WO2017197873A1 - System and method for diagnosing failure of belt-type conveyor - Google Patents

System and method for diagnosing failure of belt-type conveyor Download PDF

Info

Publication number
WO2017197873A1
WO2017197873A1 PCT/CN2016/108842 CN2016108842W WO2017197873A1 WO 2017197873 A1 WO2017197873 A1 WO 2017197873A1 CN 2016108842 W CN2016108842 W CN 2016108842W WO 2017197873 A1 WO2017197873 A1 WO 2017197873A1
Authority
WO
WIPO (PCT)
Prior art keywords
belt
belt conveyor
signal
sensor
coal
Prior art date
Application number
PCT/CN2016/108842
Other languages
French (fr)
Chinese (zh)
Inventor
陈潇
朱真才
李伟
史志远
周满山
岳彦博
江帆
Original Assignee
中国矿业大学
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 中国矿业大学 filed Critical 中国矿业大学
Publication of WO2017197873A1 publication Critical patent/WO2017197873A1/en

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
    • B65G43/02—Control devices, e.g. for safety, warning or fault-correcting detecting dangerous physical condition of load carriers, e.g. for interrupting the drive in the event of overheating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
    • B65G2203/02—Control or detection
    • B65G2203/0266—Control or detection relating to the load carrier(s)
    • B65G2203/0275—Damage on the load carrier

Definitions

  • the invention relates to a conveyor fault diagnosis system and method, in particular to a belt conveyor fault diagnosis system and method.
  • the belt conveyor is widely used in coal mine underground and metallurgy, coal, transportation, chemical and other departments due to its simple structure, large conveying capacity and strong adaptability.
  • the belt conveyor is prone to faults such as deviation, belt breakage, slippage, and stacking. These failures cause huge economic losses and casualties.
  • the belt conveyor system In order to ensure the safe and stable operation of the belt conveyor system, according to the regulations of the coal mine safety regulations, the belt conveyor system must be equipped with various protections such as anti-skid protection device, coal storage protection device, tension reduction protection device and tear protection device. Device.
  • anti-skid protection device coal storage protection device
  • tension reduction protection device tension reduction protection device
  • tear protection device tear protection device.
  • these protection measures cannot detect faults at an early stage, and most of them remain in the action protection after the failure, which is not only prone to malfunction, has certain potential risks, and has high maintenance costs at a later stage.
  • the object of the present invention is to provide a fault diagnosis system and method for a belt conveyor, which solves the problem that the protection measures of the existing belt conveyor cannot find the treatment failure at an early stage.
  • the fault diagnosis system comprises: a current sensor, a hydraulic pressure sensor, four rotational speed sensors, a PLC and a host computer; the sensors are installed at a key node position of the belt conveyor system; and the PLC is used as a lower position machine.
  • the lower machine sends a signal to stop the processing.
  • the current sensor is installed at a belt conveyor driving motor for measuring a real-time current value of the motor;
  • the oil pressure sensor is installed at a tensioning cylinder of a belt conveyor tensioning device for measuring real-time oil pressure;
  • Four speed sensors the first speed sensor is installed at the belt conveyor drive motor, connected to the motor shaft for measuring the motor output speed;
  • the second speed sensor is installed at the driven roller of the belt conveyor, and the driven roller
  • the spindle is connected to measure the rotational speed of the driven roller;
  • the third rotational speed sensor is installed under the belt 10 meters away from the tail to measure the running speed of the belt;
  • the fourth rotational speed sensor is installed under the belt 10 meters away from the nose. It is used to measure the belt running speed at this place.
  • the troubleshooting method is as follows:
  • the motor current signal and the belt tension signal are used as input quantities, and each speed sensor signal is used as an observation, and the nonlinear observation algorithm is used to observe the belt conveyor in real time;
  • the threshold value of coal (M) is determined. If the rate of change of coal falling exceeds the threshold, it indicates that there is a coal fault, and the PLC sends a signal to stop the treatment;
  • the targeted steps of establishing the observation model are:
  • the change quality of the coal flow in and out is relatively small compared to the overall transport quality.
  • the mass of the belt conveyor is divided into three parts, and the extraction unit is 1 mass m. 1 , the unit n mass m n , the overall quality of the intermediate unit is m k , and the quality of each unit in the middle of the subdivision can be obtained Write the state equation as the state quantity respectively;
  • the unit elastic coefficient is observed as the state quantity.
  • the sensor redundancy information and the speed sensor information are used, the critical state quantity is stripped for state observation and fault diagnosis, and the key state and parameters of the belt conveyor are monitored in real time, and the fault can be detected early.
  • the problem of the present invention is achieved by solving the problem that the protection measures of the existing belt conveyor cannot find the handling failure at an early stage.
  • FIG. 1 is a structural diagram of a belt conveyor condition monitoring and fault diagnosis system according to the present invention.
  • the fault diagnosis system comprises: a current sensor, a hydraulic pressure sensor, four rotational speed sensors, a PLC and a host computer; the sensors are installed at a key node position of the belt conveyor system; the PLC acts as a lower position machine to receive the sensor signal and transmits the signal to the upper position.
  • the upper computer calculates the status of the belt conveyor and diagnoses the fault in real time. When the upper computer judges that there is a fault, the lower machine sends a signal to stop the processing.
  • the current sensor is installed at a belt conveyor driving motor for measuring a real-time current value of the motor;
  • the oil pressure sensor is installed at a tensioning cylinder of a belt conveyor tensioning device for measuring real-time oil pressure;
  • Four speed sensors the first speed sensor is installed at the belt conveyor drive motor, connected to the motor shaft for measuring the motor output speed;
  • the second speed sensor is installed at the driven roller of the belt conveyor, and the driven roller
  • the spindle is connected to measure the rotational speed of the driven roller;
  • the third rotational speed sensor is installed under the belt 10 meters away from the tail to measure the running speed of the belt;
  • the fourth rotational speed sensor is installed under the belt 10 meters away from the nose. It is used to measure the belt running speed at this place.
  • the troubleshooting method is as follows:
  • the motor current signal and the belt tension signal are used as input quantities, and each speed sensor signal is used as an observation, and the nonlinear observation algorithm is used to observe the belt conveyor in real time;
  • the targeted steps of establishing the observation model are:
  • the change quality of the coal flow in and out is relatively small compared to the overall transport quality.
  • the mass of the belt conveyor is divided into three parts, and the extraction unit is 1 mass m. 1 , the unit n mass m n , the overall quality of the intermediate unit is m k , and the quality of each unit in the middle of the subdivision can be obtained Write the state equation as the state quantity respectively;
  • the unit elastic coefficient is observed as the state quantity.
  • Embodiment 1 A strategy for condition monitoring and fault diagnosis is given for a large belt conveyor system.
  • FIG. 1 shows the structure diagram of the belt conveyor condition monitoring and fault diagnosis system.
  • the detection system includes a current sensor, a hydraulic pressure sensor, four rotational speed sensors, a PLC and a host computer.
  • the current sensor is installed at the belt conveyor drive motor for measuring the real-time current value of the motor;
  • the oil pressure sensor is installed at the tensioning cylinder of the belt conveyor tensioning device for measuring the real-time oil pressure;
  • the first speed sensor is installed in the belt
  • the conveyor drive motor is connected to the motor shaft for measuring the output speed of the motor;
  • the second speed sensor is installed at the driven roller of the belt conveyor, and is connected with the driven roller spindle for measuring the rotational speed of the driven roller;
  • the three-speed sensor is installed under the belt 10 meters away from the tail of the machine (the value can be changed according to the actual working condition of 10 meters), which is used to measure the running speed of the belt.
  • the fourth speed sensor is installed under the belt 10 meters away from the nose. , used to measure the running speed of the belt.
  • the PLC receives the sensor signal and transmits the signal to the upper computer; the upper computer processes the signal in real time to realize the condition monitoring and fault diagnosis of the belt conveyor.
  • the upper computer judges that the fault occurs, the lower machine sends a signal to stop the machine. deal with.
  • Figure 2 shows the flow chart for condition monitoring and fault diagnosis of the belt conveyor.
  • Step 1 Initialize the system model and thresholds.
  • the breaking threshold of the rate of change of resistance is recommended to be ⁇ 10%, and the elastic threshold of the rate of change of the elastic coefficient is determined according to the actual situation of the conveyor belt.
  • Step 2 Collect each sensor information in real time and perform state observation.
  • each sensor information is transmitted to the PLC data acquisition module through the connection line, and the PLC communicates with the host computer in real time.
  • the host computer can directly input the collected data into the programmed system observation model program and run it, thereby obtaining the observation of key states and parameters.
  • Step 3 fault diagnosis and treatment of the belt conveyor.

