CN112781710A - Method for detecting high-frequency abnormal sound of carrier roller of belt conveyor in distributed mode - Google Patents
Method for detecting high-frequency abnormal sound of carrier roller of belt conveyor in distributed mode Download PDFInfo
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- CN112781710A CN112781710A CN201911082931.XA CN201911082931A CN112781710A CN 112781710 A CN112781710 A CN 112781710A CN 201911082931 A CN201911082931 A CN 201911082931A CN 112781710 A CN112781710 A CN 112781710A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
- G01H9/00—Measuring mechanical vibrations or ultrasonic, sonic or infrasonic waves by using radiation-sensitive means, e.g. optical means
- G01H9/004—Measuring mechanical vibrations or ultrasonic, sonic or infrasonic waves by using radiation-sensitive means, e.g. optical means using fibre optic sensors
Abstract
The invention belongs to the technical field of detecting belt conveyor carrier roller audio frequency abnormal sounds, and particularly relates to a distributed method for detecting belt conveyor carrier roller audio frequency abnormal sounds, which realizes real-time detection of belt conveyor carrier roller audio frequency abnormal sounds and fault location, thereby reducing long-distance point detection and maintenance of personnel and improving efficiency. The abnormal sound characteristic values (frequency spectrum and high amplitude) of the belt conveyor carrier roller when the belt conveyor carrier roller is seriously failed are obtained, the state of the on-site belt conveyor carrier roller is obtained in software through comparison of the characteristic values, and the carrier roller is proved to have the possibility of serious failure by matching with the characteristic values and needs to be processed in time. The distributed optical fiber audio sensor is tightly attached to and fixed on a belt conveyor frame along a belt conveyor carrier roller, the position on the sensor and the position of the belt conveyor carrier roller are calibrated, and the condition of the belt conveyor carrier roller can be obtained in real time at a terminal of the system according to the audio characteristics of the sensor.
Description
Technical Field
The invention belongs to the technical field of detecting belt conveyor carrier roller audio frequency abnormal sounds, and particularly relates to a distributed method for detecting belt conveyor carrier roller audio frequency abnormal sounds.
Background
China is the largest steel producing country in the world, annual steel production accounts for more than 50% of the world, more than 80% of the world adopts a long-flow process of iron making, converter and steel rolling, the iron making process of large-scale steel and iron combination enterprises is complex, more than 3 tons of material transportation is needed for producing 1 ton of molten iron, including sinter, pellet, coal, auxiliary materials, slag and the like, belt conveyor transportation is the most used transportation mode of the steel and iron combination enterprises, and the belt conveyor has the characteristics of high efficiency, high throughput, easiness in automation and the like. The belt feeder mainly has equipment such as steel construction frame, bearing roller, belt, power device to constitute, and the maintenance is examined to the point that so long belt mileage needs a large amount of manpowers, and the biggest core key element is exactly the abnormal sound is examined to the belt feeder point, walks along the belt feeder, in case different with normal sound, then most probably the bearing roller has taken place the trouble, if lack of oil, the bearing is bad etc..
Adopt distributed optical fiber audio sensor, lay the special optic fibre that need not power supply along the belt feeder direction, when the different sound appears in the bearing roller of a certain position or belt feeder, just can acquire information such as the frequency of audio frequency, amplitude and different sound emergence position, because audio frequency different sound signal explains that equipment trouble is more serious, harm to equipment is bigger, cause shut down and bigger trouble easily, so adopt distributed optical fiber audio sensor to acquire the high frequency signal of equipment different sound, with this replacement personnel long distance, the physical labor of high strength, realize intelligent, unmanned and digital point inspection effect.
The person skilled in the art is directed to solving the above technical problem.
Disclosure of Invention
In order to achieve the purpose, the invention provides the following technical scheme: a method for detecting the audio-frequency abnormal sound of a belt conveyor carrier roller in a distributed mode comprises the following steps:
s1, arranging an installation route by combining the structural characteristics of the belt conveyor;
s2, carrying out position calibration on the distributed optical fibers, and carrying out positioning pairing with carrier rollers or obvious marks on the belt conveyor;
s3, fixedly mounting the distributed optical fiber sensor close to a belt conveyor steel structure;
s4, connecting the distributed optical fiber sensor with the communication optical fiber, and connecting the laser source and the signal processing module;
s5, acquiring audio signals along the belt conveyor and transmitting the audio signals to an industrial computer of a central control room;
and S6, installing driver and terminal software of related equipment on the industrial computer.
