method, and the method comprises the following steps: continuously sampling n data, removing a maximum value and a minimum value, and then calculating an arithmetic average value of n-2 data;
width calculation: the detection diameter of the sensors is marked as D1, the interval between the sensors is marked as L1,
the metal foreign matter passes through x and only goes up metal detection sensor, and above-mentioned sensor detects the length of metal foreign matter the same or little different, and metal foreign matter passes through x and only goes up metal detection sensor promptly, metal foreign matter width W:
W＝(x-1)*L1+x*D1
the metal foreign matter passes through x upper metal detection sensors, and the length difference of the metal foreign matter detected by the sensors is large, namely, when the end part of the metal foreign matter passes through the upper metal detection sensor at the position, the chord length of the metal foreign matter passing through the upper metal detection sensor at the position is recorded as L2, the half chord length is L3, the sensor detection radius is R1, the intersection point of the chord length L2 and the sensor detection circular surface is recorded as A, B, the circle center is recorded as O, the angle BAO is set as a, and the data is obtained
cos(a)＝L3/R1
sin 2 (a)＝1-cos 2 (a)
The chordal center distance is H1, h1=r1 sin (a)
N1 is the width part of the detection round surface of the metal foreign body passing through the sensor, N1 = R1-H1, the same can be used for solving the width parts N2 and H2 of the metal detection sensor on the other end part of the metal foreign body passing through the position,
width W of metal foreign matter:
W＝(x-1)*L1+x*D1-H1-H2
h2=0 when only one end portion of the metallic foreign matter passes through the upper metal detection sensor at the place;
and (3) angle calculation: x is the distance between any two upper metal detection sensors in a row of upper metal detection sensors in the matrix, y is the distance that the metal foreign matters pass through the two upper metal detection sensors in sequence, x and y are taken as two right-angle sides of a right triangle, z is the hypotenuse of the right triangle, the included angle between z and x is alpha,
tanα＝y/x
α＝arctanα
＝arc y/x
obtaining an angle alpha of the metal foreign matter;
5) After the length, the width and the angle are calculated, the outline dimension of the metal foreign matters is evaluated to judge the placement position of the metal foreign matters, if the placement state can safely pass through the operation section, the operation section can not pass through the operation section, a signal is output, and the conveyor is stopped.
The length of the metal foreign matter is the distance of the metal foreign matter along the running direction of the belt, and the width of the metal foreign matter is the distance of the metal foreign matter perpendicular to the running direction of the belt.
The upper metal detection sensors are arranged in a matrix manner, a plurality of detection areas which are not mutually interfered and the detection range covers the whole belt are formed from one side of the belt to the other side, and the positions, the lengths, the widths and the angles of the metal foreign matters on the belt can be known by detecting which upper metal detection sensors the metal foreign matters pass through in sequence.
The upper metal detection sensor is an eddy current sensor, is essentially a copper coil, and obtains character information of the metal foreign matters through influence of eddy currents generated by the detected metal foreign matters on coil impedance.
The application relates to a metal detection controller which consists of a stc32 singlechip, a coil oscillating circuit, a detection coil and a signal feedback circuit, and has the functions of: and a device for detecting whether the metal foreign matter passes through the lower part of the coil and transmitting the detection signal to the main controller after processing. The program writing of the stc32 singlechip and the signal connection between the stc32 singlechip and the upper metal detection sensor are all conventional technical means of the person skilled in the art.
The main controller of the application is composed of stc32 singlechip, signal communication interface, pulse input interface, display panel, key input interface and alarm output interface, and has the functions of: and collecting signals transmitted by each upper metal detection controller, calculating the signals, namely detecting the length, the width and the angle of the metal foreign matters, and outputting alarm information. The program writing of the stc32 singlechip and the signal connection between the stc32 singlechip and the metal detection controller are all conventional technical means of the person skilled in the art.
Due to the limitation of the shape, the operation mode and the installation position of the sensor of the pipe belt machine, together with the vibration of the belt, the object on the belt can be spontaneously drawn towards the middle, and the metal foreign matters can necessarily pass through the sensor in the middle of the upper matrix metal detector. I.e. the middle sensor must detect a signal.
