CN117142045A - Belt fault monitoring method and equipment - Google Patents

Abstract

A belt fault monitoring method and equipment are provided, which are used for shortening the fault checking time of the belt conveyor and improving the transportation production efficiency, aiming at the problem of the lack of fault monitoring means of the belt conveyor in the industries of mines, metallurgy, ports and the like at present, and outputting the action condition and the position through buses by monitoring the normally open and normally closed states of a pull rope switch, a deviation switch and the like of the belt conveyor, wherein the positioning information is redundantly output in a communication mode and a binary mode so as to ensure quick response and accurate positioning during faults and eliminate the jitter influence.

Description

Belt fault monitoring method and equipment

Technical Field

The utility model relates to the technical field of belt fault monitoring, in particular to a belt fault monitoring method and equipment.

Background

At present, in industries such as mines, metallurgy, ports and the like, a belt conveyor is often used for transporting materials. Although each performance index of the belt conveyor is stable and runs well in the running process, the belt conveyor often has the problems of deviation, slipping, belt breakage and other faults. Because the belt conveyor is long in distance, a large number of pull rope switches, deviation switches, material blocking switches, slipping switches and the like are required to monitor and control the running state of the equipment. The fault control mode adopted at present is to connect normally closed points of all switches in series and then use the normally closed points as stop signals to be connected into a control loop, and meanwhile, the normally open points are connected into a monitor to monitor and display the state. However, due to the severe field environment, the normally closed point of the switch of the protection device is easy to shake, or the contact is poor after oxidation. When the normally closed point is not open and the normally open point is not closed, namely, the normally open point and the normally closed point are both in an open state, the equipment is stopped, and the monitor cannot locate the fault position. This presents a great difficulty in troubleshooting. Therefore, research on the fault monitoring technology of the belt conveyor has important significance for improving the maintenance and management level of the belt conveyor.

The following documents are searched for relevant belt fault monitoring methods and equipment:

patent 1: an intelligent monitoring system for a coal mine belt and a monitoring method thereof; application number: 202210216866.0; filing date: 2022-03-07; applicants: zhengzhou institute of occupational technology; summary: the utility model discloses an intelligent monitoring system for a coal mine belt, which comprises the following components: the system comprises a field detection subsystem, a network transmission subsystem and a data release subsystem; meanwhile, the intelligent monitoring method of the coal mine belt can realize the functions of tearing monitoring, coal pile monitoring, gas monitoring, intelligent light supplementing, intelligent dust removing, fault diagnosis and the like, so that unmanned intelligent monitoring of the underground coal mine belt conveyor is realized.

Patent 2: a belt operation fault monitoring principle prototype of a mining belt conveyor; application number: 202310535231.1; filing date: 2023-05-12; applicants: special grade university of the Deck petroleum; summary: the utility model relates to a belt operation fault monitoring principle model machine of a mining belt conveyor, which comprises a frame, a motor, a driving roller, a driven roller, a belt, a plurality of pressure sensors, a pressure regulating assembly and a controller, wherein the driving roller and the driven roller are rotatably connected to two ends of the frame, the pressure regulating assembly comprises a fixed seat, a regulating seat and a locking piece, the fixed seat is fixed on the frame and positioned below the belt, the regulating seat can be slidably connected to the fixed seat and can be close to or far from the belt and is locked on the fixed seat through the locking piece, and the pressure sensors are fixed on the regulating seat at equal intervals along the width direction of the belt. The utility model provides a belt running fault monitoring principle model machine of a mining belt conveyor, belongs to the technical field of mineral equipment, can carry out simulation experiments on belt transportation conditions in a laboratory, researches the connection between experimental data and various faults of the belt, and provides theoretical support and data support for practical application.

Patent 3: a fault positioning and monitoring system of a long belt conveyor; application number: 201420077921.3; filing date: 2014-02-24; applicants: nanjing Kang Dixin electric plant Inc.; summary: the utility model provides a long belt conveyor fault location monitoring system, long belt conveyor includes frame, belt and driving roller, and fault location monitoring system is including installing a plurality of belt off tracking monitoring nodes of belt both sides in the frame, installing a rotational speed monitoring node and installing the monitoring terminal at remote control center in driving roller department, and the belt off tracking monitoring node evenly arranges along the direction of transmission of belt in the frame, belt off tracking monitoring node and rotational speed monitoring node are respectively through first wireless transceiver module and second wireless transceiver module and the third wireless transceiver module wireless connection of monitoring terminal, the off tracking signal in each position of transmission belt and the rotational speed signal of driving roller. The utility model can be widely applied to industries such as mines, metallurgy, ports and the like. Faults such as deviation, slipping, belt breakage and the like of the belt conveyor are checked and monitored, and the production efficiency is greatly improved.