Preferably, after the laser source emits the pulse incident light, the pulse incident light is transmitted along the communication optical fiber and the distributed optical fiber sensor, the pulse incident light is scattered in the optical fiber transmission process, and a part of scattered light is scattered in the opposite direction; in the scattered light, the rayleigh post-reflected signal is stripped by the signal processing module.
Preferably, the terminal software displays the audio frequency, the amplitude and the position information in real time according to the laying position condition of the distributed optical fiber sensor calibrated on the belt conveyor.
Compared with the prior art, the invention has the beneficial effects that:
1: the domestic industry adopts the distributed optical fiber audio sensing technology for detecting the integral state of the conveying belt for the first time. A fault pre-diagnosis of the device may be performed.
2: a 'mineral conveying belt housekeeper' system is constructed by a reliable audio detection technology and artificial intelligence technology software.
3: the intelligent expert diagnosis system is perfected through scientific research, on-site running-in, artificial intelligence and inter-operation cooperation.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention and not to limit the invention. In the drawings:
FIG. 1 is a schematic flow diagram of the process of the present invention;
FIG. 2 is a schematic diagram of the operation of the distributed optical fiber audio detection system according to the present invention;
FIG. 3 is a flow of an intelligent algorithm for identifying the type of belt conveyor failure in the present invention;
FIG. 4 is a schematic view of an audio abnormal sound of a belt conveyor for distributed optical fiber detection of a steel raw material coal silo according to the present invention;
FIG. 5 is a waveform of the belt conveyor of the present invention in an on and off condition;
FIG. 6 is a schematic diagram of feature extraction of an abnormal audio frequency sound according to the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1
Referring to fig. 1-6, the present invention provides the following technical solutions: a method for detecting high-frequency abnormal sound of a carrier roller of a belt conveyor in a distributed mode comprises the following steps:
s1, arranging an installation route by combining the structural characteristics of the belt conveyor;
s2, carrying out position calibration on the distributed optical fibers, and carrying out positioning pairing with carrier rollers or obvious marks on the belt conveyor;
s3, fixedly mounting the distributed optical fiber sensor close to a belt conveyor steel structure;
s4, connecting the distributed optical fiber sensor with the communication optical fiber, and connecting the laser source and the signal processing module;
s5, acquiring audio signals along the belt conveyor and transmitting the audio signals to an industrial computer of a central control room;
and S6, installing driver and terminal software of related equipment on the industrial computer.
Specifically, after the laser source emits pulse incident light, the pulse incident light is transmitted along the communication optical fiber and the distributed optical fiber sensor, the pulse incident light is scattered in the optical fiber transmission process, and a part of scattered light is scattered in the opposite direction; in the scattered light, the rayleigh post-reflected signal is stripped by the signal processing module, and the audio signal is estimated based on the rayleigh post-reflected signal and the frequency amplitude of the audio signal. And calculating the position point corresponding to the audio frequency according to the light speed, the refractive index of the optical fiber and the calibrated optical fiber position.
Specifically, the terminal software displays audio frequency, amplitude and position information in real time according to the condition of the laying position of the distributed optical fiber sensor calibrated on the belt conveyor, and when the audio frequency and the amplitude exceed the standard values of management or rapidly rise, the system automatically alarms to prompt a user to pay attention to the change of audio frequency, so that greater loss caused by fault deterioration is prevented.