Landscapes

  • Control Of Conveyors (AREA)

Abstract

Provided are a system and method for diagnosing a failure of a belt-type conveyor; said system comprises a current sensor, an oil-pressure sensor, four rotational-speed sensors, a PLC, and a master computer; the current sensor is mounted on the drive motor of the belt-type conveyor; the oil-pressure sensor is mounted on the hydraulic cylinder of a tensioning apparatus; the first rotational-speed sensor is mounted on the drive motor of the belt-type conveyor; the second rotational-speed sensor is mounted on a driven drum of the belt-type conveyor; the third rotational-speed sensor is mounted beneath the belt, 10 m away from the machine tail; the fourth rotational-speed sensor is mounted beneath the belt, 10 m away from the machine head; the PLC, as the slave computer, receives a sensor signal and transmits the signal to the master computer; the master computer processes the signal in real time to enable status monitoring and failure diagnosis of the belt-type conveyor. The method utilizes sensor redundancy information and constructs a parsing model of the conveyor to observe its status and diagnose failures; thus failures are discovered at an early stage, enabling the healthy management of a device.

Description

一种带式输送机的故障诊断系统及方法Fault diagnosis system and method for belt conveyor 技术领域Technical field
本发明涉及一种输送机故障诊断系统及方法，特别是一种带式输送机的故障诊断系统及方法。The invention relates to a conveyor fault diagnosis system and method, in particular to a belt conveyor fault diagnosis system and method.
背景技术Background technique
目前，带式输送机由于具有结构简单、输送量大、适应性强等特点被广泛应用于煤矿井下及冶金、煤炭、交通、化工等部门。同时，在运行过程中，带式输送机极易出现跑偏、断带、打滑、堆料等故障，这些故障造成了巨大的经济损失及人员伤亡。At present, the belt conveyor is widely used in coal mine underground and metallurgy, coal, transportation, chemical and other departments due to its simple structure, large conveying capacity and strong adaptability. At the same time, during the operation, the belt conveyor is prone to faults such as deviation, belt breakage, slippage, and stacking. These failures cause huge economic losses and casualties.
为了保障带式输送系统的安全稳定运行，根据煤矿安全规程的规定，带式输送系统必须安装有防滑保护装置、堆煤保护装置、张紧力下降保护装置和防撕裂保护装置等多种保护装置。但是，这些保护措施不能在早期发现处理故障，仍大多停留在发生故障后的动作保护，不仅容易有误动作，具有一定的潜在风险，而且后期维护成本较高。In order to ensure the safe and stable operation of the belt conveyor system, according to the regulations of the coal mine safety regulations, the belt conveyor system must be equipped with various protections such as anti-skid protection device, coal storage protection device, tension reduction protection device and tear protection device. Device. However, these protection measures cannot detect faults at an early stage, and most of them remain in the action protection after the failure, which is not only prone to malfunction, has certain potential risks, and has high maintenance costs at a later stage.
发明内容Summary of the invention
本发明的目的是要提供一种带式输送机的故障诊断系统及方法，解决现有的带式输送机的保护措施不能在早期发现处理故障的问题。SUMMARY OF THE INVENTION The object of the present invention is to provide a fault diagnosis system and method for a belt conveyor, which solves the problem that the protection measures of the existing belt conveyor cannot find the treatment failure at an early stage.
本发明的目的是这样实现的：该故障诊断系统包括：电流传感器、油压传感器、四个转速传感器、PLC及上位机；所述各传感器安装在带式输送系统关键节点位置；PLC作为下位机接收传感器信号并将信号传输给上位机；上位机对信号进行实时处理从而实现带式输送机的状态监测及故障诊断，当上位机判断出现故障时，向下位机发出信号进行停机处理。The object of the present invention is achieved as follows: the fault diagnosis system comprises: a current sensor, a hydraulic pressure sensor, four rotational speed sensors, a PLC and a host computer; the sensors are installed at a key node position of the belt conveyor system; and the PLC is used as a lower position machine. Receiving the sensor signal and transmitting the signal to the upper computer; the upper computer processes the signal in real time to realize the condition monitoring and fault diagnosis of the belt conveyor. When the upper computer judges that the fault occurs, the lower machine sends a signal to stop the processing.
所述电流传感器安装在带式输送机驱动电机处，用于测量电机实时电流值；所述油压传感器安装在皮带输送机张紧装置张紧油缸处，用于测量实时油压；所述的四个转速传感器：第一转速传感器安装在带式输送机驱动电机处，与电机轴相连，用于测量电机输出转速；第二转速传感器安装在带式输送机从动滚筒处，与从动滚筒主轴相连，用于测量从动滚筒转速；第三转速传感器安装在距机尾10米处皮带下方，用于测量该处皮带运行速度；第四转速传感器安装在距机头10米处皮带下方，用于测量该处皮带运行速度。The current sensor is installed at a belt conveyor driving motor for measuring a real-time current value of the motor; the oil pressure sensor is installed at a tensioning cylinder of a belt conveyor tensioning device for measuring real-time oil pressure; Four speed sensors: the first speed sensor is installed at the belt conveyor drive motor, connected to the motor shaft for measuring the motor output speed; the second speed sensor is installed at the driven roller of the belt conveyor, and the driven roller The spindle is connected to measure the rotational speed of the driven roller; the third rotational speed sensor is installed under the belt 10 meters away from the tail to measure the running speed of the belt; the fourth rotational speed sensor is installed under the belt 10 meters away from the nose. It is used to measure the belt running speed at this place.