If special conditions occur, under the condition that the middle sensor does not detect data, the sensors on two sides detect the data, and the belt is judged to have foreign matters, and the foreign matters are embedded into the belt, at the moment, the main controller sends out an alarm signal, and the belt is stopped.
The position of the metallic foreign matter can be determined by which sensors in the matrix the metallic foreign matter passes.
Whether the metal foreign matters can be released or not is realized according to the parameter setting of the main controller, for example, the set width alarm is 500mm, and the alarm is not given as long as the width of the metal foreign matters does not exceed 500 mm; when the width of the part exceeds 500mm, generating a width alarm signal;
when the set angle alarm is 20 degrees, the angle alarm signal is generated when the angle of the metal foreign body exceeds 20 degrees as long as the angle of the metal foreign body does not exceed 20 degrees and is released.
Furthermore, in the filtering processing in the step 3), when an excessively high or excessively low signal appears, a clipping filtering mode is adopted, and when the system operates normally, a sliding average value filtering mode is adopted.
The above-mentioned too high or too low signal is a random signal.
Clipping and filtering: comparing two sampling values y (n) and y (n-1) at adjacent times n and n-1, and empirically determining the maximum allowable deviation of the two sampling times. If the difference value of the two sampling values exceeds the maximum deviation range, random interference is considered to occur, the sampling value y (n) of the next sampling value is considered to be an illegal value, and y (n) can be replaced by y (n-1) after y (n) is deleted; and if the allowable maximum deviation range is not exceeded, the sampling value is considered to be valid.
And (5) sliding average value filtering: if the number of input sampling points is N, it is assumed that 8 times of moving average filtering is adopted, and the principle of the moving average filtering is as follows: the first data output by the filter is averaged after 8 sampling periods, i.e. the 8 data input is first averaged, resulting in x_0= (x0+x1+ … +x7)/8. The sliding input of the data can be realized after 8 periods, and the filter outputs
x_i＝((7*x_i-1)+xi+7)/8，i＝1，2……。
Furthermore, the front side of the upper matrix metal detector is also provided with a front upper metal detection sensor pointing to the belt, and the front upper metal detection sensor is in signal connection with a metal detection controller.
Further, the front upper metal detection sensors are provided with a plurality of front upper matrix metal detectors.
The front upper matrix metal detector has the same structure as the upper matrix metal detector, and the detection accuracy is higher under the combined action of the front upper matrix metal detector and the upper matrix metal detector.
The front upper metal detection sensor and the upper metal detection sensor have the same structure, and the front upper metal detection sensor/the front upper matrix metal detector is connected with a metal detection controller through signals.
The utility model provides a be applied to tubular belt conveyor's matrix metal detection device, includes the belt, and the belt includes operation section and expansion section, its characterized in that still includes main control unit, metal detection controller, goes up matrix metal detector and encoder, go up matrix metal detector and to the excessive part of department's top of curling by tiling in the expansion section before operation section, go up matrix metal detector and set up the last metal detection sensor of directional belt of matrix arrangement along belt length direction, form a plurality of detection regions that do not interfere with each other and detection range cover whole belt from belt one side to the opposite side, the encoder is connected with the expansion section of belt.
The specific arrangement of the upper matrix metal detectors is preferably but not limited to the following structure:
the upper matrix metal detector is provided with two rows of upper metal detection sensors which are arranged in a matrix and are directed to the belt along the length direction of the belt, the upper metal detection sensors of the second row are positioned on the central line between the two adjacent upper metal detection sensors of the first row, namely, one side of the belt is directed to the other side of the belt, the adjacent 3 upper metal detection sensors form a group, an isosceles triangle structure is formed, and the distance between the outermost upper metal detection sensor and the outer edge of the belt is equal to the distance between the two adjacent upper metal detection sensors.
The distance between two adjacent upper metal detection sensors refers to the distance between the edges of the two upper metal detection sensors.
The upper metal detection sensor in the upper matrix metal detector of the application takes the principle that the detection ranges are not overlapped and mutually noninterfere.
To facilitate distinguishing signals, the present application numbers the sensors.