The above document shows that the fault control mode adopted at present is to connect the normally closed points of the switches in series and then use the normally closed points as stop signals to connect the control loop, and simultaneously connect the normally open points to the monitor for state monitoring and display. However, due to the severe field environment, the normally closed point of the switch of the protection device is easy to shake, or the contact is poor after oxidation. When the normally closed point is not open and the normally open point is not closed, namely, the normally open point and the normally closed point are both in an open state, the equipment is stopped, and the monitor cannot locate the fault position. This presents a great difficulty in troubleshooting.

Disclosure of Invention

The utility model aims to solve the problems and provide a belt fault monitoring method and equipment.

The belt fault monitoring method comprises the following steps:

numbering the signal output ends of a pull rope switch, a deviation switch, a blocking switch or a slipping switch on the belt, wherein the numbering mode is that the switch closest to the control cabinet is number 1, and then sequentially numbering other switches according to the principle from near to far (for example, 1,2,3 … N);

sequentially substations are carried out on the output ends of the pull switches, the off-tracking switches, the material blocking switches or the slipping switches with finished numbers, each station area comprises a plurality of output ends of the pull switches, the off-tracking switches, the material blocking switches or the slipping switches with continuous numbers, the output end of the first pull switch, the off-tracking switch, the material blocking switch or the slipping switch in each station area is a master station of the station area and is a slave station of the last station area, the independent follow-up detection of each station area is carried out, and the follow-up detection results are sent to the master station of the previous station area until the master station of the first station area obtains the follow-up detection results of all station areas;

setting a reset time threshold for a normally closed contact and a normally open contact of a pull rope switch, a deviation switch, a blocking switch or a slipping switch on the belt, wherein the threshold interval is 200-500 ms;

acquiring action signals of a normally closed contact and a normally open contact of a rope pulling switch, a deviation switch, a material blocking switch or a slipping switch in each station area exceeding a reset time threshold from the output end of a main station of the first station area;

acquiring a specific fault position according to the acquired action signals of the normally closed contact and the normally open contact of the pull switch, the deviation switch, the blocking switch or the slipping switch with numbers;

and according to the specific position of the fault, the fault is removed.

In order to realize the belt fault monitoring method, the belt fault monitoring device of the utility model comprises: the on-site monitoring module comprises a field monitoring module shell, a circuit board, a dial switch, an on-board CPU, a power supply interface, an input terminal, an output terminal, a terminal control cabinet body, a touch display screen, a PLC controller, a server, a wireless communication module, an input port, an output port and a power supply port.

Further, the on-board CPU sends normally closed contact action signals of the received belt pull switch, the deviation switch, the blocking switch or the slipping switch to the dial switch output address code, and normally open contact action information is sent to the output terminal.

Further, the input terminal is electrically connected with normally closed contacts and normally open contacts of the belt pull switch, the off-tracking switch, the blocking switch or the slipping switch.

Further, the electrical connection mode between the output terminal and the input port comprises bus connection and hard wire connection, wherein normally open contact state information of the belt pull switch, the off-tracking switch, the putty switch or the slipping switch is transmitted to the communication interface of the PLC through the bus, and normally closed contact state information is transmitted to the switching value input module of the PLC through the hard wire.

Further, the output port is electrically connected with a belt alarm bell, a band-type brake, an oil air cooler and a start-stop motor.

Working principle:

firstly, a worker sets a monitoring time threshold of a field monitoring module through a touch display screen on a terminal control cabinet, after the setting is completed, when a pull-rope switch, a deviation switch, a material blocking switch or a slipping switch of a belt acts, an onboard CPU firstly judges the reset time of normally-closed contacts of the pull-rope switch, the deviation switch, the material blocking switch or the slipping switch of the belt, if the reset time is lower than the preset monitoring time threshold, the field monitoring module does not output fault signals to the terminal control cabinet, if the reset time is higher than the preset monitoring time threshold, state information of normally-closed contacts of the pull-rope switch, the deviation switch, the material blocking switch or the slipping switch of the belt is sent to a dial switch by the onboard CPU, address code information is generated by the dial switch, and then the address code information is sent to the terminal control cabinet through hard wiring, when the normally-closed contacts of the pull-rope switch, the deviation switch, the material blocking switch or the slipping switch of the belt fail, the action information of the pull switch, the off-tracking switch, the putty switch or the slipping switch of the belt is directly sent to the terminal control cabinet by the on-board CPU, after the terminal control cabinet receives the fault signal, the PLC sends the signal to control the belt to stop, the fault information is displayed on the touch display screen, meanwhile, the fault information is stored on the server, the server communicates with the remote management center in a wired or wireless mode, because the on-site monitoring module of each pull switch, the off-tracking switch, the putty switch or the slipping switch is preset with a number, the staff can directly go to the fault point to perform fault elimination according to the number information, after the fault elimination is completed, the staff can directly return to the terminal control cabinet to restart the alarm bell, the band-type brake, the oil air cooler and the start-stop motor of the belt, and can also be remotely operated through a remote management center.

The utility model has the remarkable beneficial effects that:

(1) According to the utility model, the on-site monitoring module is used for monitoring the normally-open contact action of the switch on the basis that the existing monitoring device can only monitor the normally-closed contact action of the switch, so that the terminal control cabinet can monitor the switch even if the normally-closed contact of the switch is oxidized to cause poor contact.

(2) According to the utility model, by setting the reset threshold, the problem that the existing monitoring device can output a fault signal to cause unnecessary shutdown when the pull-cord switch is in misoperation or shake is solved, the monitoring precision is further improved, and the production efficiency is improved.

(3) The utility model is provided with 485 bus output and hard wiring output modes, namely normally open point state information of the switch is transmitted to the PLC communication interface through the 485 bus, normally closed point state is encoded into address code information and then transmitted to the PLC switching value input module through the hard wiring mode, and the two are redundant, so that the stability of the equipment is further improved.

(4) According to the utility model, all the field monitoring modules are divided into a plurality of station areas, each station area is independently and circularly checked, and for a conveyor belt of few kilometers, the time for acquiring fault information by the terminal control cabinet is greatly shortened, and the production safety is further ensured.

Drawings

FIG. 1 is a schematic diagram of an in-situ monitoring module according to the present utility model;

FIG. 2 is a schematic diagram of a terminal control cabinet according to the present utility model;

FIG. 3 is a schematic diagram of the present utility model;

the meaning of each mark in the figure is as follows:

1-a field monitoring module housing; 2-a circuit board; 3-dial switch; 4-on-board CPU; 5-a power supply interface; 6-input terminals; 7-an output terminal; 8-a terminal control cabinet body; 9-touching the display screen; 10-PLC controller; 11-a server; 12-a wireless communication module; 13-an input port; 14-an output port; 15-power supply port.

Detailed Description

The belt fault monitoring method comprises the following steps:

numbering the signal output ends of a pull rope switch, a deviation switch, a blocking switch or a slipping switch on the belt, wherein the numbering mode is that the switch closest to the control cabinet is number 1, and then sequentially numbering other switches according to the principle from near to far (for example, 1,2,3 … N);

sequentially substations are carried out on the output ends of the pull switches, the off-tracking switches, the material blocking switches or the slipping switches with finished numbers, each station area comprises a plurality of output ends of the pull switches, the off-tracking switches, the material blocking switches or the slipping switches with continuous numbers, the output end of the first pull switch, the off-tracking switch, the material blocking switch or the slipping switch in each station area is a master station of the station area and is a slave station of the last station area, the independent follow-up detection of each station area is carried out, and the follow-up detection results are sent to the master station of the previous station area until the master station of the first station area obtains the follow-up detection results of all station areas;

setting a reset time threshold for a pull switch, a deviation switch, a blocking switch or a normally-closed contact and a normally-open contact of a slipping switch on the belt, wherein the threshold interval is 300ms;

acquiring action signals of a normally closed contact and a normally open contact of a rope pulling switch, a deviation switch, a material blocking switch or a slipping switch in each station area exceeding a reset time threshold from the output end of a main station of the first station area;

acquiring a specific fault position according to the acquired action signals of the normally closed contact and the normally open contact of the pull switch, the deviation switch, the blocking switch or the slipping switch with numbers;

and according to the specific position of the fault, the fault is removed.