故障诊断方法，具体步骤如下：The troubleshooting method is as follows:
a)根据实际带式输送机的状态与监测需求，针对性的建立观测模型；a) Establish an observation model based on the actual state of the belt conveyor and the monitoring requirements;
b)根据PLC传输的传感器信息，以电机电流信号及皮带张力信号作为输入量，以各转速传感器信号作为观测量，利用非线性观测算法对带式输送机进行实时的状态观测；b) According to the sensor information transmitted by the PLC, the motor current signal and the belt tension signal are used as input quantities, and each speed sensor signal is used as an observation, and the nonlinear observation algorithm is used to observe the belt conveyor in real time;
c)进行状态监测与故障诊断：c) Perform condition monitoring and fault diagnosis:
(1)针对堆煤故障，将观测到的上游带式输送机状态m1与下游带式输送机状态mk进行求差处理，求出落煤量变化率Ml＝Δm/m1，设定堆煤阈值M(％)，若落煤量变化率超过阈值，说明出现堆煤故障，PLC发出信号进行停机处理；(1) For the coal-filling fault, the observed upstream belt conveyor state m 1 and the downstream belt conveyor state m k are subjected to differential processing, and the rate of change of the coal falling amount M l = Δm/m 1 is determined. The threshold value of coal (M) is determined. If the rate of change of coal falling exceeds the threshold, it indicates that there is a coal fault, and the PLC sends a signal to stop the treatment;
(2)针对断带故障，当单元阻力变化率超过设定断带阈值N(％)，PLC发出信号进 行停机处理；(2) For the broken belt fault, when the unit resistance change rate exceeds the set breakage threshold N (%), the PLC sends a signal into Line down processing;
(3)针对皮带效能丧失或参数改变故障，当单元弹性系数变化率超过设定弹性阈值L(％)，PLC发出信号进行停机处理。(3) For the loss of belt performance or parameter change failure, when the rate of change of the unit elastic coefficient exceeds the set elastic threshold value L (%), the PLC sends a signal to stop processing.
所述的步骤a)中，针对性的建立观测模型步骤为：In the step a), the targeted steps of establishing the observation model are:
(1)针对堆煤故障，由于煤流进出变化质量相对于整体运送质量变化较小，为了实现煤流进出质量的监测，将带式输送机上运质量分为三个部分，提取单元1质量m1，单元n质量mn，中间单元总体质量为mk，可得细分后中间每个单元质量
Figure PCTCN2016108842-appb-000001
分别作为状态量写入状态方程；(1) For the coal-filling fault, the change quality of the coal flow in and out is relatively small compared to the overall transport quality. In order to realize the monitoring of the coal inlet and outlet quality, the mass of the belt conveyor is divided into three parts, and the extraction unit is 1 mass m. 1 , the unit n mass m n , the overall quality of the intermediate unit is m k , and the quality of each unit in the middle of the subdivision can be obtained
Figure PCTCN2016108842-appb-000001
Write the state equation as the state quantity respectively;
(2)针对断带故障，由于断带多由大块物料或铁器插入皮带导致，会引起单元异常阻力，因此提取关键单元阻力值作为状态量；(2) For the fault of the broken belt, since the broken belt is mostly caused by the insertion of the bulk material or the iron into the belt, the abnormal resistance of the unit is caused, so the key unit resistance value is extracted as the state quantity;
(3)针对皮带的效能丧失或者参数改变，将单元弹性系数作为状态量进行观测。(3) For the loss of performance or parameter change of the belt, the unit elastic coefficient is observed as the state quantity.
有益效果及优点：由于采用了上述方案，利用传感器冗余信息，以及转速传感器信息，剥离关键状态量进行状态观测与故障诊断，实时监测带式输送机的关键状态及参数，能够在早期发现故障，实现设备的健康管理，降低设备维护成本。解决了现有的带式输送机的保护措施不能在早期发现处理故障的问题，达到了本发明的目的。Advantageous effects and advantages: Due to the above scheme, the sensor redundancy information and the speed sensor information are used, the critical state quantity is stripped for state observation and fault diagnosis, and the key state and parameters of the belt conveyor are monitored in real time, and the fault can be detected early. To achieve healthy management of equipment and reduce equipment maintenance costs. The problem of the present invention is achieved by solving the problem that the protection measures of the existing belt conveyor cannot find the handling failure at an early stage.
附图说明DRAWINGS
图1为本发明的带式输送机状态监测与故障诊断系统结构图。1 is a structural diagram of a belt conveyor condition monitoring and fault diagnosis system according to the present invention.
图2为本发明的带式输送机状态监测与故障诊断流程图。2 is a flow chart of condition monitoring and fault diagnosis of the belt conveyor of the present invention.
具体实施方式detailed description
