TWI812410B - Method for monitoring conveyor belt - Google Patents
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Abstract
Description
本發明是關於一種監診方法，且特別是關於一種輸送帶的監診方法。 The present invention relates to a monitoring method, and in particular to a monitoring method for a conveyor belt.
由於造成輸送帶高溫而發生火災的原因有很多，例如轉動件潤滑不足、動火作業不慎、天候、設備老化、輸送帶/輥輪磨耗導致偏斜、落料積料等多元因素。若僅用單一檢測方式或技術，往往無法有效檢出潛在異況高溫，無法防患火災於未然。 There are many reasons for fires due to high temperature on conveyor belts, such as insufficient lubrication of rotating parts, careless hot work, weather, equipment aging, conveyor belt/roller wear causing deflection, blanking material accumulation and other multiple factors. If only a single detection method or technology is used, it is often impossible to effectively detect potential abnormal high temperatures and prevent fires in the bud.
回顧過去的防止輸送帶火災的方式，是透過輸送帶燃燒時，偵測所產出的火焰/煙氣成分、熱線熱導偵檢器鎔斷機制、滅火灑水噴頭感測、抑或熱顯像裝置，來實現抑制或撲滅火災，避免輸送帶持續延燒，造成更大的損失。 Looking back at the past, the methods to prevent conveyor belt fires were to detect the flame/smoke components produced when the conveyor belt burns, the cutting-off mechanism of hot-wire thermal conductivity detectors, fire sprinkler nozzle sensing, or thermal imaging. Device to suppress or extinguish the fire to prevent the conveyor belt from continuing to burn and causing greater losses.
依據過去事故發生之情境，輸送帶在運轉期間若存在高溫源，持續加熱皮帶，但若輸送帶仍處於運轉狀態，輸送帶溫度將會有效地被分散，雖輸送帶本身會發生一定程度的溫升，但不易發生輸送帶燃燒事故。同時依據過去經驗，高溫源有極大的機率是從單側引起，進而延伸到整 條輸送帶。具體而言，輸送帶之偏斜除可能造成原料輸送效率不佳外，也是火災的潛在主因之一，此外，嚴重偏斜更將直接觸發輸送機緊急停止開關，造成產線無預期停機。因此，如何對於輸送帶運行狀態之偏斜或高溫異況進行即時的監診，為此領域技術人員所關心的議題。 According to the scenarios of past accidents, if there is a high temperature source during the operation of the conveyor belt, the belt will continue to be heated. However, if the conveyor belt is still in operation, the temperature of the conveyor belt will be effectively dispersed, although the conveyor belt itself will generate a certain degree of temperature. liters, but conveyor belt burning accidents are less likely to occur. At the same time, based on past experience, there is a high probability that the high temperature source is caused from one side and then extends to the entire conveyor belt. Specifically, the deflection of the conveyor belt may not only cause poor raw material transportation efficiency, but also be one of the potential main causes of fires. In addition, severe deflection will directly trigger the emergency stop switch of the conveyor, causing the production line to shut down unexpectedly. Therefore, how to conduct real-time monitoring of deviations or high temperature abnormalities in the conveyor belt's operating status is a matter of concern to those skilled in the field.
本發明之目的在於提出一種輸送帶的監診方法，包括：取得輸送帶的第一側的第一振動訊號及輸送帶的第二側的第二振動訊號，其中第一側與第二側於第一方向上彼此相對，其中輸送帶朝向垂直於第一方向的第二方向輸送；根據第一振動訊號與第二振動訊號來判斷輸送帶為啟動運轉或停止狀態；當判定輸送帶為啟動運轉，根據第一振動訊號與第二振動訊號來判斷輸送帶為有料運載或無料空載；及當判定輸送帶於為啟動運轉且為有料運載，取得輸送帶的第一側的第一背膠溫度及輸送帶的第二側的第二背膠溫度，根據第一振動訊號、第二振動訊號、第一背膠溫度與第二背膠溫度來判斷輸送帶是否發生單側偏斜且發生單側異況高溫。 The object of the present invention is to provide a method for monitoring a conveyor belt, which includes: obtaining a first vibration signal on the first side of the conveyor belt and a second vibration signal on the second side of the conveyor belt, wherein the first side and the second side are Opposite each other in the first direction, where the conveyor belt is transported in a second direction perpendicular to the first direction; according to the first vibration signal and the second vibration signal, it is determined whether the conveyor belt is starting or stopped; when it is determined that the conveyor belt is starting , based on the first vibration signal and the second vibration signal, determine whether the conveyor belt is carrying material or is empty; and when it is determined that the conveyor belt is starting to operate and is carrying material, obtain the first adhesive temperature of the first side of the conveyor belt and the second adhesive temperature on the second side of the conveyor belt. Based on the first vibration signal, the second vibration signal, the first adhesive temperature and the second adhesive temperature, it is determined whether the conveyor belt has unilateral deflection and whether the conveyor belt has unilateral deflection. Extremely high temperatures.
在一些實施例中，上述輸送帶的監診方法更包括：利用分別設於輸送帶的第一側與第二側的二組三軸加速規來取得輸送帶的第一側的第一振動訊號及第二側的第二振動訊號；及利用分別設於輸送帶的第一側與第二側的二組無線偵溫器來取得輸送帶的第一側的第一背膠溫度及第二 側的第二背膠溫度。 In some embodiments, the above-mentioned monitoring method of the conveyor belt further includes: using two sets of three-axis accelerometers respectively provided on the first side and the second side of the conveyor belt to obtain the first vibration signal of the first side of the conveyor belt. and the second vibration signal on the second side; and using two sets of wireless temperature detectors respectively provided on the first side and the second side of the conveyor belt to obtain the first adhesive temperature and the second back glue temperature on the first side of the conveyor belt. The second adhesive temperature on the side.