Specifically, the principle of distributed abnormal sound detection is as follows:
the distributed optical fiber audio frequency detection technology is a sound vibration detection radar technology in optical fibers. Coded laser pulses are emitted into an optical fiber for acoustic vibration detection, and structural parameters such as material density, curvature radius and the like are changed due to the action of external stress on the optical fiber in the forward propagation process of the optical pulses, so that the forward-transmitted optical pulses generate a backscattering phenomenon, and the backscattering light is called Rayleigh (Rayleigh) scattering light;
stress change caused by external acoustic vibration at a certain position on the optical fiber can affect a backward Rayleigh scattering signal at the position, the change of Rayleigh scattering light signal characteristics and the external acoustic vibration at the position have close corresponding relation, and real-time detection of the external acoustic vibration signal at the position can be realized by detecting and analyzing the Rayleigh scattering light signal change at the position by the rear-end signal demodulation equipment. The working principle of the system is shown in figure 1:
localization principle of distributed audio signals:
the positions of the distributed audio signals are positioned by utilizing an optical time domain reflection technology. If the time required for the incident light pulse signal to return to the incident end of the optical fiber through backscattering is t when the detection laser pulse transmits a distance L in the optical fiber, the distance traveled by the laser pulse in the optical fiber is 2L, and then:
2L=V·t
v is the transmission speed of light in the optical fiber; c is the speed of light in vacuum; and n is the refractive index of the optical fiber material.
The distance between the position point of the measured acoustic vibration signal and the emitting position of the light source is as follows:
therefore, the time difference between the emission of the detection light pulse signal and the receiving of the backward Rayleigh scattering light signal is calculated, and the accurate position of the generation of each acoustic vibration signal can be determined.
The distributed audio detection technology is adopted to realize the detection of the abnormal audio of the belt conveyor in the steel industry:
the detection optical fibers are fixed on the inner walls of channel steel on two sides of the on-site belt conveyor, the detection optical fibers can be used as a continuous distributed audio sensor array along the running line of the belt conveyor due to a fully distributed sensing system, and the specific detection and alarm process is shown in figure 1. In the belt conveyor fault identification algorithm, the system adopts a wavelet analysis and machine learning based algorithm, and the specific flow of signal processing is shown in fig. 3;
the system utilizes the wavelet packet to orthogonally decompose different components in the signal into independent frequency bands without redundancy and omission, and judges the running state of each detection position of the belt conveyor according to the energy change in each frequency band. When the belt conveyor has mechanical faults, different inhibiting or enhancing effects can be generated on each frequency component of the audio signal at the position, and compared with the normal running state of the belt conveyor, the energy of partial frequency band can be increased or reduced, so that the energy of each frequency component of the signal contains abundant mechanical fault information, the energy change of some frequency bands corresponds to the specific type of a certain fault, the mapping relation between the energy of the sound vibration signal frequency band at each point along the belt conveyor and the corresponding fault state can be established by utilizing the characteristic, and the fault type of the belt conveyor can be judged by machine learning and intelligent analysis of the energy of each frequency component;
the main fault feature extraction process comprises wavelet decomposition, 4 layers of wavelet decomposition are carried out on the diagnosis signals, wherein wavelet coefficients S1 of high-frequency signals are obtained, and since audio sound signals mainly come from serious bearing faults of the carrier roller, shutdown processing is required, otherwise serious accidents such as belt conveyor tearing, deviation and fire caused by friction can be caused, and identification of the audio sound signals is particularly important.
Example of audio-frequency abnormal sound detection of ironmaking raw material coal silo belt conveyor:
the Bao steel raw materials total 30 coal silos, the coal storage capacity of single silo reaches 1.4 ten thousand tons, the total coal storage capacity reaches 33 ten thousand tons, it is the important fuel supply logistics system of Bao steel, the whole logistics mode adopts the belt conveyor to transport, the system adopts the unmanned operation, because the coal has flammable characteristic, the belt conveyor trouble serious of the whole system may cause the fire accident, Bao steel also happens because the high temperature produced after the serious trouble of bearing roller historically, the high temperature bearing roller draws the fire accident of coal burning system after the coal system shuts down, cause great loss. Therefore, a distributed audio signal acquisition system is additionally arranged on a raw material coal silo belt conveyor system, which has important significance for avoiding safety accidents and production accidents, and fig. 4 is a schematic diagram of audio detection on a coal silo belt conveyor;
after the system obtains the audio information of each position of the belt conveyor, the system sends signals to a signal processing system through optical fiber transmission, fig. 5 is a position-waveform diagram of the belt conveyor audio information after passing through the signal processing system, as can be seen from the diagram, the whole detection distance is about 560 meters, at the position of the first half, because the belt conveyor stops running, no audio signal exists, at the position of the second half, in the running audio signal transmission system of a belt conveyor carrier roller;
when the carrier roller has a fault, the audio frequency characteristic of the carrier roller is obviously different from that of a normal carrier roller, according to measurement, the frequency and the amplitude of the carrier roller are higher than those of normal carrier roller operation, and an audio signal with high frequency and large amplitude is represented by extracting a characteristic value, as shown in fig. 6; the abnormal sound appears at the 440 m position, the carrier roller obviously breaks down, and equipment operation and maintenance personnel can quickly go to the designated position to maintain or replace without carpet spot inspection, so that the labor amount and the working efficiency of the field operation and maintenance personnel can be greatly reduced.