该故障诊断系统包括：电流传感器、油压传感器、四个转速传感器、PLC及上位机；所述各传感器安装在带式输送系统关键节点位置；PLC作为下位机接收传感器信号并将信号传输给上位机；上位机对信号进行实时处理从而实现带式输送机的状态监测及故障诊断，当上位机判断出现故障时，向下位机发出信号进行停机处理。The fault diagnosis system comprises: a current sensor, a hydraulic pressure sensor, four rotational speed sensors, a PLC and a host computer; the sensors are installed at a key node position of the belt conveyor system; the PLC acts as a lower position machine to receive the sensor signal and transmits the signal to the upper position. The upper computer calculates the status of the belt conveyor and diagnoses the fault in real time. When the upper computer judges that there is a fault, the lower machine sends a signal to stop the processing.
所述电流传感器安装在带式输送机驱动电机处，用于测量电机实时电流值；所述油压传感器安装在皮带输送机张紧装置张紧油缸处，用于测量实时油压；所述的四个转速传感器：第一转速传感器安装在带式输送机驱动电机处，与电机轴相连，用于测量电机输出转速；第二转速传感器安装在带式输送机从动滚筒处，与从动滚筒主轴相连，用于测量从动滚筒转速；第三转速传感器安装在距机尾10米处皮带下方，用于测量该处皮带运行速度；第四转速传感器安装在距机头10米处皮带下方，用于测量该处皮带运行速度。The current sensor is installed at a belt conveyor driving motor for measuring a real-time current value of the motor; the oil pressure sensor is installed at a tensioning cylinder of a belt conveyor tensioning device for measuring real-time oil pressure; Four speed sensors: the first speed sensor is installed at the belt conveyor drive motor, connected to the motor shaft for measuring the motor output speed; the second speed sensor is installed at the driven roller of the belt conveyor, and the driven roller The spindle is connected to measure the rotational speed of the driven roller; the third rotational speed sensor is installed under the belt 10 meters away from the tail to measure the running speed of the belt; the fourth rotational speed sensor is installed under the belt 10 meters away from the nose. It is used to measure the belt running speed at this place.
故障诊断方法，具体步骤如下：The troubleshooting method is as follows:
a)根据实际带式输送机的状态与监测需求，针对性的建立观测模型；a) Establish an observation model based on the actual state of the belt conveyor and the monitoring requirements;
b)根据PLC传输的传感器信息，以电机电流信号及皮带张力信号作为输入量，以各转速传感器信号作为观测量，利用非线性观测算法对带式输送机进行实时的状态观测；b) According to the sensor information transmitted by the PLC, the motor current signal and the belt tension signal are used as input quantities, and each speed sensor signal is used as an observation, and the nonlinear observation algorithm is used to observe the belt conveyor in real time;
c)进行状态监测与故障诊断：(1)针对堆煤故障，将观测到的上游带式输送机状态m1与下游带式输送机状态mk进行求差处理，求出落煤量变化率Ml＝Δm/m1，设定堆煤阈值 M(％)，若落煤量变化率超过阈值，说明出现堆煤故障，PLC发出信号进行停机处理；c) Perform condition monitoring and fault diagnosis: (1) For the coal-filling fault, the observed upstream belt conveyor state m 1 and the downstream belt conveyor state m k are subjected to differential processing to determine the rate of change of the coal falling volume. M l = Δm / m 1 , set the threshold value of coal pile M (%), if the rate of change of coal falling exceeds the threshold value, it indicates that coal mining failure occurs, and the PLC sends a signal to stop the treatment;
(2)针对断带故障，当单元阻力变化率超过设定断带阈值N(％)，PLC发出信号进行停机处理；(2) For the fault of the broken belt, when the unit resistance change rate exceeds the set breakage threshold N (%), the PLC sends a signal to stop the processing;
(3)针对皮带效能丧失或参数改变故障，当单元弹性系数变化率超过设定弹性阈值L(％)，PLC发出信号进行停机处理。(3) For the loss of belt performance or parameter change failure, when the rate of change of the unit elastic coefficient exceeds the set elastic threshold value L (%), the PLC sends a signal to stop processing.
所述的步骤a)中，针对性的建立观测模型步骤为：In the step a), the targeted steps of establishing the observation model are:
(1)针对堆煤故障，由于煤流进出变化质量相对于整体运送质量变化较小，为了实现煤流进出质量的监测，将带式输送机上运质量分为三个部分，提取单元1质量m1，单元n质量mn，中间单元总体质量为mk，可得细分后中间每个单元质量
Figure PCTCN2016108842-appb-000002
分别作为状态量写入状态方程；(1) For the coal-filling fault, the change quality of the coal flow in and out is relatively small compared to the overall transport quality. In order to realize the monitoring of the coal inlet and outlet quality, the mass of the belt conveyor is divided into three parts, and the extraction unit is 1 mass m. 1 , the unit n mass m n , the overall quality of the intermediate unit is m k , and the quality of each unit in the middle of the subdivision can be obtained
Figure PCTCN2016108842-appb-000002
Write the state equation as the state quantity respectively;
(2)针对断带故障，由于断带多由大块物料或铁器插入皮带导致，会引起单元异常阻力，因此提取关键单元阻力值作为状态量；(2) For the fault of the broken belt, since the broken belt is mostly caused by the insertion of the bulk material or the iron into the belt, the abnormal resistance of the unit is caused, so the key unit resistance value is extracted as the state quantity;