在一些實施例中，上述輸送帶的監診方法更包括：於先前時點，取得輸送帶的第一側的第三振動訊號及第二側的第四振動訊號；於緊接於先前時點之後的當前時點，取得輸送帶的第一側的第一振動訊號及第二側的第二振動訊號；及根據第一振動訊號、第二振動訊號、第三振動訊號與第四振動訊號來判斷輸送帶於當前時點為啟動運轉或停止狀態。 In some embodiments, the above-mentioned monitoring method of the conveyor belt further includes: obtaining a third vibration signal of the first side and a fourth vibration signal of the second side of the conveyor belt at a previous time point; At the current time point, obtain the first vibration signal on the first side of the conveyor belt and the second vibration signal on the second side; and determine the conveyor belt based on the first vibration signal, the second vibration signal, the third vibration signal and the fourth vibration signal. It is running or stopped at the current time.
在一些實施例中，上述第一振動訊號、第二振動訊號、第三振動訊號與第四振動訊號之每一者為三軸向振動數值。輸送帶的第一側的當前時點i的第一振動訊號以(Ax1i,Ay1i,Az1i)表示，輸送帶的第二側的當前時點i的第二振動訊號以(Ax2i,Ay2i,Az2i)表示，輸送帶的第一側的先前時點(i-1)的第三振動訊號以(Ax1(i-1),Ay1(i-1),Az1(i-1))表示，輸送帶的第二側的先前時點(i-1)的第四振動訊號以(Ax2(i-1),Ay2(i-1),Az2(i-1)表示。上述輸送帶的監診方法更包括：將第一振動訊號減去第三振動訊號並進行下式運算，(Ax1i-Ax1(i-1))+(Ay1i-Ay1(i-1))+(Az1i-Az1(i-1))，以取得輸送帶的第一側於先前時點與當前時點之間的第一振動變化幅值；將第二振動訊號減去第四振動訊號並進行下式運算，(Ax2i-Ax2(i-1))+(Ay2i-Ay2(i-1))+(Az2i-Az2(i-1))，以取得輸送帶的第二側於先前時點與當前時點之間的第二振動變化幅值；及當第一振動變化幅值與第二振動變化幅值之任一者的絕對 值大於第一閥值時，則判定輸送帶於當前時點為啟動運轉。 In some embodiments, each of the first vibration signal, the second vibration signal, the third vibration signal and the fourth vibration signal is a three-axis vibration value. The first vibration signal of the current time point i on the first side of the conveyor belt is represented by (A x1i ,A y1i ,A z1i ), and the second vibration signal of the current time point i on the second side of the conveyor belt is represented by (A x2i ,A y2i ,A z2i ) means that the third vibration signal of the previous time point (i-1) on the first side of the conveyor belt is expressed as (A x1(i-1) ,A y1(i-1) ,A z1(i-1) ) means that the fourth vibration signal of the previous time point (i-1) on the second side of the conveyor belt is represented by (A x2(i-1) , A y2(i-1) , A z2(i-1 ). The above The monitoring method of the conveyor belt further includes: subtracting the third vibration signal from the first vibration signal and performing the following calculation, (A x1i -A x1(i-1) )+(A y1i -A y1(i-1) )+(A z1i -A z1(i-1) ) to obtain the first vibration change amplitude of the first side of the conveyor belt between the previous time point and the current time point; subtract the fourth vibration signal from the second vibration signal And perform the following formula calculation, (A x2i -A x2(i-1) )+(A y2i -A y2(i-1) )+(A z2i -A z2(i-1) ) to obtain the conveyor belt The second vibration change amplitude of the second side between the previous time point and the current time point; and when the absolute value of any one of the first vibration change amplitude and the second vibration change amplitude is greater than the first threshold, it is determined The conveyor belt is running at the current time.
在一些實施例中，上述輸送帶的監診方法更包括：當第一振動變化幅值的絕對值與第二振動變化幅值的絕對值皆不大於第一閥值時，則判定輸送帶於當前時點為停止狀態；當第一振動變化幅值與第二振動變化幅值之任一者的絕對值大於第二閥值時，則判定輸送帶於當前時點為啟動運轉且為有料運載，其中第二閥值大於第一閥值；及當第一振動變化幅值與第二振動變化幅值之任一者的絕對值大於第一閥值但不大於第二閥值時，則判定輸送帶於當前時點為啟動運轉且為無料空載。 In some embodiments, the above-mentioned monitoring method of the conveyor belt further includes: when neither the absolute value of the first vibration change amplitude nor the absolute value of the second vibration change amplitude is greater than the first threshold, it is determined that the conveyor belt is in The current time point is in a stopped state; when the absolute value of either the first vibration change amplitude and the second vibration change amplitude is greater than the second threshold, it is determined that the conveyor belt is started and is carrying materials at the current time point, where The second threshold is greater than the first threshold; and when the absolute value of either the first vibration change amplitude and the second vibration change amplitude is greater than the first threshold but not greater than the second threshold, the conveyor belt is determined to be At the current point in time, the operation is started and there is no material and no load.