In order to realize the belt fault monitoring method, the belt fault monitoring device of the utility model comprises: the on-site monitoring module comprises a field monitoring module shell 1, a circuit board 2, a dial switch 3, an on-board CPU4, a power supply interface 5, an input terminal 6, an output terminal 7, a terminal control cabinet body 8, a touch display screen 9, a PLC controller 10, a server 11, a wireless communication module 12, an input port 13, an output port 14 and a power supply port 15, wherein the circuit board 2 welded with the dial switch 3, the on-board CPU4, the power supply interface 5, the input terminal 6 and the output terminal 7 is fixedly arranged in the field monitoring module shell 1, the power supply interface 5 is respectively connected with the dial switch 3 and the on-board CPU4, the input terminal 6 is electrically connected with the input end of the on-board CPU4, the output end of the on-board CPU4 is respectively electrically connected with the dial switch 3 and the output terminal 7, the dial switch 3 is electrically connected with the output terminal 7, the touch display screen 9 is embedded above the front surface of the terminal control cabinet body 8, the input port 13, the output port 14 and the power supply port 15 are embedded below the front surface of the terminal control cabinet body 8, the PLC controller 10, the server 11 and the wireless communication module 12 are fixedly arranged in the terminal control cabinet body 8, the input port 10, the input port 11 and the wireless communication module 12 are fixedly arranged in the terminal control cabinet body 8, the input port 10 is electrically connected with the input port 6 and the input terminal 4 is electrically connected with the input terminal 7 and the input terminal 7, the input terminal 7 is electrically connected with the input terminal 7 and the input terminal 7 electrically to the input terminal 7.

Preferably, the on-board CPU4 sends the normally closed contact action signal of the received belt pull switch, the deviation switch, the blocking switch or the slipping switch to the dial switch 3 to output the address code, and the normally open contact action information is sent to the output terminal 7.

Preferably, the input terminal 6 is electrically connected with a normally closed contact and a normally open contact of the belt pull switch, the off-tracking switch, the material blocking switch or the slipping switch.

Preferably, the electrical connection between the output terminal 7 and the input port 13 includes 485 bus connection and hard wire connection, wherein normally open contact state information of the belt pull switch, the off-tracking switch, the blocking switch or the slipping switch is transmitted to the communication interface of the PLC controller 10 through the 485 bus, and normally closed contact state information is transmitted to the switching value input module of the PLC controller 10 through hard wire.

Preferably, the output port 14 is electrically connected to a belt alarm bell, a band-type brake, an oil cooler, and a start-stop motor.

The wiring of each terminal on the input terminal 6 and the output terminal 7 is shown in the following table:

input terminal number	Input function	Output terminal number	Output function
				1	+24V	11	+24V
2	GND	12	GND
				3	Fault feedback	13	Fault feedback
4	Normally closed at upper end	14	Normally closed output
				5	Output 6	15	Output 6
6	Output 5	16	Output 5
				7	Output 4	17	Output 4
8	Output 3	18	Output 3
				9	Output 2	19	Output 2
10	Output 1	20	Output 1

Communication wiring and arrangement

The No. 1 requirement is used as a host, the coding switch is arranged in such a way that both 1 and 8 are turned ON;

2-16 are all required to be used as slaves, and 8 of the coding switch is OFF;

the lower 4 bits that can be hosting must be 0001, i.e., 4 addresses No. 1, 17, 33, 49, where:

communication of pipe 1-17;

communication No. 17 pipe No. 17-33;

communication number 33 pipe 33-49;

communication No. 49 pipe No. 49-65.

Communication protocol: 9600 baud rate, 8 bits of data, 1 bit stopped, no check,

a data format, each substation occupies 2 data,

data 1: the upper 8 bits represent the voltage and the lower 8 bits are the timing increment.

Data 2: the upper 8 bits are the belt jam switch state and the lower 8 bits are the code switch state.

The address number 0 and the address number 1 are reserved for the current equipment to use;

numbers 1 and 2 are data for device number 1;

numbers 3 and 4 are data for device number 2;

……

the communication flow and thinking:

the PLC need only read data from address # 1 for less than 128,

the 1# address is used as a host, 2 data are read from the 2# -16# address at regular time, and then the data of the 17# -64# device are read from the 17# address into the 1# address respectively. Thus the 1# address will hold all the data for the entire site area.

The 17# address is used as a host, 2 data are read from the 18# 32# at regular time, and then the data of the 49# 64# device are read from the 33 # address into the 17# address respectively. Thus, the 17# address only stores all data of the 17# -64# station area.