The encoder of the present application is connected to the deployment section in a number of ways:
1) The rotating shaft of the encoder is contacted with the lower surface of the unfolding section through a roller;
2) The encoder is arranged at the tail shaft of the driving motor;
3) The rotating shaft of the encoder is connected with one end of a driving roller or a driven roller or a tensioning roller at the unfolding section.
The encoder of the application is a mature commercial product in the prior art, and the encoder can be purchased respectively and then assembled for use, and also can be purchased as an integrated roller encoder, for example, the roller encoder produced by the Jitai Wufeng electronic technology Co., ltd.
Furthermore, the front side of the upper matrix metal detector is also provided with a front upper metal detection sensor pointing to the belt, and the front upper metal detection sensor is in signal connection with a metal detection controller.
Further, the front upper metal detection sensors are provided with a plurality of front upper matrix metal detectors, and the arrangement mode and the detection principle of the front upper matrix metal detectors are the same as those of the front upper matrix metal detectors.
The application has the following advantages:
1) The shape of the metal foreign matters can be accurately calculated through the collaborative detection of a plurality of metal detection sensors in the upper matrix metal detector, whether the metal foreign matters safely pass through the belt running section can be evaluated, and the false alarm shutdown times are reduced;
2) The belt running section can be effectively prevented from being damaged by oversized and overlong metal foreign matters, and the service life of the belt is prolonged.
Drawings
FIG. 1 is a schematic diagram of the principle of width calculation when one end portion of a metallic foreign object passes through a certain sensor;
FIG. 2 is a schematic diagram of the angle calculation of the present application;
FIG. 3 is a schematic diagram of the structure of the present application;
FIG. 4 is a schematic diagram showing the positions and numbers of the upper matrix metal detector and the front upper metal detection sensor in the embodiment 1 and the embodiment 2 of the present application;
FIG. 5 is a schematic representation of the numbering of the sensors of the present application employing an upper matrix metal detector and a front upper matrix metal detector;
FIG. 6 is a schematic structural view of part 1 in embodiment 1 of the present application;
fig. 7 is a schematic structural view of part 2 in embodiment 2 of the present application.
As shown in the figure: 1. an operation section; 2. an expansion section; 3. an upper matrix metal detector; 4. an encoder; 5. a front upper metal detection sensor; 6. a metal detection controller; 7. a main controller; 8. front upper matrix metal detector.
Detailed Description
Embodiments of the technical scheme of the present application will be described in detail below with reference to the accompanying drawings. The following examples are only for more clearly illustrating the technical aspects of the present application, and thus are merely examples, and are not intended to limit the scope of the present application. It is noted that unless otherwise indicated, technical or scientific terms used herein should be given the ordinary meaning as understood by one of ordinary skill in the art to which this application belongs.
In the embodiment of the application, the length of the metal foreign matter (part) is the distance of the metal foreign matter along the running direction of the belt, and the width is the distance of the metal foreign matter perpendicular to the running direction of the belt.
Example 1
As shown in fig. 3 and 4, an upper matrix metal detector 3 and a front upper metal detection sensor 5 which are distributed at 10000mm intervals are arranged above the part of the expansion section 2 before the operation section 1, which is excessive from tiling to curling, the rotating shaft of the encoder 4 is contacted with the lower surface of the expansion section 2 through rollers, the upper matrix metal detector 3, the front upper metal detection sensor 5 and the encoder 4 are all in signal connection with a metal detection controller 5, and the metal detection controller 5 is in signal connection with a main controller 6.
The front upper metal detection sensor 5 is numbered 1A1-1, the upper matrix metal detector 3 comprises five upper metal detection sensors, the upper metal detection sensors are arranged in two rows of matrix, the first row is numbered 2A, the second row is numbered 2B, the total number of the sensors is sequentially numbered 2A1-1, 2B1-2, 2A2-3, 2B2-4 and 2A3-5 from top to bottom in the figure, the 2B1-2 of the second row is positioned on a central line between the 2A1-1 and 2A2-3 of the first row, the 2B2-4 of the second row is positioned on a central line between the 2A2-3 and 2A3-5 of the first row, namely, the adjacent 3 upper metal detection sensors form an isosceles triangle, the detection diameter of the upper metal detection sensors is 200mm (denoted as D1), the interval between the first row and the second row is 200mm, the interval between the belt transverse sensors is 133mm (denoted as L1), and the interval between the 2A1-3 and the side edges of the belt is 133mm.