在一些實施例中，上述輸送帶的監診方法更包括：利用設於輸送帶之上方的上方無線偵溫器來取得當前時點的環境溫度及於輸送帶上之原料的原料溫度；當第一背膠溫度與第二背膠溫度之任一者大於原料溫度且大於環境溫度的情況下，對於輸送帶於當前時點i的第一振動訊號與第二振動訊號進行下式運算，(Ax1i+Ay1i+Az1i)-(Ax2i+Ay2i+Az2i)，以取得輸送帶於當前時點的偏斜偵測量；及當偏斜偵測量的絕對值大於或等於第三閥值時，則判定輸送帶於當前時點發生單側偏斜且發生單側異況高溫。 In some embodiments, the above-mentioned monitoring method of the conveyor belt further includes: using an upper wireless temperature detector located above the conveyor belt to obtain the ambient temperature at the current point in time and the raw material temperature of the raw materials on the conveyor belt; when the first When either the back glue temperature or the second back glue temperature is greater than the raw material temperature and greater than the ambient temperature, the following formula is calculated for the first vibration signal and the second vibration signal of the conveyor belt at the current time point i, (A x1i + A y1i +A z1i )-(A x2i +A y2i +A z2i ) to obtain the deflection detection amount of the conveyor belt at the current point in time; and when the absolute value of the deflection detection amount is greater than or equal to the third threshold , then it is determined that the conveyor belt has unilateral deflection and abnormal high temperature on one side at the current point in time.
在一些實施例中，上述輸送帶的監診方法更包括：當偏斜偵測量大於或等於0且大於或等於第三閥值時，則判定輸送帶的第一側於當前時點發生單側偏斜且發生單側 異況高溫；及當偏斜偵測量小於或等於0且偏斜偵測量的絕對值大於或等於第三閥值時，則判定輸送帶的第二側於當前時點發生單側偏斜且發生單側異況高溫。 In some embodiments, the above-mentioned monitoring method of the conveyor belt further includes: when the deflection detection amount is greater than or equal to 0 and greater than or equal to the third threshold, then determining that the first side of the conveyor belt is unilateral at the current time point. Deflection occurs unilaterally Abnormally high temperature; and when the deflection detection amount is less than or equal to 0 and the absolute value of the deflection detection amount is greater than or equal to the third threshold, it is determined that the second side of the conveyor belt is unilaterally deflected at the current point in time and A unilateral abnormal high temperature occurs.
在一些實施例中，上述輸送帶的監診方法更包括：當偏斜偵測量的絕對值小於第三閥值時，則判定輸送帶於當前時點並未發生單側偏斜；當判定輸送帶於當前時點並未發生單側偏斜時，藉由加權移動平均演算法來預估於緊接於當前時點之後的下一時點的輸送帶的第一側的第五背膠溫度且預估於下一時點的輸送帶的第二側的第六背膠溫度；及根據第五背膠溫度與第六背膠溫度來預測輸送帶於下一時點是否發生溫升異況。 In some embodiments, the above-described conveyor belt monitoring method further includes: when the absolute value of the deflection detection amount is less than a third threshold, it is determined that the conveyor belt has not unilaterally deflected at the current time point; When the belt does not deflect on one side at the current time point, the weighted moving average algorithm is used to estimate the fifth adhesive temperature on the first side of the conveyor belt at the next time point immediately after the current time point and estimate The sixth adhesive temperature of the second side of the conveyor belt at the next time point; and predicting whether a temperature rise abnormality will occur on the conveyor belt at the next time point based on the fifth adhesive temperature and the sixth adhesive temperature.
在一些實施例中，上述第五背膠溫度以下式表示，W1Tbt1i+W2Tbt1(i-1)+W3Tbt1(i-2)+W4Tbt1(i-3)+W5Tbt1(i-4)，其中W1、W2、W3、W4、W5為權重值且W1>W2>W3>W4>W5，其中Tbt1i為輸送帶的第一側的當前時點i的第一背膠溫度，其中Tbt1(i-1)為輸送帶的第一側的先前時點(i-1)的背膠溫度，其中Tbt1(i-2)為輸送帶的第一側的先前時點之前一時點的背膠溫度，其中Tbt1(i-3)為輸送帶的第一側的先前時點之前二時點的背膠溫度，其中Tbt1(i-4)為輸送帶的第一側的先前時點之前三時點的背膠溫度。上述第六背膠溫度以下式表示，W1Tbt2i+W2Tbt2(i-1)+W3Tbt2(i-2)+W4Tbt2(i-3)+W5Tbt2(i-4)，其中Tbt2i為輸送帶的第二側的當前時點i的第二背膠溫度，其中Tbt2(i-1)為輸送帶的第二側的先前 時點(i-1)的背膠溫度，其中Tbt2(i-2)為輸送帶的第二側的先前時點之前一時點的背膠溫度，其中Tbt2(i-3)為輸送帶的第二側的先前時點之前二時點的背膠溫度，其中Tbt2(i-4)為輸送帶的第二側的先前時點之前三時點的背膠溫度。 In some embodiments, the fifth back glue temperature is represented by the following formula, W 1 T bt1i +W 2 T bt1(i-1) +W 3 T bt1(i-2) +W 4 T bt1(i-3) +W 5 T bt1(i-4) , where W 1 , W 2 , W 3 , W 4 , and W 5 are weight values and W 1 >W 2 >W 3 >W 4 >W 5 , where T bt1i is the transport The first adhesive temperature of the first side of the conveyor belt at the current time point i, where T bt1 (i-1) is the adhesive temperature of the previous time point (i-1) of the first side of the conveyor belt, where T bt1 (i- 2) is the adhesive temperature at one time point before the previous time point on the first side of the conveyor belt, where T bt1 (i-3) is the adhesive temperature at two time points before the previous time point on the first side of the conveyor belt, where T bt1 ( i-4) is the adhesive temperature at three time points before the previous time point on the first side of the conveyor belt. The above-mentioned sixth adhesive temperature is expressed by the following formula, W 1 T bt2i +W 2 T bt2(i-1) +W 3 T bt2(i-2) +W 4 T bt2(i-3) +W 5 T bt2( i-4) , where T bt2i is the second adhesive temperature at the current time point i on the second side of the conveyor belt, where T bt2(i-1) is the temperature of the previous time point (i-1) on the second side of the conveyor belt. Back glue temperature, where T bt2(i-2) is the temperature of the back glue one time point before the previous time point on the second side of the conveyor belt, where T bt2(i-3) is two times before the previous time point on the second side of the conveyor belt The adhesive temperature at the time point, where T bt2 (i-4) is the adhesive temperature at three time points before the previous time point on the second side of the conveyor belt.
