JP2021128110A - Belt conveyor monitoring device - Google Patents

Abstract

To provide a belt conveyor monitoring device that does not need a patrol by a skilled worker.SOLUTION: The belt conveyor monitoring device includes: a plurality of directional microphones for collecting sound data of a roller of a belt conveyor; a camera for collecting image data of the belt conveyor; a trigger switch for starting and stopping data collection by the directional microphones and by the camera at the same time; and an information terminal for calculating a monitor screen obtained by overlapping the image data on a sound pressure distribution calculated for each frequency by sound data frequency analysis processing.SELECTED DRAWING: Figure 1

Description

The present application relates to a belt conveyor monitoring device.

Belt conveyors that transport luggage, etc. in factories, power plants, etc. are used for a long period of time to transport heavy objects, so part of the conveyor belt is cut off in the middle of the conveyor path, and the rollers that support the conveyor belt fall off. Unexpected accidents and failures may occur.
In order to detect such accidents and failures at an early stage, it was common for skilled workers to patroll along the belt conveyor on a regular basis and inspect them directly visually and audibly.

In recent years, an abnormality detection method has been proposed in which the rotating mechanical sound of a roller constituting a belt conveyor is acquired and analyzed. In this detection method, the rotating mechanical sound of the roller is first measured and analyzed over a wide range using an omnidirectional microphone to detect the presence or absence of an abnormality (discovery mode), and then the roller is partially measured in detail using a directional microphone. The abnormal part is identified (diagnosis mode) by measuring the rotating mechanical sound of the above (Patent Document 1).

JP-A-2002-107223

The method for detecting an abnormality of a belt conveyor described in Patent Document 1 requires a discovery mode using an omnidirectional microphone and a diagnostic mode using a directional microphone, and has a problem that it takes a long time to patrol.
In addition, the rollers that support the conveyor belt of the belt conveyor are often installed close to each other at intervals of about 1 m, and the rotating mechanical noise of the rollers is very loud. There was a problem that it was difficult to identify.

The present application has been made to solve the above-mentioned problems, and an object of the present application is to obtain a belt conveyor monitoring device that facilitates abnormality detection of a belt conveyor and does not require patrol by skilled workers.

The belt conveyor monitoring device of the present application simultaneously starts data collection of a plurality of directional microphones for collecting sound data of rollers of a belt conveyor, a camera for collecting image data of a belt conveyor, and a plurality of directional microphones and cameras. It is equipped with a trigger switch for stopping and an information terminal for creating a monitoring screen in which image data is superimposed on a sound pressure distribution calculated for each frequency by frequency analysis processing of sound data.

The belt conveyor monitoring device of the present application facilitates detection of abnormalities in the belt conveyor, and can monitor abnormalities in the belt conveyor without the need for patrols by skilled workers.

It is a block diagram of the belt conveyor monitoring apparatus which concerns on Embodiment 1. FIG. It is a figure explaining operation and data processing of the belt conveyor monitoring apparatus which concerns on Embodiment 1. FIG. It is a figure which shows the monitoring screen which concerns on Embodiment 1. FIG. It is a figure which shows the monitoring screen which concerns on Embodiment 1. FIG. It is a block diagram of the belt conveyor monitoring apparatus which concerns on Embodiment 2. FIG. It is a figure explaining operation and data processing of the belt conveyor monitoring apparatus which concerns on Embodiment 2. FIG. It is a figure which shows the monitoring screen which concerns on Embodiment 2. FIG.

In the description of the embodiment and each figure, the parts with the same reference numerals indicate the same or corresponding parts.

Embodiment 1.
The belt conveyor monitoring device of the first embodiment will be described with reference to FIGS. 1 to 4.
FIG. 1 is a configuration diagram of the belt conveyor monitoring device of the first embodiment, and FIG. 2 is a diagram for explaining the operation and data processing of the belt conveyor monitoring device of the first embodiment. Further, FIGS. 3 and 4 are monitoring screens of the belt conveyor monitoring device.

<Structure of belt conveyor monitoring device>
FIG. 1 shows a configuration diagram of the belt conveyor monitoring device 1.
In the belt conveyor monitoring device 1, a plurality of directional microphones 3 for collecting the rotating mechanical sounds of rollers and a camera 6 for collecting ambient image data are connected to a data processing amplifier 4, and an information terminal 7 such as a tablet computer is further connected. It has a configuration connected to. A trigger switch 5 that controls the acquisition of the sound data of the directional microphone 3 and the image data of the camera is connected to the data processing amplifier 4.

