JP5456999B2 - Belt support roller monitoring system - Google Patents

Description

  The present invention relates to a belt support roller monitoring system for monitoring an abnormality of a belt support roller which is disposed at intervals in the length direction of the conveyor belt and rotatably supports the conveyor belt, and more particularly to efficiently detect the abnormality. It relates to what can be monitored.

  Conveyor belts used for transporting coal and ore are very long to convey long distances, and are therefore configured to support multiple locations with a large number of spaced belt support rollers. ing. Such a belt support roller bears the vertical load of the conveyor belt, but a rotatable roller supported at both ends by bearings such as roller bearings is driven by the traveling conveyor belt to rotate and rotate. It is comprised so that driving | running | working of a belt may not be inhibited. However, since these are mechanically moved, there is a possibility of failure, and in particular, the bearing becomes hard and the rollers cannot be driven, which may lead to failure of the conveyor belt.

Conventionally, with respect to such a rotation failure of the belt support roller, a device has been proposed in which each belt support roller is provided with a sensor for detecting a failure and a transmission means for transmitting information on the failure ( For example, see Patent Document 1.)
JP 2005-30588 A

  However, in the prior art, it is necessary to install a sensor or the like for each belt support roller, which is enormous in terms of cost, and even if it is found that the belt support roller has failed. Therefore, a system for collecting the information is indispensable, and a large amount of cost is required also in this respect.

  The present invention has been made in view of such problems, and an object thereof is to provide a belt support roller monitoring system that is simple and can greatly reduce the cost.

<1> is a belt support roller monitoring system that monitors an abnormality of a belt support roller that is disposed at intervals in the length direction of the conveyor belt and rotatably supports the conveyor belt.
A sensor unit is provided on the conveyor belt, the sensor unit detects a physical quantity received from the belt support roller, a determination unit that determines abnormality of the belt support roller based on a measurement value obtained from the sensor, and a determination result And a transmission means for transmitting the data stored in the memory by radio waves to the outside of the conveyor belt and receiving the data transmitted from the transmission means outside the conveyor belt A belt support roller monitoring system provided with a receiving station.

  <2> means that only the data of the belt support roller that is determined to be abnormal is not transmitted from the transmission unit, and the data of the belt support roller that is determined not to be abnormal by the determination unit in <1>. The belt support roller monitoring system according to claim 1, wherein the transmission is performed from the transmission unit.

  <3> is that the data of the belt support roller determined not to be abnormal by the determination unit in <2> is not stored in the memory, and only the data of the belt support roller determined to be abnormal is stored in the memory. A belt support roller monitoring system, wherein the belt support roller monitoring system is stored in a memory.

  <4> is abnormal in <3>, in which counter means for detecting the order of each belt support roller for detecting the physical quantity along the length direction of the conveyor belt and an initiator for clearing the counter are provided. The belt support roller monitoring system stores only the order of the belt support roller determined to be in the memory.

<5> is configured so that, in <4> , the sensor is configured to detect the physical quantity continuously while the conveyor belt is running, and the physical quantity changes when the sensor passes the belt support roller. And when the measured value from the sensor exceeds a predetermined first threshold value, the counter means advances the counter by one because the sensor has passed one of the belt support rollers, and the determination means A belt support roller monitoring system configured to determine that the belt support roller is abnormal when the measured value exceeds a predetermined second threshold value.

<6>, in <4> or <5>, the CPU provided in the sensor unit, which is the composed constitute the determining means and the counter means in the CPU belt support rollers monitoring system.

  <7> is configured such that, in <6>, the receiving station periodically transmits a data transmission command, and the CPU transmits data to the receiving station when the data transmission command is received. A belt support roller monitoring system for operating a transmission means.

<8> includes a start signal transmission station that transmits a signal for instructing clearing of data including counter data as the initiator in <7>, and the CPU sends the signal from the start signal transmission station to the signal when receiving a belt support rollers monitoring system comprising configured to clear at least the counter.

  According to <1>, a sensor for detecting a physical quantity received from the belt support roller by a sensor unit provided on the conveyor belt, and a determination unit for determining abnormality of the belt support roller based on a measurement value obtained from the sensor And a memory for storing data including the determination result, and a transmission means for transmitting the data stored in the memory by radio waves to the outside of the conveyor belt, and transmitted from the transmission means to the outside of the conveyor belt Since a receiving station for receiving data is provided, information on which belt supporting roller is broken in the sensor unit is held in the sensor unit without providing a sensor or transmitting means for each belt supporting roller, and the information is received by the receiving station. The belt support roller can be monitored for failures with a simple and low-cost system.