The numbering rules are as follows:
1A1-1
from left to right: 1 refers to group 1, A refers to row 1, 1 refers to group 1, -1 refers to general group 1.
2B1-2
From left to right: 2 refers to group 2, B refers to row 2, 1, -2 refers to the general 2.
The first row of 3 sensors (2A 1-1, 2A1-3, 2A 1-5) of the upper matrix metal detector 3 is arranged at 10000mm of the belt, and the second row of two sensors (2B 1-2, 2B 2-4) is arranged at 10400 mm.
Given a belt width of 1800mm, the principle of this embodiment will be described in detail below with reference to item 1.
As shown in fig. 6: part 1 parameters: 800mm in length, 1600mm in width, and 0 deg. in angle.
When part 1 passed 1A1-1, the recorded data, the start data was 0mm and the end data was 1000mm. The part length is (1000-0) -200=800 mm. (end data-start data) -sensor diameter = part length.
As part 1 passes over upper matrix metal detector 3, data is recorded:
2A1-1 starting data are 10000mm, ending data are 11000mm, and the length of the part passing through the sensor is (11000-10000) -200=800 mm.
2B1-2 starting data are 10400mm, ending data are 11400mm, and the length of the part through the sensor is (11400-10400) -200=800 mm.
2A2-3 starting data are 10000mm, ending data are 11000mm, and the length of the part passing through the sensor is (11000-10000) -200=800 mm.
2B2-4 starting data are 10400mm, ending data are 11400mm, and the length of the part through the sensor is (11400-10400) -200=800 mm.
2A3-5 start data 10000mm, end data 11000mm, part length through sensor (11000-10000) -200=800 mm.
The length of the part collected by the sensors is 800 as known from the five groups of data, and in actual detection, the situation is not the same, so that the part length is firstly sequenced once, then the mathematical expectation E (x) and the variance D (x) are calculated on the group of data, the discrete degree of the group of data is judged, when the D (x) of the group of data is smaller, the group of data is accurate in detection, the average value of the group of data can be selected as the length value of the part, if the D (x) is larger, the abnormality of the group of data is indicated, the length calculation is performed by adopting a median average filtering method, and the method comprises the following steps: continuously sampling n data, removing a maximum value and a minimum value, and then calculating an arithmetic average value of n-2 data;
width calculation: five sensors 2A1-1, 2B1-2, 2A2-3, 2B2-4 and 2A3-5 are adopted for the part 1, the calculated lengths of the part passing through the sensors are all about 800, the part 1 can be known to pass through 5 sensors completely,
the present case applies to w= (x-1) l1+x D1, where x=5,
W＝(5-1)*133+5*200＝1520mm。
since the width of the part already exceeds the maximum width of the sensor placement position, the calculated value is the maximum width of the sensor placement position.
And (3) angle calculation: since part 1 passes through all five sensors and the part length of each sensor is consistent, two sensors may be chosen, for example, using the distance between 2A1-1, 2B1-2 sensors, distance x=100 (2 A1-1 sensor radius) +133 (distance between 2A1-1 and 2B 1-2) +100 (2B 1-2 sensor radius) =333 mm, since part passes through 2A1-1 and then 2B1-2, 2B1-2 start data minus 2A1-1 start data: 10400-10000=400 mm, and since the distance between the first row and the second row of the sensor is 200mm and the diameter of the sensor is 200mm, the initial data of the second row needs to be moved forward by 400mm, so y=400-400=0 mm, namely the angle of the part 1 is 0.
Therefore, the part 1 can be judged to be a rectangular metal foreign body with the length of 800mm, the width of 1520mm and the angle of 0 degree, the difference from the actual size of the part 1 is small, the width alarm is set to be 500mm, the angle alarm is set to be 20 degrees, and the main controller sends an alarm signal and the belt is stopped because the width exceeds 500 mm.