(3)针对皮带的效能丧失或者参数改变，将单元弹性系数作为状态量进行观测。(3) For the loss of performance or parameter change of the belt, the unit elastic coefficient is observed as the state quantity.
实施例1：针对大型带式输送系统，给出一种状态监测与故障诊断的策略。Embodiment 1: A strategy for condition monitoring and fault diagnosis is given for a large belt conveyor system.
图1所示为带式输送机状态监测与故障诊断系统结构图，该检测系统包括电流传感器、油压传感器、四个转速传感器、PLC及上位机。电流传感器安装在带式输送机驱动电机处，用于测量电机实时电流值；油压传感器安装在皮带输送机张紧装置张紧油缸处，用于测量实时油压；第一转速传感器安装在带式输送机驱动电机处，与电机轴相连，用于测量电机输出转速；第二转速传感器安装在带式输送机从动滚筒处，与从动滚筒主轴相连，用于测量从动滚筒转速；第三转速传感器安装在距机尾10米处皮带下方(根据实际工况10米数值可进行一定变动)，用于测量该处皮带运行速度；第四转速传感器安装在距机头10米处皮带下方，用于测量该处皮带运行速度。PLC作为下位机接收传感器信号并将信号传输给上位机；上位机对信号进行实时处理从而实现带式输送机的状态监测及故障诊断，当上位机判断出现故障时，向下位机发出信号进行停机处理。Figure 1 shows the structure diagram of the belt conveyor condition monitoring and fault diagnosis system. The detection system includes a current sensor, a hydraulic pressure sensor, four rotational speed sensors, a PLC and a host computer. The current sensor is installed at the belt conveyor drive motor for measuring the real-time current value of the motor; the oil pressure sensor is installed at the tensioning cylinder of the belt conveyor tensioning device for measuring the real-time oil pressure; the first speed sensor is installed in the belt The conveyor drive motor is connected to the motor shaft for measuring the output speed of the motor; the second speed sensor is installed at the driven roller of the belt conveyor, and is connected with the driven roller spindle for measuring the rotational speed of the driven roller; The three-speed sensor is installed under the belt 10 meters away from the tail of the machine (the value can be changed according to the actual working condition of 10 meters), which is used to measure the running speed of the belt. The fourth speed sensor is installed under the belt 10 meters away from the nose. , used to measure the running speed of the belt. As the lower computer, the PLC receives the sensor signal and transmits the signal to the upper computer; the upper computer processes the signal in real time to realize the condition monitoring and fault diagnosis of the belt conveyor. When the upper computer judges that the fault occurs, the lower machine sends a signal to stop the machine. deal with.
图2所示为带式输送机状态监测与故障诊断流程图。Figure 2 shows the flow chart for condition monitoring and fault diagnosis of the belt conveyor.
步骤1，初始化系统模型及阈值。 Step 1. Initialize the system model and thresholds.
在上位机中设置落煤变化率的堆煤阈值M(％)、阻力变化率的断带阈值N(％)、弹性系数变化率的弹性阈值L(％)，落煤变化率的堆煤阈值及阻力变化率的断带阈值推荐使用±10％，弹性系数变化率的弹性阈值需根据输送带实际情况确定。The stacking coal threshold M (%) of the falling coal rate of change, the breaking threshold N (%) of the rate of change of the resistance, the elastic threshold L (%) of the rate of change of the elastic coefficient, and the coal-filling threshold of the rate of change of the falling coal in the upper machine The breaking threshold of the rate of change of resistance is recommended to be ±10%, and the elastic threshold of the rate of change of the elastic coefficient is determined according to the actual situation of the conveyor belt.
步骤2，实时采集各传感器信息并进行状态观测。Step 2: Collect each sensor information in real time and perform state observation.
在现场应用过程中，随着带式输送机的启动，各传感器信息通过连接线传入PLC数据采集模块，PLC实时与上位机进行通讯。在opc通讯环境下，上位机能够将所采集到的数据直接输入编制好的系统观测模型程序并运行，从而得到关键状态及参数的观测量。In the field application process, with the start of the belt conveyor, each sensor information is transmitted to the PLC data acquisition module through the connection line, and the PLC communicates with the host computer in real time. In the opc communication environment, the host computer can directly input the collected data into the programmed system observation model program and run it, thereby obtaining the observation of key states and parameters.
步骤3，带式输送机的故障诊断及处理。 Step 3, fault diagnosis and treatment of the belt conveyor.
当落煤量变化率超过设定堆煤阈值M(％)，说明出现堆煤故障，PLC发出信号进行停机处理；当单元阻力变化率超过设定断带阈值N(％)，说明出现断带或类似故障，PLC 发出信号进行停机处理；当单元弹性系数变化率超过设定弹性阈值L(％)，说明皮带效能丧失或参数改变故障，PLC发出信号进行停机处理。 When the rate of change of coal falling exceeds the set coal threshold M (%), it indicates that there is a coal fault, and the PLC sends a signal to stop the treatment; when the unit resistance change rate exceeds the set break threshold N (%), it indicates that there is a broken belt or Similar failure, PLC Signal is sent to stop processing; when the unit elastic coefficient change rate exceeds the set elastic threshold L (%), indicating that the belt performance is lost or the parameter changes, the PLC sends a signal to stop processing.