在一些實施例中，上述輸送帶的監診方法更包括：當判定輸送帶為停止狀態，藉由加權移動平均演算法來預估於緊接於當前時點之後的下一時點的輸送帶的第一側的背膠溫度且預估於下一時點的輸送帶的第二側的背膠溫度，從而據以預測停止狀態之輸送帶於下一時點是否發生溫升異況。 In some embodiments, the above-mentioned monitoring method of the conveyor belt further includes: when it is determined that the conveyor belt is in a stopped state, using a weighted moving average algorithm to estimate the conveyor belt at the next time point immediately after the current time point. The adhesive temperature on one side is estimated to be the adhesive temperature on the second side of the conveyor belt at the next point in time, thereby predicting whether a temperature rise abnormality will occur in the stopped conveyor belt at the next point in time.
在一些實施例中，上述輸送帶的監診方法更包括：當判定輸送帶為啟動運轉且為無料空載，藉由加權移動平均演算法來預估於緊接於當前時點之後的下一時點的輸送帶的第一側的背膠溫度且預估於下一時點的輸送帶的第二側的背膠溫度，從而據以預測啟動運轉且無料空載之輸送帶於下一時點是否發生溫升異況。 In some embodiments, the above-mentioned monitoring method of the conveyor belt further includes: when it is determined that the conveyor belt is running and has no material or load, using a weighted moving average algorithm to predict the next time point immediately after the current time point. The temperature of the adhesive on the first side of the conveyor belt is estimated at the next point in time, so as to predict whether the conveyor belt will be warm at the next point in time when it is started and has no material or load. Exception.
為讓本發明的上述特徵和優點能更明顯易懂，下文特舉實施例，並配合所附圖式作詳細說明如下。 In order to make the above-mentioned features and advantages of the present invention more obvious and easy to understand, embodiments are given below and described in detail with reference to the accompanying drawings.
122,124:三軸加速規 122,124: Three-axis accelerometer
142,144,146:無線偵溫器 142,144,146:Wireless thermometer
200,220:輸送帶 200,220: Conveyor belt
300:輥輪 300:Roller
400:原料 400:Raw materials
D1:第一方向 D1: first direction
D2:第二方向 D2: second direction
S1-S10:步驟 S1-S10: Steps
從以下結合所附圖式所做的詳細描述，可對本發明之態樣有更佳的了解。需注意的是，根據業界的標準實務，各特徵並未依比例繪示。事實上，為了使討論更為清楚， 各特徵的尺寸都可任意地增加或減少。 The aspect of the present invention can be better understood from the following detailed description combined with the accompanying drawings. It should be noted that, in accordance with standard industry practice, features are not drawn to scale. In fact, to make the discussion clearer, The size of each feature can be increased or decreased as desired.
[圖1]係根據本發明的實施例之輸送帶的監診技術的元件佈設示意圖。 [Fig. 1] is a schematic diagram of component layout of a conveyor belt monitoring technology according to an embodiment of the present invention.
[圖2]係根據本發明的實施例之輸送帶的監診方法的流程圖。 [Fig. 2] is a flowchart of a conveyor belt monitoring method according to an embodiment of the present invention.
以下仔細討論本發明的實施例。然而，可以理解的是，實施例提供許多可應用的概念，其可實施於各式各樣的特定內容中。所討論、揭示之實施例僅供說明，並非用以限定本發明之範圍。關於本文中所使用之『第一』、『第二』、...等，並非特別指次序或順位的意思，其僅為了區別以相同技術用語描述的元件或操作。 Embodiments of the present invention are discussed in detail below. It is to be appreciated, however, that the embodiments provide many applicable concepts that can be embodied in a wide variety of specific contexts. The embodiments discussed and disclosed are for illustration only and are not intended to limit the scope of the invention. The terms "first", "second", ..., etc. used in this article do not specifically refer to the order or order, but are only used to distinguish components or operations described with the same technical terms.