Example 2
The structure of this embodiment is the same as that of embodiment 1, and the numbers of the front upper metal detection sensor 5 and the upper matrix metal detector 3 are the same as those of embodiment 1.
As shown in fig. 6: part 2 parameters: 600mm in length, 600mm in width and 45 DEG in angle
When part 2 passed 1A1-1, the recorded data was 300mm for the start and 600mm for the end. The length of the part passing the sensor is (600-300) -200=100 mm, (end data-start data) -sensor diameter=length of the part passing the sensor.
As part 2 passes over upper matrix metal detector 3, data is recorded:
2A1-1 did not detect data.
2B1-2 starting data are 10400mm, ending data are 10690mm, and the length of the part through the sensor is (10690-10400) -200=90 mm.
2A2-3 starting data were 10300mm and ending data were 10600mm. The length of the part passing the sensor is (10300-10600) -200=100 mm.
2B2-4 starting data are 11000mm and ending data are 11290mm. The length of the part passing the sensor is (11290-11000) -200=90 mm.
2A3-5 did not detect data.
From the above five sets of data, the lengths of the parts 2 collected by the 2B1-2, 2A2-3 and 2B2-4 passing through the sensors are 90mm,100mm and 90mm respectively, namely that only the parts 2,2B1-2 and 2B2-4 are detected by the three sensors completely by the 2A2-3, namely that the upper end part of the part 2 passes through the 2B1-2, the middle part of the part 2 passes through the 2A2-3 completely, and the lower end part of the part 2 passes through the 2B2-4.
Part length: 2B2-4 end data (part 2 was located off the 2 nd row of sensors) is 11000mm,2B1-2 start data (part 2 was located on the 2 nd row of sensors) is 10400mm,
part length: 11290-10400-200 =690 mm.
Width calculation
2B1-2 the length of the test piece 2 through the sensor is 90mm.
2A2-3 the length of the test piece 2 through the sensor is 100mm.
2B2-4 the length of the test piece 2 through the sensor is 90mm.
The calculated lengths of the three parts 2 have larger phase difference, and after the length detection, the length of the part 2 actually passing through the sensor is judged to be 100, namely, only parts 2,2B1-2 and 2B2-4 which are completely detected by the three sensors are considered to be partially detected by the three sensors, as shown in fig. 1: the chord length of the part 2 passing through the 2B1-2 sensor on the sensor circular surface is recorded as l2=290 (end position minus start position) -100 (part length) =190 mm, the half chord length is l3=95 mm, the diameter of the sensor is d1=200 mm, the radius is r1=100 mm, at this time, the intersection point of the chord length L2 and the circle is recorded as A, B, the circle center is recorded as O, the angle ABO is set as a, and the data is obtained from the above
cos(a)＝L3/R1＝0.95
sin 2 (a)＝1-cos 2 (a)＝0.0975
Let the chordal center distance be H1, h1=r1=sin (a) =31 mm.
Let N1 be the width of the part 2 upper end passing the 2B1-2 sensor, n1=r1-h1=100-31=69 mm.
The same applies to finding the width of part 2 passing 2B2-4 sensor n2=69 mm, where part 2 width applies the formula w= (x-1) ×l1+ (x-1) ×d-H1-H2, where x=3
W＝(3-1)*133+(3-1)*200-31-31＝604mm。
The angle detection method is as shown in fig. 2:
since the detected part 2 passes through the 3 sensors with lengths of 90mm,100mm,90mm and 100mm being data detected by the intermediate sensor, the part is considered to pass through 2A2-3 in its entirety and 2B1-2 and 2B2-4 in its part.
When x selects the distance between 2B1-2 and 2A 2-3:
x=100 (sensor diameter/2) -h1+133 (width direction two sensor pitch) +100 (sensor diameter/2) =302 mm;
y=10300 (2 A2-3 start data) - (10400 (2B 1-2 start data) -400 (since the first row and the second row of sensors are 200mm apart and the sensor diameter is 200mm, start data of the second row needs to be moved forward by 400mm. So that subtraction is required 400))=300 mm;
a＝arctan(a)＝arc(300/302)＝44.80°；
when x selects the distance between 2A2-3 and 2B 2-4:
x=100 (sensor diameter/2) -h2+133 (width direction two sensor pitch) +100 (sensor diameter/2) =302 mm;
y= (11000 (2B 2-4 start data) -400 (because the first row of sensors is 200mm apart from the second row, the sensor diameter is 200mm, so the start data of the second row needs to be moved forward by 400mm. So the start data needs to be subtracted by 400)) -10300 (2 A2-3 start data) =300 mm;
a＝arctan(a)＝arc(300/302)＝44.80°；
the two angle calculations are similar and it can be considered that the angle of the part 2 is 44.80 deg. at this time.