Claims (4)

  1. 一种带式输送机的故障诊断系统，其特征是：该故障诊断系统包括：电流传感器、油压传感器、四个转速传感器、PLC及上位机；所述各传感器安装在带式输送系统关键节点位置；PLC作为下位机接收传感器信号并将信号传输给上位机；上位机对信号进行实时处理从而实现带式输送机的状态监测及故障诊断，当上位机判断出现故障时，向下位机发出信号进行停机处理。A fault diagnosis system for a belt conveyor, characterized in that: the fault diagnosis system comprises: a current sensor, a hydraulic pressure sensor, four rotational speed sensors, a PLC and a host computer; the sensors are installed at key nodes of the belt conveyor system; Position; PLC as the lower computer receives the sensor signal and transmits the signal to the upper computer; the upper computer processes the signal in real time to realize the condition monitoring and fault diagnosis of the belt conveyor. When the upper computer judges that the fault occurs, the lower machine sends a signal. Stop processing.
  2. 根据权利要求1所述的一种带式输送机的故障诊断系统，其特征是：所述电流传感器安装在带式输送机驱动电机处，用于测量电机实时电流值；所述油压传感器安装在皮带输送机张紧装置张紧油缸处，用于测量实时油压；所述的四个转速传感器：第一转速传感器安装在带式输送机驱动电机处，与电机轴相连，用于测量电机输出转速；第二转速传感器安装在带式输送机从动滚筒处，与从动滚筒主轴相连，用于测量从动滚筒转速；第三转速传感器安装在距机尾10米处皮带下方，用于测量该处皮带运行速度；第四转速传感器安装在距机头10米处皮带下方，用于测量该处皮带运行速度。A fault diagnosis system for a belt conveyor according to claim 1, wherein said current sensor is installed at a belt conveyor drive motor for measuring a real-time current value of the motor; said oil pressure sensor is installed At the belt conveyor tensioning device tensioning cylinder for measuring the real-time oil pressure; the four speed sensors: the first speed sensor is installed at the belt conveyor drive motor, connected to the motor shaft for measuring the motor Output speed; the second speed sensor is installed at the driven roller of the belt conveyor, connected to the driven drum main shaft for measuring the rotational speed of the driven drum; the third speed sensor is installed under the belt 10 meters away from the tail for The running speed of the belt is measured; the fourth speed sensor is installed under the belt 10 meters away from the head to measure the running speed of the belt.
  3. 权利要求1所述的一种带式输送机的故障诊断系统的诊断方法，其特征是：故障诊断方法，具体步骤如下：The method for diagnosing a fault diagnosis system for a belt conveyor according to claim 1, characterized in that: the fault diagnosis method, the specific steps are as follows:
    a)根据实际带式输送机的状态与监测需求，针对性的建立观测模型；a) Establish an observation model based on the actual state of the belt conveyor and the monitoring requirements;
    b)根据PLC传输的传感器信息，以电机电流信号及皮带张力信号作为输入量，以各转速传感器信号作为观测量，利用非线性观测算法对带式输送机进行实时的状态观测；b) According to the sensor information transmitted by the PLC, the motor current signal and the belt tension signal are used as input quantities, and each speed sensor signal is used as an observation, and the nonlinear observation algorithm is used to observe the belt conveyor in real time;
    c)进行状态监测与故障诊断：c) Perform condition monitoring and fault diagnosis:
    (1)针对堆煤故障，将观测到的上游带式输送机状态m1与下游带式输送机状态mk进行求差处理，求出落煤量变化率Ml＝Δm/m1，设定堆煤阈值M(％)，若落煤量变化率超过阈值，说明出现堆煤故障，PLC发出信号进行停机处理；(1) For the coal-filling fault, the observed upstream belt conveyor state m 1 and the downstream belt conveyor state m k are subjected to differential processing, and the rate of change of the coal falling amount M l = Δm/m 1 is determined. The threshold value of coal (M) is determined. If the rate of change of coal falling exceeds the threshold, it indicates that there is a coal fault, and the PLC sends a signal to stop the treatment;
    (2)针对断带故障，当单元阻力变化率超过设定断带阈值N(％)，PLC发出信号进行停机处理；(2) For the fault of the broken belt, when the unit resistance change rate exceeds the set breakage threshold N (%), the PLC sends a signal to stop the processing;
    (3)针对皮带效能丧失或参数改变故障，当单元弹性系数变化率超过设定弹性阈值L(％)，PLC发出信号进行停机处理。(3) For the loss of belt performance or parameter change failure, when the rate of change of the unit elastic coefficient exceeds the set elastic threshold value L (%), the PLC sends a signal to stop processing.
  4. 根据权利要求3所述的一种带式输送机的故障诊断系统及方法，其特征是：所述的步骤a)中，针对性的建立观测模型步骤为：The fault diagnosis system and method for a belt conveyor according to claim 3, wherein in the step a), the step of establishing an observation model in a targeted manner is:
    (1)针对堆煤故障，由于煤流进出变化质量相对于整体运送质量变化较小，为了实现煤流进出质量的监测，将带式输送机上运质量分为三个部分，提取单元1质量m1，单元n质量mn，中间单元总体质量为mk，可得细分后中间每个单元质量
    Figure PCTCN2016108842-appb-100001
    分别作为状态量写入状态方程；    (1) For the coal-filling fault, the change quality of the coal flow in and out is relatively small compared to the overall transport quality. In order to realize the monitoring of the coal inlet and outlet quality, the mass of the belt conveyor is divided into three parts, and the extraction unit is 1 mass m. 1 , the unit n mass m n , the overall quality of the intermediate unit is m k , and the quality of each unit in the middle of the subdivision can be obtained
    Figure PCTCN2016108842-appb-100001
    Write the state equation as the state quantity respectively;
    (2)针对断带故障，由于断带多由大块物料或铁器插入皮带导致，会引起单元异常阻力，因此提取关键单元阻力值作为状态量；(2) For the fault of the broken belt, since the broken belt is mostly caused by the insertion of the bulk material or the iron into the belt, the abnormal resistance of the unit is caused, so the key unit resistance value is extracted as the state quantity;
    (3)针对皮带的效能丧失或者参数改变，将单元弹性系数作为状态量进行观测。 (3) For the loss of performance or parameter change of the belt, the unit elastic coefficient is observed as the state quantity.
PCT/CN2016/108842 2016-05-16 2016-12-07 System and method for diagnosing failure of belt-type conveyor WO2017197873A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CN201610323974.2 2016-05-16
CN201610323974.2A CN105800278B (en) 2016-05-16 2016-05-16 A kind of fault diagnosis system and method for ribbon conveyer