The directional microphone 3 and the camera 6 can be attached to the helmet of a worker who patrols the belt conveyor. The directional microphone 3 is attached to the left and right positions of the helmet so that when a worker wears the helmet and patrolls around the belt conveyor, the rotating mechanical sound of the rollers of the belt conveyor can be easily collected. It is preferable to mount it facing the conveyor side.
The data processing amplifier 4 and the information terminal 7 can be carried by a worker during the patrol. Further, the trigger switch 5 can be patrolled by an operator while holding it in his / her hand.

In FIG. 1, an example in which two directional microphones 3 are used has been described, but at least two, typically four or more directional microphones 3, are used so that the directivity can be improved and the distance from the sound source can be estimated. Is preferably used.

<Operation of belt conveyor monitoring device and data processing>
FIG. 2 is a diagram for explaining the operation and data processing of the belt conveyor monitoring device.
The worker wears the belt conveyor monitoring device 1 shown in FIG. 1 and presses the trigger switch 5 to start collecting sound data and image data.

The worker points the directional microphone 3 and the camera 6 at the belt conveyor and patrols along the belt conveyor. At this time, the worker does not need to pay attention to the abnormal sound of the belt conveyor, and only needs to pay attention to the collection of sound data and image data.

During the patrol, sound data is collected via the directional microphone 3 and stored in the information terminal 7 via the data processing amplifier 4. The image data is collected via the camera 6 and stored in the information terminal 7 via the data processing amplifier 4 in the same manner as the sound data.
Finally, the trigger switch 5 is pressed again to stop the collection of sound data and image data, and the patrol is completed.

Frequency analysis processing is performed on the collected sound data in parallel with the collection of the sound data or after the sound data is stored in the information terminal 7. The frequency analysis process calculates a sound pressure distribution indicating a change in sound pressure (loudness) with a change in the measurement position for a plurality of frequency ranges.

After the patrol is completed, the mapping process between the sound pressure distribution data calculated by the frequency analysis process and the image data is performed. Here, the mapping process refers to a process of superimposing and displaying the image data of the belt conveyor on the sound pressure distribution data obtained by performing the frequency analysis process on the sound data, and on the sound pressure distribution obtained by the mapping process. The screen on which the image data is superimposed is called the monitoring screen.

In the mapping process, it is necessary to align the sound pressure distribution and the image data and superimpose them. In the first embodiment, the sound data and the image data are both collected in synchronization with the trigger switch 5. Therefore, by superimposing the sound pressure distribution based on the sound data and the image data in accordance with the start time and the stop time of each data collection, the image data is superimposed on the sound pressure distribution of the belt conveyor without deviation. You can get a monitoring screen.

<Monitoring screen>
In the first embodiment, frequency analysis processing of the collected sound data is performed, and monitoring screens are created for two types of frequencies.
First, a monitoring screen was obtained using the sound pressure distribution at a relatively low frequency of 1 kHz. As will be described later, at this frequency, all the rollers of the belt conveyor used in the first embodiment emit a rotating mechanical sound having substantially the same magnitude.

Second, a monitoring screen was created using the sound pressure distribution at a relatively high frequency of 8 kHz. At this frequency, as will be explained later with reference to the figure, not all rollers make a rotating mechanical noise of the same magnitude, but only one specific roller makes a loud rotating mechanical noise, and the other rollers make a loud rotating mechanical noise. It can be said that the rotation operation is different from that of.

FIG. 3 shows a monitoring screen in which image data is mapped on a roller sound pressure distribution at 1 kHz.
In FIG. 3, the five circles indicate the rollers 21 of the belt conveyor, the belt 20 is arranged on the rollers 21, and the belt conveyor is observed from the side surface.
A sound pressure distribution 22 having a frequency of 1 kHz is shown on the back surfaces of the belt 20 and the roller 21, and the dark-colored portion 23 indicates a high sound pressure and the light-colored portion 24 indicates a low sound pressure. ..

In the sound pressure distribution 22 at 1 kHz, the high sound pressure and dark colored portion 23 all coincided with the positions of the five rollers 21. In other words, all the rollers 21 emit a rotating mechanical sound having a frequency of 1 kHz with substantially the same intensity, and do not represent an abnormality of the rollers.

FIG. 4 shows a monitoring screen in which image data is mapped on a sound pressure distribution at a frequency of 8 kHz.
FIG. 4 shows a state in which the belt 20 is arranged on the rollers 21 of the five belt conveyors as in FIG. 3, and FIG. 4 shows a sound pressure distribution 25 at a frequency of 8 kHz on the back surface. ..