本發明是關於一種輸送帶的監診技術。圖1係根據本發明的實施例之輸送帶的監診技術的元件佈設示意圖，圖1所示者為前視圖。輸送帶200透過輥輪300的帶動而沿著平行於第二方向D2之方向輸送，其中圖1的上半部的輸送帶200的輸送方向相反於圖1的下半部的輸送帶220的輸送方向，舉例而言，若圖1的上半部的輸送帶200的輸送方向為穿出圖面的方向，則圖1的下半部的輸送帶220的輸送方向為穿入圖面的方向。應注意的是，本文後續的陳述內容皆是針對圖1的上半部的輸送帶200所述。
The invention relates to a monitoring technology for conveyor belts. FIG. 1 is a schematic diagram of component layout of a conveyor belt monitoring technology according to an embodiment of the present invention. What is shown in FIG. 1 is a front view. The
本發明的輸送帶200用以進行原料輸送，舉例而言，輸送帶可例如為用以進行煤礦輸送之輸煤皮帶，或者，
輸送帶也可例如為輸鐵皮帶，本發明並不限制輸送帶的應用。
The
本發明於輸送帶200之背面處的相對兩側分別設置了無線偵溫器與三軸加速規。如圖1所示，本發明於輸送帶200的第一側(即圖1中的左側)設置無線偵溫器142與三軸加速規122，本發明於輸送帶200的第二側(即圖1中的右側)設置無線偵溫器144與三軸加速規124。上述之第一側與第二側在平行於第一方向D1之方向上彼此相對，且第一方向D1垂直於第二方向D2。
In the present invention, a wireless temperature detector and a three-axis accelerometer are respectively provided on opposite sides of the back of the
本發明將利用無線偵溫器(即無線偵溫器142、144)以非接觸式的方式來取得輸送帶200背膠表面溫度，在本發明的實施例中，無線偵溫器例如為紅外線偵溫器。本發明也將利用固設於用以帶動輸送帶200之輥輪300的支架上的三軸加速規(即三軸加速規122、124)來透過三軸振動量測功能以取得輸送帶200的振動訊號。
The present invention uses wireless temperature detectors (i.e.,
具體而言，本發明利用無線偵溫器142來取得輸送帶200的第一側的背膠溫度，且利用無線偵溫器144來取得輸送帶200的第二側的背膠溫度。具體而言，本發明利用三軸加速規122來取得輸送帶200的第一側的振動訊號，且利用三軸加速規124來取得輸送帶200的第二側的振動訊號。
Specifically, the present invention uses the
圖2係根據本發明的實施例之輸送帶200的監診方法的流程圖。於步驟S1，利用設於輸送帶200的第一側的三軸加速規122來取得輸送帶200的第一側的第一振
動訊號，並且利用設於輸送帶200的第二側的三軸加速規124來取得輸送帶200的第二側的第二振動訊號。步驟S1的細節陳述如下。首先，於一先前時點，取得輸送帶200的第一側的第三振動訊號以及輸送帶200的第二側的第四振動訊號。接著，於緊接於先前時點之後的一當前時點，取得輸送帶200的第一側的第一振動訊號以及輸送帶200的第二側的第二振動訊號。於步驟S2，根據第一振動訊號、第二振動訊號、第三振動訊號與第四振動訊號來判斷輸送帶200於當前時點為啟動運轉或停止狀態。於步驟S3，當判定輸送帶200為啟動運轉，根據第一振動訊號、第二振動訊號、第三振動訊號與第四振動訊號來判斷輸送帶200於當前時點為有料運載或無料空載。於步驟S4，利用設於輸送帶200的上方的無線偵溫器146(或者稱為上方無線偵溫器)來取得環境溫度以及於輸送帶200上之原料400(例如為煤礦或鐵等)的原料溫度。於步驟S5，利用設於輸送帶200的第一側的無線偵溫器142來取得輸送帶200的第一側的第一背膠溫度，並且利用設於輸送帶200的第二側的無線偵溫器144來取得輸送帶200的第二側的第二背膠溫度。於步驟S6，當判定輸送帶200於為啟動運轉且為有料運載，根據第一振動訊號、第二振動訊號、第一背膠溫度與第二背膠溫度來判斷輸送帶200是否發生單側偏斜且發生單側異況高溫。於步驟S7，當判定輸送帶200發生單側偏斜且發生單側異況高溫，則發出對應的警報(例如搭配消防滅火系統，實施自動噴水降溫，以達
提早預測輸送帶火災的發生，進而防範火災事故於未然)。於步驟S8，當判定輸送帶200並未發生單側偏斜，進行溫升異況偵測。於步驟S9，當判定輸送帶200為停止狀態，進行靜止溫升偵測。於步驟S10，當判定輸送帶200為啟動運轉且為無料空載，進行空載溫升偵測。圖2的流程之前、之後、以及各步驟之間也可以加入其他的步驟。圖2各步驟可以用電腦(例如個人電腦、工業電腦、嵌入式電腦等)、電路(例如可程式化邏輯控制器、嵌入式電路等)或者是電腦化軟體實作，本揭露並不在此限。
FIG. 2 is a flow chart of a monitoring method of the
其中，步驟S1與步驟S2的細節陳述如下。首先，於一先前時點，取得輸送帶200的第一側的第三振動訊號以及輸送帶200的第二側的第四振動訊號。接著，於緊接於先前時點之後的一當前時點，取得輸送帶200的第一側的第一振動訊號以及輸送帶200的第二側的第二振動訊號。然後，根據第一振動訊號、第二振動訊號、第三振動訊號與第四振動訊號來判斷輸送帶200於當前時點為啟動運轉或停止狀態。
Among them, the details of step S1 and step S2 are as follows. First, at a previous time point, the third vibration signal of the first side of the
在本發明的實施例中，上述之第一振動訊號、第二振動訊號、第三振動訊號與第四振動訊號之每一者為三軸向(即x軸，y軸，z軸)振動數值。輸送帶200的第一側的當前時點(在本文中以i表示)的第一振動訊號在本文中以(Ax1i,Ay1i,Az1i)表示，輸送帶200的第二側的當前時點i的第二振動訊號在本文中以(Ax2i,Ay2i,Az2i)表示，輸送帶200的第一側的先前時點(在本文中以(i-1)表示)的
第三振動訊號在本文中以(Ax1(i-1),Ay1(i-1),Az1(i-1))表示，輸送帶200的第二側的先前時點(i-1)的第四振動訊號在本文中以(Ax2(i-1),Ay2(i-1),Az2(i-1)表示。
In an embodiment of the present invention, each of the above-mentioned first vibration signal, second vibration signal, third vibration signal and fourth vibration signal is a three-axis (i.e. x-axis, y-axis, z-axis) vibration value. . The first vibration signal of the current time point (represented by i in this article) of the first side of the