If the two angle calculations differ greatly, the following method can be adopted for calculation again,
the width of the part 2 was calculated previously
W＝(x-1)*L1+(x-1)*D-H1-H2
＝(3-1)*133+(3-1)*200-31-31
＝604mm
I.e. x=604 mm;
calculating x is the data detected by using 2B1-2 to 2B2-4, and y is also the data detected by using 2B1-2 to 2B2-4
y=11000 (2B 2-4 start data) -10400 (2B 1-2 start data) =600 mm;
at this time, the angle of the part is tan (a) =600/604, a=arctan (a) =arc (600/604) = 44.81 °, at this time, the calculated angle values are compared, if two angles are similar, the angle value is taken, and if three angles are not similar, the average value of the angles is taken.
Since the 2A2-3 sensor is placed in the middle of the belt during detection, and the part 2 completely passes through the 2A2-3 sensor, according to the calculated angle, the width of the part 2 itself can be calculated as 100mm sin 44.8=70 mm.
Therefore, the part 2 can be judged to be a strip-shaped metal foreign body which is 70mm wide, 690mm long, 604mm wide and 44.8 degrees in angle, and is matched with the actual situation, the width alarm is set to be 500mm, the angle alarm is set to be 20 degrees, and the main controller sends an alarm signal because the width exceeds 500mm and the angle exceeds 20 degrees, and the belt is stopped.
The foregoing embodiments are merely for illustrating the technical solution of the present application, and are not limited thereto, for example, the front upper metal detection sensor may be omitted (the detection accuracy may be reduced) or a plurality of front upper metal detection sensors may be used for the front upper matrix metal detector, and the sensor numbering rule is shown in fig. 5 (the detection accuracy may be improved).
Although the application has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the application, and are intended to be included within the scope of the appended claims and description.
Claims (7)
1. A matrix metal detection method applied to a tubular belt conveyor is characterized by comprising the following steps:
1) An upper matrix metal detector pointing to the belt is arranged above the part of the expansion section before the operation section, which is in transition from tiling to crimping, the upper matrix metal detector comprises a plurality of upper metal detection sensors which are arranged in a matrix, the detection diameters of the upper metal detection sensors are not overlapped with each other, an encoder is arranged on the belt, and the upper matrix metal detector and the encoder are connected with a metal detection controller through signals;
2) The belt runs, the upper matrix metal detector transmits signals to the metal detection controller after detecting the metal foreign matters, and meanwhile, the data recorded by the encoder at the moment are transmitted to the metal detection controller;
3) The metal detection controller carries out filtering processing on the signals detected by the upper matrix metal detector;
4) And transmitting the signals subjected to filtering pretreatment to a main controller for length, position, angle and width calculation:
and (3) calculating the length: the filtered signals are input into a main controller to obtain metal foreign matter signals, the metal foreign matter signals are recorded as C1 by combining an encoder, the metal foreign matter signals are recorded as C2 after the metal foreign matter signals are not detected, the length C=C2-C1 of the metal foreign matter is equal to or more than one data detected by an upper metal detection sensor, the upper matrix metal detector is provided with a plurality of upper metal detection sensors, after a plurality of groups of data are obtained, the data are subjected to length calculation by adopting a median average filtering method, and the method comprises the following steps: continuously sampling n data, removing a maximum value and a minimum value, and then calculating an arithmetic average value of n-2 data;
width calculation: the detection diameter of the sensors is marked as D1, the interval between the sensors is marked as L1,
the metal foreign matter passes through x and only goes up metal detection sensor, and above-mentioned sensor detects the length of metal foreign matter the same or little different, and metal foreign matter passes through x and only goes up metal detection sensor promptly, metal foreign matter width W:
W＝(x-1)*L1+x*D1