  According to <2>, the data of the belt support roller determined not to be abnormal by the determination unit is not transmitted from the transmission unit, and only the data of the belt support roller determined to be abnormal is transmitted to the transmission unit. Therefore, the necessary information can be transmitted by transmitting a small amount of data to the receiving station, and the reliability of communication can be improved by shortening the communication time.

  According to <3>, the belt support roller data determined not to be abnormal by the determination means is not stored in the memory, but only the data of the belt support roller determined to be abnormal is stored in the memory. Therefore, the capacity of the memory can be kept small, and the reliability of communication can be further improved by shortening the data input / output time for the memory.

  According to <4>, it is determined that there is an abnormality by providing counter means for detecting the order of each belt support roller for detecting the physical quantity along the length direction of the conveyor belt and an initiator for clearing the counter. Since only the order of the belt support rollers is stored in the memory, information indicating which belt support roller has failed can be expressed with the least amount of data.

  According to <5>, the sensor is configured to detect the physical quantity continuously while the conveyor belt is running, and the physical quantity selected when the sensor passes the belt support roller is selected. The counter means advances the counter by one because the sensor has passed one of the belt support rollers when the measured value from the sensor exceeds a predetermined first threshold, and the determination means Since the belt support roller is determined to be abnormal when the value exceeds a predetermined second threshold value, the belt support roller can be identified only by measuring the physical quantity with a sensor. Thus, it is possible to determine whether or not the specified belt support roller is faulty, and it is possible to collect information on which belt support roller is faulty very easily.

According to <6>, a CPU provided in the sensor unit, said determining means and said counter means so configured in this CPU, it is possible to configure the sensor unit compact.

  According to <7>, the receiving station is configured to periodically transmit a data transmission command, and the CPU is configured to transmit a data to the receiving station when receiving the data transmission command. Since the sensor unit is operated, the data is transmitted only when the sensor unit enters the range in which the command signal from the receiving station can be received, so that the data transmission can be minimized.

  According to <8>, as the initiator, a start signal transmission station that transmits a signal for instructing clearing of data including counter data is provided outside the conveyor belt, and the CPU receives at least the signal when the signal is received. Since the counter value is cleared, the initiator can be configured with a simple mechanism.

  A belt support roller monitoring system according to an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a conceptual diagram showing a belt support roller monitoring system according to this embodiment. The belt support roller monitoring system 10 includes a sensor unit 2 embedded in an endless conveyor belt 1 and data transmitted from the sensor unit 2. And a receiving station 5 for receiving. In addition to being supported by driven and driven pulleys 9 at both ends, the conveyor belt 10 is also shown in FIG. 2 in a schematic cross-sectional view of the conveyor belt 1 and can be arranged at intervals along the length of the conveyor belt. The belt support roller 3 supports the conveyor belt 1 to prevent a large tension from being applied due to the vertical load.

  The sensor unit 2 continuously detects a physical quantity received by the conveyor belt, for example, a shear stress in the length direction applied to the surface of the conveyor belt, and based on the detected information, It has a function of judging abnormality and transmitting the result to the receiving station by radio waves. For this reason, the sensor unit 2 is provided corresponding to each row of belt support rollers 3 arranged in the width direction of the conveyor belt. In the case shown in FIG. Correspondingly, the sensor units 2 are arranged in three rows in the conveyor belt width direction. Reference numeral 8 denotes a conveyed object.

  FIG. 3 is a block diagram showing the configuration of the sensor unit 2. The sensor unit 2 is based on the sensor 11 that detects the physical quantity received by the conveyor belt 1 and the physical quantity at a position corresponding to the belt support roller 3. The determination means 13 for determining whether or not the belt support roller 3 is abnormal, the counter means 14 for counting the increase in the order of the belt support rollers, the memory 15 for storing the determination result, and the memory 15 The transmission means 16 is configured to transmit data to the receiving station 5 (also serving as an end signal transmitting station). Here, it is preferable that the determination unit 13 and the counter unit 14 are constituted by the CPU 12.