The specific implementation mode also comprises a remote management center which is communicated with the terminal control cabinet in a wired or wireless mode and is used for remotely managing the site.

Claims (6)

1. A belt fault monitoring method, the method comprising:

numbering the signal output ends of a pull rope switch, a deviation switch, a blocking switch or a slipping switch on the belt, wherein the numbering mode is that the switch closest to the control cabinet is number 1, and then sequentially numbering other switches according to the principle from near to far (for example, 1,2,3 … N);

sequentially substations are carried out on the output ends of the pull switches, the off-tracking switches, the material blocking switches or the slipping switches with finished numbers, each station area comprises a plurality of output ends of the pull switches, the off-tracking switches, the material blocking switches or the slipping switches with continuous numbers, the output end of the first pull switch, the off-tracking switch, the material blocking switch or the slipping switch in each station area is a master station of the station area and is a slave station of the last station area, the independent follow-up detection of each station area is carried out, and the follow-up detection results are sent to the master station of the previous station area until the master station of the first station area obtains the follow-up detection results of all station areas;

setting a reset time threshold for a normally closed contact and a normally open contact of a pull rope switch, a deviation switch, a blocking switch or a slipping switch on the belt, wherein the threshold interval is 200-500 ms;

acquiring action signals of a normally closed contact and a normally open contact of a rope pulling switch, a deviation switch, a material blocking switch or a slipping switch in each station area exceeding a reset time threshold from the output end of a main station of the first station area;

acquiring a specific fault position according to the acquired action signals of the normally closed contact and the normally open contact of the pull switch, the deviation switch, the blocking switch or the slipping switch with numbers;

and according to the specific position of the fault, the fault is removed.

2. A belt fault monitoring device implementing the belt fault monitoring method of claim 1, comprising: the on-site monitoring module comprises a field monitoring module shell (1), a circuit board (2), a dial switch (3), an on-board CPU (4), a power supply interface (5), an input terminal (6), an output terminal (7), a terminal control cabinet body (8), a touch display screen (9), a PLC (programmable logic controller) (10), a server (11), a wireless communication module (12), an input port (13), an output port (14) and a power supply port (15), wherein the circuit board (2) welded with the dial switch (3), the on-board CPU (4), the power supply interface (5), the input terminal (6) and the output terminal (7) is fixedly arranged in the field monitoring module shell (1), the power supply interface (5) is respectively connected with the dial switch (3) and the on-board CPU (4), the input terminal (6) is electrically connected with the input end of the on-board CPU (4), the output end of the on-board CPU (4) is respectively electrically connected with the dial switch (3) and the output terminal (7), the dial switch (3) is electrically connected with the output terminal (7), the touch display screen (9) is embedded on the front surface of the terminal control cabinet body (8), the input port (13) is embedded on the front surface of the input port (7) and the power supply port (7) is embedded on the side of the terminal control cabinet body (8), PLC controller (10), server (11) and wireless communication module (12) fixed mounting are inside terminal control cabinet body (8), and power supply port (15) are connected with touch display screen (9), PLC controller (10), server (11) and wireless communication module (12) respectively, and PLC controller (10) are connected with touch display screen (9), server (11), wireless communication module (12), input port (13) and output port (14) electric connection respectively, output terminal (7) and input port (13) electric connection, output port (14) and input terminal (6) electric connection.

3. The belt fault monitoring device of claim 2, wherein: and the on-board CPU (4) sends normally closed contact action signals of the received belt pull switch, the deviation switch, the blocking switch or the slipping switch to the dial switch (3) to output address codes, and normally open contact action information is sent to the output terminal (7).

4. The belt fault monitoring device of claim 2, wherein: the input terminal (6) is electrically connected with a normally closed contact and a normally open contact of the belt pull switch, the off-tracking switch, the putty switch or the slipping switch.

5. The belt fault monitoring device of claim 2, wherein: the electrical connection mode between the output terminal (7) and the input port (13) comprises 485 bus connection and hard wire connection, wherein normally open contact state information of the belt pull switch, the off-tracking switch, the putty switch or the slipping switch is transmitted to a communication interface of the PLC (10) through the 485 bus, and normally closed contact state information is transmitted to a switching value input module of the PLC (10) through the hard wire.

6. The belt fault monitoring device of claim 2, wherein: the output port (14) is electrically connected with a belt alarm bell, a band-type brake, an oil air cooler and a start-stop motor.