the metal foreign matter passes through x upper metal detection sensors, and the difference of the lengths of the metal foreign matter detected by the sensors is large, namely, when the end part of the metal foreign matter passes through the upper metal detection sensor at the position, the chord length of the metal foreign matter passing through the upper metal detection sensor at the position is recorded as L2, the half chord length is L3, the sensor detection radius is R1, the intersection point of the chord length L2 and the sensor detection circular surface is recorded as A, B, the circle center is recorded as O, the angle ABO is set as a, and the data is obtained
cos(a)＝L3/R1
sin 2 (a)＝1-cos 2 (a)
The chordal center distance is H1, h1=r1 sin (a)
N1 is the width part of the detection round surface of the metal foreign body passing through the sensor, N1 = R1-H1, the same can be used for solving the width parts N2 and H2 of the metal detection sensor on the other end part of the metal foreign body passing through the position,
width W of metal foreign matter:
W＝(x-1)*L1+(x-1)*D1-H1-H2
h2=0 when only one end portion of the metallic foreign matter passes through the upper metal detection sensor at the place;
and (3) angle calculation: x is the distance between any two upper metal detection sensors in a row of upper metal detection sensors in the matrix, y is the distance that the metal foreign matters pass through the two upper metal detection sensors in sequence, x and y are taken as two right-angle sides of a right triangle, z is the hypotenuse of the right triangle, the included angle between z and x is alpha,
tanα＝y/x
α＝arctanα
＝arc y/x
obtaining an angle alpha of the metal foreign matter;
5) After the length, the width and the angle are calculated, the outline dimension of the metal foreign matters is evaluated to judge the placement position of the metal foreign matters, if the placement state can safely pass through the operation section, the operation section can not pass through the operation section, a signal is output, and the conveyor is stopped.
2. The matrix metal detection method for a tubular belt conveyor according to claim 1, wherein step 3) filtering is performed by limiting filtering when an excessively high or excessively low signal is present, and the system is performed by sliding average filtering during normal operation.
3. The matrix metal detection method for a tubular belt conveyor according to claim 1, wherein the front side of the upper matrix metal detector is further provided with a front upper metal detection sensor directed toward the belt, the front upper metal detection sensor being in signal connection with the metal detection controller.
4. A matrix metal detection method for a tubular belt conveyor according to claim 3 wherein a plurality of front upper metal detection sensors are provided, the plurality of front upper metal detection sensors comprising a front upper matrix metal detector.
5. The utility model provides a be applied to tubular belt conveyor's matrix metal detection device, includes the belt, and the belt includes operation section and expansion section, its characterized in that still includes main control unit, metal detection controller, goes up matrix metal detector and encoder, go up matrix metal detector and to the excessive part of department's top of curling by tiling in the expansion section before operation section, go up matrix metal detector and set up the last metal detection sensor of directional belt of matrix arrangement along belt length direction, form a plurality of detection regions that do not interfere with each other and detection range cover whole belt from belt one side to the opposite side, the encoder is connected with the expansion section of belt.
6. The matrix metal detection device for a tubular belt conveyor of claim 5, wherein the front side of the upper matrix metal detector is further provided with a front upper metal detection sensor directed toward the belt, the front upper metal detection sensor being in signal connection with the metal detection controller.
7. The matrix metal detector for a tubular belt conveyor of claim 6, wherein the plurality of front upper metal detectors are arranged in the same manner as the front upper matrix metal detectors.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117019682A (en) * | 2023-10-08 | 2023-11-10 | 山东力达智能车辆产业技术研究院有限公司 | Device and method for measuring angle of part for manufacturing motor home |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117019682A (en) * | 2023-10-08 | 2023-11-10 | 山东力达智能车辆产业技术研究院有限公司 | Device and method for measuring angle of part for manufacturing motor home |
| CN117019682B (en) * | 2023-10-08 | 2024-01-05 | 山东力达智能车辆产业技术研究院有限公司 | Device and method for measuring angle of part for manufacturing motor home |
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