  In addition to the sensor unit 2 and the receiving station 5, the belt support roller monitoring system 10 starts the sensor unit 2 from outside the conveyor belt and clears the count result by the counting means 14 to start counting. A start signal transmitting station 10 for transmitting a start signal is provided, while the sensor unit 2 is provided with receiving means 17 for receiving the start signal.

  Further, an end signal transmitting station for transmitting an end signal for terminating the sensor unit 2 can be provided separately from the receiving station 5. However, as shown in FIG. 3, the receiving station 5 also serves as this end signal transmitting station. It may be.

  Then, the transmission means 16 and the reception means 17 forming part of the sensor unit 2 are configured by RFID, and the reception station 5 (also serving as an end signal transmission station) and the start signal transmission station 10 are transmitted with a data transmission command in a short cycle. Preferably, the signal (and the end signal) and the start signal are each transmitted, so that only when the sensor unit 2 is close to the respective station 5, 10 communication is performed between them. be able to.

  In order to start or end transmission of signals corresponding to the start signal transmitting station 4 and the receiving station 5, respectively, remote control means (not shown) connected to the stations 4 and 5 or the computer 7 are used. Thus, for example, a start signal can be automatically transmitted once a day at a predetermined time, or it can be manually operated.

  A method for monitoring the presence or absence of abnormality of the belt support roller by using the belt support roller monitoring system configured as described above will be described below. The sensor unit 2 is configured so as to maintain the power saving mode as an initial state, but can be brought out of the power saving mode by a signal from the outside by radio waves. 1, the CPU 12 of the sensor unit 2 receives the signal when it approaches the start signal transmission station 4 that transmits the start signal in a short cycle and reaches within a range where radio waves can be detected therefrom. Based on the start signal input via the means 17, the power saving mode of the sensor unit 2 is canceled and the counter value held by the counter means 14 is cleared to zero. At this time, the CPU 12 may also clear the data held in the memory 15.

  Thereafter, the sensor unit 2 leaves the radio wave detection range of the start signal transmission station 4 as the conveyor belt 1 travels, and passes over the first belt support roller 3 (3A). For example, when the sensor 11 is configured to detect the shear stress in the length direction of the conveyor belt on the surface of the conveyor belt, the sensor 11 outputs a signal having a continuous waveform as shown in FIGS. This signal is input to the determination means 13 and the counter means 14 constituting a part of the CPU 12.

  FIG. 4 is a graph showing changes in the output signal from the sensor 11 with time on the horizontal axis and signal magnitude on the vertical axis. When the sensor 11 passes over the belt support roller 3, the conveyor belt is shown. On the inner surface of 1, a shearing force due to a slight slip with the belt support roller 3 acts, and a change in signal proportional to the shearing force appears as shown in the S part in the figure. The output signal at this time is much smaller than the first threshold A at a portion far from the belt support roller 3 and exceeds the first threshold A only when the sensor 11 passes the belt support roller 2. It is possible to set the threshold value A. By setting in this way, it is possible to detect that the sensor 11 has passed the belt support roller 2.

  When the counter means 14 is configured to increase the counter by 1 when the first threshold A is exceeded, the belt support rollers can be ordered. That is, for example, the counter value until the sensor 11 reaches the roller 3B after passing the roller 3A is 1, and the counter value until the sensor 11 reaches the roller 3C after passing the roller 3B is 2. .

  FIG. 5 is a graph showing the change in the output signal from the sensor 11 when the sensor 11 passes the belt support roller 3 (corresponding to the S portion in FIG. 4), and the solid line shows the change in the normal state. The broken line represents the change in the abnormal case. If the belt support roller 3 fails and the bearing does not operate normally and does not follow the conveyor belt 1, a large frictional force is applied to the surface of the conveyor belt 1. Works. At this time, the output signal from the sensor 11 is smaller than the second threshold B when the belt support roller 3 is normal, and the threshold B is set so as to exceed the second threshold B for the first time when the belt support roller 3 becomes abnormal. Thus, the determination means 13 can determine whether or not the belt support roller 3 is operating abnormally.