步驟S2之判斷輸送帶200於當前時點為啟動運轉或停止狀態的細節陳述如下。針對輸送帶200的第一側，將上述之第一振動訊號減去第三振動訊號並進行下式式(1)之運算：A (p-p)1=(A x1i -A x1(i-1))+(A y1i -A y1(i-1))+(A z1i -A z1(i-1)) (1)以取得輸送帶200的第一側於先前時點(i-1)與當前時點i之間的第一振動變化幅值A(p-p)1。另外，針對輸送帶200的第二側，將上述之第二振動訊號減去第四振動訊號並進行下式式(2)之運算：A (p-p)2=(A x2i -A x2(i-1))+(A y2i -A y2(i-1))+(A z2i -A z2(i-1)) (2)以取得輸送帶200的第二側於先前時點(i-1)與當前時點i之間的第二振動變化幅值A(p-p)2。最後，當第一振動變化幅值A(p-p)1與第二振動變化幅值A(p-p)2之任一者的絕對值大於第一閥值時，則判定輸送帶200於當前時點為啟動運轉。
The details of determining whether the
具體而言，本發明利用先前時點的振動訊號與當前時點的振動訊號來進行運算並將運算結果與第一閥值做比較以判斷輸送帶200的啟停狀態，第一閥值可為操作人員之經驗數值或依據歷史資料推算出的參考數值。換言之，本發明於步驟S1與步驟S2透過三軸加速規122、124之三軸振動量測功能來偵測出輸送帶200的啟停狀態。
Specifically, the present invention uses the vibration signal at the previous time point and the vibration signal at the current time point to perform calculations and compares the calculation result with a first threshold value to determine the start and stop status of the
接著，於步驟S3，當判定輸送帶200於當前時點為啟動運轉，進一步根據第一振動訊號、第二振動訊號、第三振動訊號與第四振動訊號來判斷輸送帶200於當前時點為有料運載或無料空載。步驟S3之判斷輸送帶200於當前時點為有料運載或無料空載的細節陳述如下。當第一振動變化幅值A(p-p)1與第二振動變化幅值A(p-p)2之任一者的絕對值大於第二閥值時，則判定輸送帶200於當前時點為啟動運轉且為有料運載。其中第二閥值大於第一閥值。
Next, in step S3, when it is determined that the
具體而言，本發明利用先前時點的振動訊號與當前時點的振動訊號來進行運算並將運算結果與大於第一閥值之第二閥值做比較以進一步判斷輸送帶200的空載/有載狀態，第二閥值可為操作人員之經驗數值或依據歷史資料推算出的參考數值。換言之，本發明於步驟S1與步驟S3透過三軸加速規122、124之三軸振動量測功能來偵測出輸送帶200的空載/有載狀態。
Specifically, the present invention uses the vibration signal at the previous time point and the vibration signal at the current time point to perform calculations and compares the calculation result with a second threshold value greater than the first threshold value to further determine whether the
其中，步驟S4、步驟S5與步驟S6的細節陳述如下。首先，於步驟S4，利用設於輸送帶200的上方的無線偵溫器146來取得當前時點的環境溫度(在本文中以Te表示)以及於輸送帶200上之原料400的當前時點的原料溫度(在本文中以Tm表示)。接著，於步驟S5，利用設於輸送帶200的第一側的無線偵溫器142來取得輸送帶200的第一側的當前時點(在本文中以i表示)的第一背膠溫度(在本文中以Tbt1i表示)以及利用設於輸送帶200的
第二側的無線偵溫器144來取得輸送帶200的第二側的當前時點(在本文中以i表示)的第二背膠溫度(在本文中以Tbt2i表示)。然後，於步驟S6，根據當前時點的環境溫度Te、原料溫度Tm、第一背膠溫度Tbt1i、第二背膠溫度Tbt2i、第一振動訊號(Ax1i,Ay1i,Az1i)與第二振動訊號(Ax2i,Ay2i,Az2i)來判斷輸送帶200於當前時點是否發生單側偏斜且發生單側異況高溫。
Among them, the details of step S4, step S5 and step S6 are as follows. First, in step S4, the
步驟S6之判斷輸送帶200於當前時點是否發生單側偏斜且發生單側異況高溫的細節陳述如下。首先，判斷第一背膠溫度Tbt1i與第二背膠溫度Tbt2i之任一者是否大於原料溫度Tm且大於環境溫度Te。接著，當第一背膠溫度Tbt1i與第二背膠溫度Tbt2i之任一者大於原料溫度Tm且大於環境溫度Te(即
具體而言，本發明利用輸送帶200之相對兩側的當前時點的振動訊號來進行運算並將運算結果與第三閥值做比較以判斷輸送帶200的偏移現象，第三閥值可為操作
人員之經驗數值或依據歷史資料推算出的參考數值。換言之，本發明於步驟S6透過三軸加速規122、124之三軸振動量測功能來偵測出輸送帶200的偏移現象。
Specifically, the present invention uses the vibration signals of the opposite sides of the
步驟S6之判斷輸送帶200於當前時點是否發生單側偏斜且發生單側異況高溫的具體作法陳述如下。當偏斜偵測量大於或等於0(即△Adiff≧0)且偏斜偵測量大於或等於第三閥值(即△Adiff≧第三閥值)時，則判定輸送帶200的第一側於當前時點發生單側偏斜且發生單側異況高溫(步驟S7)。此外，當偏斜偵測量小於或等於0(即△Adiff≦0)且偏斜偵測量的絕對值大於或等於第三閥值(即|△A diff |≧第三閥值)時，則判定輸送帶200的第二側於當前時點發生單側偏斜且發生單側異況高溫(步驟S7)。
The specific method of determining whether the
此外，若於步驟S6，偏斜偵測量的絕對值小於第三閥值(即|△A diff |<第三閥值)時，則進入步驟S8，判定輸送帶200於當前時點並未發生單側偏斜，並接著進行溫升異況偵測。 In addition, if in step S6, the absolute value of the deflection detection amount is less than the third threshold (i.e. |△ A diff | Unilateral deflection, and then perform temperature rise abnormality detection.