In the sound pressure distribution 25 at 8 kHz, a dark-colored portion 26 is observed centering on the portion of the second roller 21 from the left. Therefore, unlike the other rollers 21, the roller 21 emits a very strong rotating mechanical sound at a frequency of 8 kHz, and can be determined to be abnormal.

In the first embodiment, the sound pressure distributions 22 and 25 on the back surface of the monitoring screen are shown in monochrome shades, but it is also effective to represent the sound pressure distributions 22 and 25 in color. By expressing the sound pressure distributions 22 and 25 in color, an abnormality can be easily detected even by checking the monitoring screen for a short time.

In the belt conveyor monitoring device 1 shown in the first embodiment, it is possible to detect an abnormality in the rollers of the belt conveyor without requiring the patrol of a skilled worker. However, each roller may be composed of three sub-rollers, and it is not always possible to detect which of the sub-rollers has an abnormality with this device.
In this case, after detecting an abnormal roller using the belt conveyor monitoring device 1 of the first embodiment, it is necessary for a skilled worker to observe the sub-roller and determine which sub-roller has an abnormality. Become. At this time, by analyzing the monitoring screen in the first embodiment in detail, it may be possible to obtain effective information for assisting the abnormality detection of the subroller.

Embodiment 2.
In the first embodiment, the image data and the sound data are collected in synchronization, and the image data is mapped on the sound pressure distribution at each frequency to obtain a monitoring screen, which is used for monitoring the belt conveyor. ..

The second embodiment is different in that only the sound data is collected during the patrol, and the drawing data of the roller arrangement diagram of the belt conveyor captured in advance is superimposed on the sound pressure distribution at each frequency by the mapping process. ing.

<Structure of belt conveyor monitoring device>
FIG. 5 shows a configuration diagram of the belt conveyor monitoring device 8.
It differs from the belt conveyor monitoring device 1 of the first embodiment in that it does not include a camera 6 for collecting image data.
In the first embodiment, the image data was collected in synchronization with the sound data, but in the second embodiment, the image data is not collected, and the roller arrangement diagram of the belt conveyor to be patrolled in advance is shown. The drawing data is taken into the information terminal 7 and saved.

<Operation of belt conveyor monitoring device and data processing>
FIG. 6 is a diagram illustrating the operation and data processing of the belt conveyor monitoring device 8.
First, as described above, the drawing data of the roller layout of the belt conveyor to be patrolled is taken in advance and stored on the information terminal 7.
It is also possible to store and handle drawing data for a plurality of belt conveyors, and the information terminal 7 is stored and used with an identification number capable of identifying each belt conveyor.
When starting the patrol, the identification number of the belt conveyor is input to the information terminal 7, and the drawing data of the roller layout of the belt conveyor to be patrol is read out.

The operator attaches the belt conveyor monitoring device 8 shown in FIG. 5 and presses the trigger switch 5 to start collecting sound data.
Among the plurality of belt conveyors that the worker patrols, the position of the belt conveyor that has started collecting sound data is recorded, for example, the first roller 21 of the first belt conveyor.
The worker points the directional microphone 3 at the belt conveyor and carries out a patrol along the belt conveyor. At this time, the worker does not need to pay attention to the abnormal sound of the belt conveyor, and only needs to pay attention to the collection of sound data.

Finally, press the trigger switch 5 again to stop the sound data collection, and at the same time, set the position of the belt conveyor when the sound data collection is stopped, for example, the number of belt conveyors at the start of sound data collection. Record like what number of roller 21 etc.
In parallel with the collection of the sound data or after the sound data is stored in the information terminal 7, the sound data is subjected to frequency analysis processing to calculate the sound pressure distribution for each frequency.

The sound pressure distribution is obtained for a plurality of frequencies by the frequency analysis process of the sound data, and the drawing data of the roller arrangement diagram of the belt conveyor is superimposed on the sound pressure distribution by the mapping process to obtain the monitoring screen.
In the mapping process, the mapping process is performed by matching the start and stop of sound data collection for calculating the sound pressure distribution with the position of the drawing data corresponding to the position of the belt conveyor recorded at these timings. , It is possible to obtain a monitoring screen in which drawing data is superimposed on the sound pressure distribution without deviation.