  Then, for example, immediately after the ordering of the belt support rollers 3 using the first threshold A, the presence or absence of abnormality of the belt support roller is determined, and the order when this determination is performed is determined as the presence or absence of abnormality. By using the number of the belt support roller as the determination target, it is possible to associate each belt support roller with the presence or absence of an abnormality with respect to the belt support roller.

  For example, when the order when judged to be normal is 1 and the order when judged as abnormal is 2, the first belt support roller is normal and the second belt support roller is abnormal. It means that.

  The calculation results obtained by the determination unit 13 and the counter unit 14 of the CPU 12 are temporarily stored in the memory 15. After the sensor unit 11 further advances in the traveling direction of the conveyor belt 1 and enters the detection range of the data transmission command signal transmitted by the receiving station 5 in a short cycle, this signal is input to the CPU 12 via the receiving means 17. Then, the CPU 12 operates so as to transmit the data in the memory 15 via the transmission unit 16. The receiving station 5 receives the signal from the sensor unit 2, and the data regarding the presence / absence of abnormality of the belt supporting roller 3 received by the receiving station 5 is finally processed by the computer 7 connected thereto. Made.

  Here, as data to be stored in the memory 15, in order to save the capacity of the memory 15, the normal belt support roller 3 is not stored in the memory as data, but only the order corresponding to the abnormality should be stored. For example, the memory capacity can be reduced. For example, when data of 2, 8, and 11 are stored in the memory 15, the second, eighth, and eleventh belt support rollers 3 counted from the start signal transmission station 4 are abnormal, and other than that This means that the belt support roller 3 is normal.

  The data stored in the memory 15 in this way has a small capacity, and the amount of data to be transmitted is extremely small even when data is transmitted to the receiving station 5, so that the communication time is extremely short and data transmission to the receiving station 5 is prevented. It can be done reliably.

  In the above description, when the conveyor belt 1 circulates once, the abnormal belt support roller 3 is determined. However, when data is collected by running the multi-circular conveyor belt 1, due to variations in detection, etc. The order of the belt support rollers 3 determined to be abnormal may be different from the actual order. In such a case, as a final determination, the detection probability of the abnormal belt support rollers is a predetermined value or more. If only this is determined to be abnormal, the determination reliability can be improved.

  An example is shown below. Table 1 shows the primary determination results indicating the order corresponding to the belt support rollers detected in the first, second, and third turns of the conveyor belt 1. Based on the primary determination result, the probability that each belt support roller is determined to be abnormal is calculated as shown in Table 2, and those having a probability of 50% or more are determined to be abnormal in the final determination. The results are as shown in Table 2.

  As described above, the signal level higher than the first threshold A is adopted as the second threshold for determining the presence / absence of the abnormality in the belt support roller 3, but instead, the second threshold is set to the second threshold. For example, as shown in FIG. 6 as a case where the solid line is a normal waveform and the broken line is an abnormal waveform, the time T1 from the positive peak to the negative peak is shown in FIG. The second threshold C is set, and when the value C1 of the time T1 in the actual waveform is larger than the second threshold C, this is determined to be normal, and the value C2 of the time T1 in the actual waveform is smaller than the threshold C. Sometimes this can be determined to be abnormal.

  Further, as shown in FIG. 8 in the same manner as the threshold value along the time axis, a second threshold value D is set for the time T2 from the positive start point to the negative end point. When the value D1 of the time T2 in the current waveform is larger than the second threshold value D, it is determined as normal, and when the value D2 of the time T2 in the actual waveform is smaller than the threshold value D, it can be determined as abnormal.

  FIG. 8 is a conceptual diagram showing a first modification of the embodiment according to the present invention. A belt support roller monitoring system 10A of this modification is different from the belt support roller monitoring system 10 of the embodiment described above. The point is that the function of the reception station 5 and the function of the start signal transmission station 4 in the belt support roller monitoring system 10 are integrated and arranged as the external station 6, whereby the data stored in the memory 15 is stored. The only difference is that the timing of transmission to the outside is delayed, and there is no difference in basic functions.

  FIG. 9 is a conceptual diagram showing a second modification of the embodiment according to the present invention. The belt support roller monitoring system 10B of this modification is different from the belt support roller monitoring system 10 of the embodiment described above. The only difference is that a series of belt support rollers are divided into a plurality of groups, and start signal transmission stations 4A, 4B, and 4C and reception stations 5A, 5B, and 5C are provided for each group. If the number of the belt support rollers 3 is large, there is a possibility that even if the sensor 11 passes through the belt support roller 2, it may not be detected by the first threshold A. In such a case, the actual belt support roller 3 and the detected order of the belt support rollers do not match.