其中，步驟S8之溫升異況偵測的具體做法陳述如下。首先，藉由加權移動平均演算法(weight moving average，WMA)，根據輸送帶200的第一側的最近五個時點的背膠溫度來預估於緊接於當前時點之後的下一時點的輸送帶200的第一側的第五背膠溫度，且根據輸送帶200的第二側的最近五個時點的背膠溫度來預估於下一時點的輸送帶200的第二側的第六背膠溫度。接著，根據第五背膠溫度與第六背膠溫度來預測輸送帶200於下一時點
是否發生溫升異況。
Among them, the specific method of detecting abnormal temperature rise in step S8 is described below. First, a weighted moving average (WMA) algorithm is used to estimate the conveying at the next time point immediately following the current time point based on the adhesive temperatures of the first side of the
步驟S8之溫升異況偵測的細節陳述如下。藉由加權移動平均演算法來取得下一時點(在本文中以(i+1)表示)的輸送帶200的第一側的第五背膠溫度(在本文中以Tbt1(i+1)表示)，第五背膠溫度的算式如下式(4)所示：T bt1(i+1)=W 1 T bt1i +W 2 T bt1(i-i)+W 3 T bt1(i-2)+W 4 T bt1(i-3)+W 5 T bt1(i-4) (4)其中W1、W2、W3、W4、W5為權重值且W1>W2>W3>W4>W5，權重值W1、W2、W3、W4、W5可為操作人員之經驗數值或依據歷史資料推算出的參考數值。其中Tbt1i為輸送帶200的第一側的當前時點i的第一背膠溫度，其中Tbt1(i-1)為輸送帶200的第一側的先前時點(i-1)的背膠溫度，其中Tbt1(i-2)為輸送帶200的第一側的先前時點之前一時點的背膠溫度，其中Tbt1(i-3)為輸送帶200的第一側的先前時點之前二時點的背膠溫度，其中Tbt1(i-4)為輸送帶200的第一側的先前時點之前三時點的背膠溫度。此外，藉由加權移動平均演算法來取得下一時點的輸送帶200的第二側的第六背膠溫度(在本文中以Tbt2(i+1)表示)，第六背膠溫度的算式如下式(5)所示：T bt2(i+1)=W 1 T bt2i +W 2 T bt2(i-i)+W 3 T bt2(i-2)+W 4 T bt2(i-3)+W 5 T bt2(i-4) (5)其中Tbt2i為輸送帶200的第二側的當前時點i的第二背膠溫度，其中Tbt2(i-1)為輸送帶200的第二側的先前時點(i-1)的背膠溫度，其中Tbt2(i-2)為輸送帶200的第二側的先前時點之前一時點的背膠溫度，其中Tbt2(i-3)為輸送帶200的第二側的先前時點之前二時點的背膠溫度，其
中Tbt2(i-4)為輸送帶200的第二側的先前時點之前三時點的背膠溫度。
The details of the temperature rise abnormality detection in step S8 are as follows. A weighted moving average algorithm is used to obtain the fifth adhesive temperature (T bt1(i+1) in this article) of the first side of the conveyor belt 200 at the next time point (in this article, (i+1)). Expressed), the calculation formula of the fifth adhesive temperature is as follows: T bt 1( i +1) = W 1 T bt 1 i + W 2 T bt 1( i - i ) + W 3 T bt 1 ( i -2) + W 4 T bt 1( i -3) + W 5 T bt 1( i -4) (4) Where W 1 , W 2 , W 3 , W 4 , W 5 are weight values and W 1 >W 2 >W 3 >W 4 >W 5. The weight values W 1 , W 2 , W 3 , W 4 , and W 5 can be the operator's experience values or reference values calculated based on historical data. Where T bt1i is the first adhesive temperature of the first side of the
具體而言，本發明利用加權移動平均演算法來預測下一時點的輸送帶200的相對兩側的背膠溫度並據以判斷溫升異況。其中，本發明利用加權移動平均演算法來預測下一時點的背膠溫度的原因在於，若是採用無線偵溫器測得的背膠溫度可能會因為一些不確定的因素而取得離群值(outliers)，從而造成後續誤判的情形。針對溫升異況之判斷方式，舉例而言，吾人可設定輸送帶200的第一側的溫度警戒閥值，如此一來，當下一時點的輸送帶200的第一側的第五背膠溫度超過輸送帶200的第一側的溫度警戒閥值時，可發出對應的警報。舉例而言，吾人可設定輸送帶200的第二側的溫度警戒閥值，如此一來，當下一時點的輸送帶200的第二側的第六背膠溫度超過輸送帶200的第二側的溫度警戒閥值時，可發出對應的警報。舉例而言，吾人可設定輸送帶200的第一側與第二側的溫差警戒閥值。如此一來，當下一時點的輸送帶200的第一側的第五背膠溫度與第二側的第六背膠溫度的溫差超過輸送帶200的第一側與第二側的溫差警戒閥值時，可發出對應的警報。從而可以針對所發出的警報進行對應的防範，例如搭配消防滅火系統，實施自動噴水降溫，以達提早預測輸送帶火災的發生，進而防範火災事故於未然。
Specifically, the present invention uses a weighted moving average algorithm to predict the adhesive temperatures on opposite sides of the
此外，若於步驟S2，當第一振動變化幅值的絕對值與第二振動變化幅值的絕對值皆不大於第一閥值時，則
進入步驟S9，判定輸送帶200於當前時點為停止狀態，並接著進行靜止溫升偵測。
In addition, if in step S2, when neither the absolute value of the first vibration change amplitude nor the absolute value of the second vibration change amplitude is greater than the first threshold, then
Entering step S9, it is determined that the
此外，若於步驟S3，當第一振動變化幅值與第二振動變化幅值之任一者的絕對值大於第一閥值但不大於第二閥值時，則進入步驟S10，判定輸送帶200於當前時點為啟動運轉且為無料空載，並接著進行空載溫升偵測。
In addition, if in step S3, when the absolute value of either the first vibration change amplitude or the second vibration change amplitude is greater than the first threshold but not greater than the second threshold, then step S10 is entered to determine whether the