<Monitoring screen>
FIG. 7 shows the monitoring screen of the second embodiment.
Similar to the first embodiment, the sound pressure distribution obtained for the rotating mechanical sound of the roller 21 at frequencies of 1 kHz and 8 kHz is used.
In the first embodiment, these two sound pressure distributions are shown on another monitoring screen, but in the second embodiment, the sound pressure distribution arranged on the back surface of the monitoring screen is displayed on the progress of the belt conveyor on the monitoring screen. It is divided horizontally along the direction, and the upper half uses a sound pressure distribution 28 having a frequency of 1 kHz, and the lower half uses a sound pressure distribution 27 having a frequency of 8 kHz.

Similar to FIGS. 3 and 4 of the first embodiment, the five circles shown in FIG. 7 indicate the roller 21, and the belt conveyor on which the belt 20 is arranged is observed from the side surface. There is. Further, two sound pressure distributions 27 and 28 having frequencies of 1 kHz and 8 kHz are arranged on the back surface thereof.

As described above, the upper halves of the sound pressure distributions 27 and 28 shown on the back surface of FIG. 7 are the sound pressure distribution 28 at 1 kHz, and the sound pressures at the positions corresponding to all the rollers 21 are high. It can be seen that at the frequency, all the rollers 21 emit a rotating mechanical sound of the same intensity.
The lower half shows the sound pressure distribution 27 at 8 kHz, indicating that the sound pressure is high centering on the second roller 21 from the left. This means that the second roller 21 from the left emits a louder rotating mechanical noise than the other rollers 21, and it can be determined that an abnormality has occurred.

Also in the second embodiment, the sound pressure distributions 27 and 28 on the back surface of the monitoring screen are shown in monochrome shades, but it is also effective to represent the sound pressure distributions 27 and 28 in color, and the sound pressure distribution in color. By representing 27 and 28, it is possible to easily detect an abnormality even by checking the monitoring screen for a short time.
Further, the back surface of the monitoring screen is horizontally divided along the traveling direction of the belt conveyor described on the monitoring screen, and is composed of a plurality of sound pressure distributions 27 and 28 having different frequencies, so that the frequency is different. The difference in sound pressure distribution can be clearly seen. Further, a peculiar sound pressure distribution can be found, and an abnormality in the rotating mechanical sound of the roller 21 can be easily detected.

Although various exemplary embodiments and examples have been described in the present application, the various features, embodiments, and functions described in one or more embodiments may be applied to the application of a particular embodiment. Not limited, it can be applied to embodiments alone or in various combinations.
Therefore, innumerable variations not illustrated are envisioned within the scope of the techniques disclosed herein. For example, it is assumed that at least one component is modified, added or omitted, and further, at least one component is extracted and combined with the components of other embodiments.

1 Belt conveyor monitoring device, 3 Directional microphone, 4 Data processing amplifier, 5 Trigger switch, 6 Camera, 7 Information terminal, 8 Belt conveyor monitoring device, 20 belts, 21 rollers, 22 Sound pressure distribution, 23 Dark part, 24 Thin Part, 25 sound pressure distribution, 26 dark part, 27 sound pressure distribution, 28 sound pressure distribution.

Claims (5)

With multiple directional microphones that collect sound data from the conveyor belt rollers,
A camera that collects image data of the belt conveyor and
A trigger switch that starts and stops data collection of the plurality of directional microphones and the camera at the same time,
An information terminal that creates a monitoring screen in which the image data is superimposed on the sound pressure distribution calculated for each frequency by the frequency analysis process of the sound data.
Belt conveyor monitoring device equipped with. The superposition of the image data on the sound pressure distribution is
The belt conveyor monitoring device according to claim 1, wherein the start time and stop time of data collection of the sound data for calculating the sound pressure distribution and the image data are overlapped in accordance with each other. With multiple directional microphones that collect sound data from the conveyor belt rollers,
A trigger switch that starts and stops the collection of sound data from the plurality of directional microphones,
It has drawing data of the roller arrangement drawing of the belt conveyor.
An information terminal that creates a monitoring screen in which the drawing data is superimposed on the sound pressure distribution calculated for each frequency by the frequency analysis process of the sound data.
Belt conveyor monitoring device equipped with. The superimposition of the drawing data on the sound pressure distribution is
The start and stop of the sound data collection for calculating the sound pressure distribution and the position of the drawing data corresponding to the position of the belt conveyor recorded at the start and stop are overlapped with each other. The belt conveyor monitoring device according to claim 3, wherein the belt conveyor monitoring device is characterized by the above. The sound pressure distribution constituting the monitoring screen is divided in the horizontal direction along the traveling direction of the belt conveyor described on the monitoring screen, and is composed of a plurality of the sound pressure distributions having different frequencies. The belt conveyor monitoring device according to any one of claims 1 to 4, which is characteristic.

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