The working principle and the using process of the invention are as follows: the special optical fiber Rayleigh backscattering principle is utilized to detect audio information along the optical fiber direction, the special distributed audio detection optical fibers are installed on a large number of belt conveyor steel structures of iron and steel enterprises, audio signals with different frequencies and amplitudes sent out in belt conveyor carrier roller abnormity can be detected, when the carrier roller has serious faults, the frequency and the amplitude of the audio are large compared with normal conditions, and the high-frequency abnormal signals are detected through the signal processing system and prompt a user to pay attention. The method is simple to install, sensitive in signal, free of long-distance point detection of equipment operation and maintenance personnel and capable of automatically giving an alarm in abnormal conditions. Automatic, intelligent and unmanned intelligent point inspection can be realized.
Finally, it should be noted that: although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that changes may be made in the embodiments and/or equivalents thereof without departing from the spirit and scope of the invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (3)
1. A method for detecting the audio abnormal sound of a belt conveyor carrier roller in a distributed manner is characterized in that; the method comprises the following steps:
s1, arranging an installation route by combining the structural characteristics of the belt conveyor;
s2, carrying out position calibration on the distributed optical fibers, and carrying out positioning pairing with carrier rollers or obvious marks on the belt conveyor;
s3, fixedly mounting the distributed optical fiber sensor close to a belt conveyor steel structure;
s4, connecting the distributed optical fiber sensor with the communication optical fiber, and connecting the laser source and the signal processing module;
s5, acquiring audio signals along the belt conveyor and transmitting the audio signals to an industrial computer of a central control room;
and S6, installing driver and terminal software of related equipment on the industrial computer.
2. The method for detecting the audio abnormal sound of the belt conveyor carrier roller in the distributed mode according to claim 1, wherein the method comprises the following steps: after the laser source emits pulse incident light, the pulse incident light is transmitted along the communication optical fiber and the distributed optical fiber sensor, the pulse incident light is scattered in the optical fiber transmission process, and a part of scattered light is scattered towards the reverse direction; in the scattered light, the rayleigh post-reflected signal is stripped by the signal processing module.
3. The method for detecting the audio abnormal sound of the belt conveyor carrier roller in the distributed mode according to claim 1, wherein the method comprises the following steps: and the terminal software displays audio frequency, amplitude and position information in real time according to the laying position condition of the distributed optical fiber sensor calibrated on the belt conveyor.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113607741A (en) * | 2021-07-30 | 2021-11-05 | 煤炭科学研究总院 | Belt joint defect detection method and device and electronic equipment |
| CN114486259A (en) * | 2022-01-05 | 2022-05-13 | 电子科技大学 | Signal processing method of distributed optical fiber acoustic sensing system for optimizing variational modal decomposition |
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| CN108109319A (en) * | 2017-12-11 | 2018-06-01 | 山西省交通科学研究院 | It is a kind of by distributed optical fiber temperature measurement data integration in the method for tunnel comprehensive monitoring system |
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| US20030158729A1 (en) * | 2002-02-15 | 2003-08-21 | Radiodetection Limited | Methods and systems for generating-phase derivative sound |
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| CN114486259A (en) * | 2022-01-05 | 2022-05-13 | 电子科技大学 | Signal processing method of distributed optical fiber acoustic sensing system for optimizing variational modal decomposition |
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Application publication date: 20210511 |