  Therefore, as in the belt support roller monitoring system 10B of this modification, the probability of inconsistencies occurring as a group is reduced by reducing the number of belt support rollers that are targeted when data is transferred to the receiving station. Can do. In this case, the data received at the receiving stations 5A, 5B, and 5C may be processed individually by connecting computers to the receiving stations 5A, 5B, and 5C. The receiving stations 5A, 5B, and 5C may be connected to only a memory (may be a hard disk) for storing data, and the memory may separately take out the data.

It is a conceptual diagram which shows the belt support roller monitoring system of embodiment which concerns on this invention. It is sectional drawing which shows a conveyor belt. It is a block diagram which shows the structure of a sensor unit. It is a graph which shows the change of the output signal of a sensor. It is a graph which shows the change of the output signal of a sensor at the time of passing a sensor unit belt support roller, and the 2nd threshold. It is a graph which shows the change of the output signal of a sensor at the time of passing a sensor unit belt support roller, and other 2nd threshold values. It is a graph which shows the change of the output signal of a sensor at the time of passing a sensor unit belt support roller, and other 2nd threshold values. It is a conceptual diagram which shows the 1st modification of the belt support roller monitoring system of embodiment. It is a conceptual diagram which shows the 2nd modification of the belt support roller monitoring system of embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Conveyor belt 2 Sensor unit 3, 3A, 3B Belt support roller 4, 4A, 4B, 4C Start signal transmission station 5, 5A, 5B, 5C Reception station 6 External station 8 Conveyed object 9 Pulley 7 Computer 10, 10A, 10B Belt support roller monitoring system 11 Sensor 12 CPU
13 Determination Unit 14 Counter Unit 15 Memory 16 Transmission Unit 17 Reception Unit 18 RFID

Claims (8)

In a belt support roller monitoring system that monitors an abnormality of a belt support roller that is disposed at intervals in the length direction of the conveyor belt and rotatably supports the conveyor belt,
A sensor unit is provided on the conveyor belt, the sensor unit detects a physical quantity received from the belt support roller, a determination unit that determines abnormality of the belt support roller based on a measurement value obtained from the sensor, and a determination result And a transmission means for transmitting the data stored in the memory by radio waves to the outside of the conveyor belt and receiving the data transmitted from the transmission means outside the conveyor belt A belt support roller monitoring system with a receiving station.   The belt support roller data determined not to be abnormal by the determination unit is not transmitted from the transmission unit, and only the data of the belt support roller determined to be abnormal is transmitted from the transmission unit. The belt support roller monitoring system according to claim 1.   The belt support roller data determined not to be abnormal by the determination means is not stored in the memory, but only the belt support roller data determined to be abnormal is stored in the memory. Item 3. The belt support roller monitoring system according to Item 2.   Counter means for detecting the order of the belt support rollers for detecting the physical quantity along the length direction of the conveyor belt and an initiator for clearing the counter are provided. 4. The belt support roller monitoring system according to claim 3, wherein only the order is stored in a memory.   The sensor is configured to detect the physical quantity continuously during the running of the conveyor belt, and selects the physical quantity that changes when the sensor passes the belt support roller. When the measured value from exceeds a predetermined first threshold, the sensor advances one counter as having passed one of the belt support rollers, and the determination means determines that the measured value is predetermined. The belt support roller monitoring system according to claim 4, wherein the belt support roller monitoring system is configured to determine that the belt support roller is abnormal when the second threshold value is exceeded. The sensor unit of the CPU provided in the judging means and the belt support rollers monitoring system according to the counter means to claim 4 or 5 comprising constituted by this CPU.   The receiving station is configured to periodically transmit a data transmission command, and when the CPU receives the data transmission command, the CPU operates transmission means to transmit data to the receiving station. 6. The belt support roller monitoring system according to 6. As the initiator, provided the start signal transmission station for transmitting a signal for commanding to clear the data includes a counter data out of the conveyor, the CPU, when the start signal originating station receives the signal, at least the counter 8. A belt support roller monitoring system according to claim 7 configured to clear.

Images