Publications (1)

Publication Number Publication Date
WO2017197873A1 true WO2017197873A1 (en) 2017-11-23

Family

ID=56452333

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CN2016/108842 WO2017197873A1 (en) 2016-05-16 2016-12-07 System and method for diagnosing failure of belt-type conveyor

Country Status (2)

Country Link
CN (1) CN105800278B (en)
WO (1) WO2017197873A1 (en)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110436140A (en) * 2019-09-06 2019-11-12 浙江朗奥物流科技有限公司 A kind of Multifunctional belt conveyer testboard
CN111071735A (en) * 2019-12-31 2020-04-28 中冶北方（大连）工程技术有限公司 Power frequency transmission adhesive tape running and slipping detection device and detection method
CN113306989A (en) * 2021-05-28 2021-08-27 华能国际电力股份有限公司营口电厂 Method for timely detecting deviation of belt conveyor of power plant coal conveying system
CN113753525A (en) * 2021-10-19 2021-12-07 精基科技有限公司 Fault protection system and fault elimination method of belt conveyor
CN113777353A (en) * 2021-09-10 2021-12-10 新余钢铁股份有限公司 Fault diagnosis method for belt scale speed sensor
CN113884167A (en) * 2021-09-15 2022-01-04 湖南库特智能科技有限公司 Method and system for measuring working capacity of movable crusher
CN114048880A (en) * 2021-11-26 2022-02-15 江苏科技大学 Particle swarm optimization-based fault diagnosis method for opening valve
CN114590552A (en) * 2020-12-04 2022-06-07 南京宝地梅山产城发展有限公司 Intelligent ore drawing device of ore leakage trolley
CN117068696A (en) * 2023-10-17 2023-11-17 山西潞安环保能源开发股份有限公司 Intelligent recognition belt coal pile monitoring device and method

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105800278B (en) * 2016-05-16 2018-10-09 中国矿业大学 A kind of fault diagnosis system and method for ribbon conveyer
CN110040468B (en) * 2018-01-15 2021-03-05 中冶长天国际工程有限责任公司 Fault diagnosis method and device for belt conveyor
CN109178833A (en) * 2018-08-14 2019-01-11 安徽中联九通机械设备有限公司 A kind of belt feeder operational monitoring method
CN110775570A (en) * 2019-11-26 2020-02-11 安徽德睿智能技术有限公司 Belt feeder control system
CN110980192A (en) * 2019-12-10 2020-04-10 安徽银河物联通信技术有限公司 Belt tearing detection method
CN114834853B (en) * 2022-07-01 2022-12-06 山西戴德测控技术有限公司 Coal conveying control method, device, equipment and storage medium based on coal flow difference

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SU1666413A1 (en) * 1988-12-20 1991-07-30 Киевский Политехнический Институт Им.50-Летия Великой Октябрьской Социалистической Революции Method for controlling belt conveyor
JPH0912128A (en) * 1995-06-30 1997-01-14 Sumitomo Metal Ind Ltd Belt scratch detecting device for belt conveyor device
CN201670556U (en) * 2010-04-27 2010-12-15 上海科大重工集团有限公司 Automatic fault recognition system of large belt conveyer
CN202245194U (en) * 2011-06-23 2012-05-30 宿州中矿三杰科技有限公司 Comprehensive protecting and monitoring device for networked belt conveyor
CN103224118A (en) * 2013-04-15 2013-07-31 新汶矿业集团有限责任公司 Automatic tensioning system of belt conveyor and applications thereof
CN203728108U (en) * 2014-03-14 2014-07-23 西安科技大学 Comprehensive safety performance parameter acquisition and transmission device for mining belt conveyer
CN204297588U (en) * 2014-12-02 2015-04-29 电光防爆科技（上海）有限公司 A kind of colliery Belt transport monitored control system
CN104648944A (en) * 2013-11-21 2015-05-27 陕西子竹电子有限公司 PCC-based integrated control system for sealing-tape machine transportation
CN104648946A (en) * 2013-11-22 2015-05-27 陕西亚泰电器科技有限公司 PLC based belt conveyor electrical control system
CN105692118A (en) * 2016-04-01 2016-06-22 西安科技大学 Fault monitoring and early warning system and method for belt conveyor of mine
CN105800278A (en) * 2016-05-16 2016-07-27 中国矿业大学 Fault diagnosis system and method of belt conveyor

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SU1666413A1 (en) * 1988-12-20 1991-07-30 Киевский Политехнический Институт Им.50-Летия Великой Октябрьской Социалистической Революции Method for controlling belt conveyor
JPH0912128A (en) * 1995-06-30 1997-01-14 Sumitomo Metal Ind Ltd Belt scratch detecting device for belt conveyor device
CN201670556U (en) * 2010-04-27 2010-12-15 上海科大重工集团有限公司 Automatic fault recognition system of large belt conveyer
CN202245194U (en) * 2011-06-23 2012-05-30 宿州中矿三杰科技有限公司 Comprehensive protecting and monitoring device for networked belt conveyor
CN103224118A (en) * 2013-04-15 2013-07-31 新汶矿业集团有限责任公司 Automatic tensioning system of belt conveyor and applications thereof
CN104648944A (en) * 2013-11-21 2015-05-27 陕西子竹电子有限公司 PCC-based integrated control system for sealing-tape machine transportation
CN104648946A (en) * 2013-11-22 2015-05-27 陕西亚泰电器科技有限公司 PLC based belt conveyor electrical control system
CN203728108U (en) * 2014-03-14 2014-07-23 西安科技大学 Comprehensive safety performance parameter acquisition and transmission device for mining belt conveyer
CN204297588U (en) * 2014-12-02 2015-04-29 电光防爆科技（上海）有限公司 A kind of colliery Belt transport monitored control system
CN105692118A (en) * 2016-04-01 2016-06-22 西安科技大学 Fault monitoring and early warning system and method for belt conveyor of mine
CN105800278A (en) * 2016-05-16 2016-07-27 中国矿业大学 Fault diagnosis system and method of belt conveyor

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110436140A (en) * 2019-09-06 2019-11-12 浙江朗奥物流科技有限公司 A kind of Multifunctional belt conveyer testboard
CN110436140B (en) * 2019-09-06 2024-04-09 浙江朗奥物流科技有限公司 Multifunctional belt conveyor test board
CN111071735A (en) * 2019-12-31 2020-04-28 中冶北方（大连）工程技术有限公司 Power frequency transmission adhesive tape running and slipping detection device and detection method
CN111071735B (en) * 2019-12-31 2024-05-10 中冶北方（大连）工程技术有限公司 Device and method for detecting operation and slipping of power frequency transmission adhesive tape
CN114590552A (en) * 2020-12-04 2022-06-07 南京宝地梅山产城发展有限公司 Intelligent ore drawing device of ore leakage trolley
CN114590552B (en) * 2020-12-04 2023-05-12 南京宝地梅山产城发展有限公司 Intelligent ore drawing device of ore leakage trolley
CN113306989A (en) * 2021-05-28 2021-08-27 华能国际电力股份有限公司营口电厂 Method for timely detecting deviation of belt conveyor of power plant coal conveying system
CN113777353A (en) * 2021-09-10 2021-12-10 新余钢铁股份有限公司 Fault diagnosis method for belt scale speed sensor
CN113884167B (en) * 2021-09-15 2024-03-01 湖南库特智能科技有限公司 Working capacity metering method and system for mobile crusher
CN113884167A (en) * 2021-09-15 2022-01-04 湖南库特智能科技有限公司 Method and system for measuring working capacity of movable crusher
CN113753525A (en) * 2021-10-19 2021-12-07 精基科技有限公司 Fault protection system and fault elimination method of belt conveyor
CN114048880A (en) * 2021-11-26 2022-02-15 江苏科技大学 Particle swarm optimization-based fault diagnosis method for opening valve
CN114048880B (en) * 2021-11-26 2024-05-24 江苏科技大学 Particle swarm optimization-based opening valve fault diagnosis method
CN117068696B (en) * 2023-10-17 2023-12-22 山西潞安环保能源开发股份有限公司 Intelligent recognition belt coal pile monitoring device and method
CN117068696A (en) * 2023-10-17 2023-11-17 山西潞安环保能源开发股份有限公司 Intelligent recognition belt coal pile monitoring device and method

Also Published As

Publication number Publication date
CN105800278B (en) 2018-10-09
CN105800278A (en) 2016-07-27

Similar Documents

Publication Publication Date Title
WO2017197873A1 (en) System and method for diagnosing failure of belt-type conveyor
WO2016045389A1 (en) Broken link detection method for drag flight conveyor
CN105858126B (en) A kind of scraper conveyer chain fault diagnosis system and method
WO2017197875A1 (en) Apparatus and method for tension monitoring of chain of scraper conveyor
JP6557110B2 (en) Condition diagnosis apparatus and program
CN103180793B (en) Apparatus for diagnosis of abnormality and industrial machinery
CN103454113B (en) A kind of rotating machinery health monitor method be applicable in working conditions change situation
JP5010032B2 (en) Online diagnosis method for geothermal power generation facilities
CN103115667B (en) A kind of sensor-based vibration monitoring device
CN106354123A (en) System for automatically detecting faults of large-scale mechanical equipment based on internet of things
CN102730384A (en) Fault detection system and method applicable to belt conveyor conveying system
CN204984825U (en) Oil -field flooding pump intelligence diagnosis monitoring device
CN108318230A (en) A kind of petrochemical industry rotating machine sets trouble-shooter and its diagnostic method
CN104133468B (en) Fault diagnosis method for crushing and screening process
CN106524962B (en) A kind of walking wheel of coal cutter abrasion amount detecting device and abrasion loss detect method for early warning
CN202673654U (en) On-line fault intelligent diagnosis device of drilling pump
WO2020228139A1 (en) Monitoring and early warning system and method for transmission device failure of scraper conveyor
CN106495043A (en) Derrick crane mechanism driving system safety guard and method
CN203259853U (en) Coal sorter conveying chain comprehensive monitoring device
WO2021157232A1 (en) Vibration processing device, vibration processing method, and program
CN110849607B (en) Method for estimating gear jamming of spring operating mechanism of circuit breaker
CN108020154A (en) The test method and test system of currency examination device
CN108204903A (en) A kind of maize harvesting machine Transmission Trouble diagnostic system and method
CN106444569A (en) Pumping unit belt protection method and device
CN110889205A (en) Method, device, equipment and storage medium for monitoring hydraulic station

Legal Events

Date Code Title Description
NENP Non-entry into the national phase

Ref country code: DE

121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 16902252

Country of ref document: EP

Kind code of ref document: A1

122 Ep: pct application non-entry in european phase

Ref document number: 16902252

Country of ref document: EP

Kind code of ref document: A1