上述之步驟S9的靜止溫升偵測與步驟S10之空載溫升偵測基本上與步驟S8之溫升異況偵測的做法類似，意即，會利用加權移動平均演算法來預測下一時點的輸送帶200的相對兩側的背膠溫度並據以判斷溫升異況，由於做法類似，於此不再贅述。然而，應注意的是，步驟S8的溫升異況偵測、步驟S9的靜止溫升偵測、步驟S10的空載溫升偵測所分別採用的權重值W1、W2、W3、W4、W5可能是採用不同的數值，這是因為步驟S8的溫升異況偵測為有料運載的情況、步驟S9的靜止溫升偵測為停止狀態的情況、步驟S10的空載溫升偵測為無料空載的情況，這些情況的溫升異況表現會有所不同，舉例而言，停止狀態的靜止溫升的溫升異況表現可能會是較為快速的升溫(例如指數型的升溫)，而無料空載的空載溫升的溫升異況表現則可能會是較緩慢的升溫(例如直線型的升溫)，因此，應須針對這些情況之不同的溫升表現來據以選擇各自合適的權重值。
The above-mentioned static temperature rise detection in step S9 and no-load temperature rise detection in step S10 are basically similar to the temperature rise abnormality detection in step S8, that is, a weighted moving average algorithm will be used to predict the next time. Point the glue temperature on the opposite sides of the
綜合上述，本發明提出一種輸送帶的監診方法，除能有效辨識輸送帶潛在異況高溫外，同時可以進行輸送帶 運轉狀態監診。具體而言，雖然輸送帶火災原因有許多，但輸送帶仍是最後，同時也是最關鍵的關注點。因此，本發明提出一種輸送帶的監診方法，以非接觸(無線偵溫)的方式，在輸送帶同一位置的左右兩側安裝無線偵溫器(兩組)，偵測輸送帶背膠表面溫度，同時亦偵測輸送帶所承載原料之原料溫度和環境溫度為參考基礎，以權重式移動平均演算法來有效並識別輸送帶溫升異況，搭配消防滅火系統，實施自動噴水降溫，以達提早預測輸送帶火災的發生，進而防範火災事故於未然。此外，本發明亦具備三軸振動量測功能，透過安裝於輸送帶兩側的三軸加速規所提供的振動訊號，能有效獲知輸送帶啟停及空/重載之狀態，同時輸送帶在運轉時所發生的偏移現象，也能有效檢測；當輥輪因摩擦嚴重導致高溫毀損之前，本發明亦能透過振動訊號進行檢測。透過與輸送帶的相對兩側的背膠溫度進行比對，一面可避免因皮帶偏移所導致單側溫升，所引起之可能的潛在火災事故；另一面，可提前在輸送帶尚未在嚴重偏移而導致緊急停機發生之前，提早給予使用者提醒，以便於進行適度調整。本發明參考過去輸送帶火災事故之種類與型式，以無線偵溫器與三軸加速規進行輸送帶狀態監診，除可快速準確檢測輸送帶溫升異況，另外還具備輸送帶運轉狀態與偏斜偵測等性能。除可監測輸送帶運作狀態的資訊提供與偏斜檢知外，透過結合噴水降溫系統，能即時迅速地避免火災事故。 Based on the above, the present invention proposes a method for monitoring conveyor belts. In addition to effectively identifying potential abnormal high temperatures on conveyor belts, the present invention can also perform conveyor belt monitoring. Operation status monitoring. Specifically, while there are many causes of conveyor belt fires, the conveyor belt remains the last and most critical concern. Therefore, the present invention proposes a method for monitoring conveyor belts. In a non-contact (wireless temperature detection) manner, wireless temperature detectors (two groups) are installed on the left and right sides of the same position on the conveyor belt to detect the adhesive surface of the conveyor belt. Temperature, while also detecting the raw material temperature and ambient temperature of the raw materials carried by the conveyor belt as a reference basis, a weighted moving average algorithm is used to effectively identify abnormal temperature rises on the conveyor belt, and is equipped with a fire extinguishing system to implement automatic water spraying to cool down. It can predict the occurrence of conveyor belt fires in advance and prevent fire accidents before they happen. In addition, the present invention also has a three-axis vibration measurement function. Through the vibration signals provided by the three-axis accelerometers installed on both sides of the conveyor belt, the start-stop and empty/heavy-load status of the conveyor belt can be effectively known. At the same time, the conveyor belt is in The deflection phenomenon that occurs during operation can also be effectively detected; before the roller is damaged due to high temperature due to severe friction, the present invention can also detect it through vibration signals. By comparing the temperature of the adhesive on the opposite sides of the conveyor belt, on the one hand, the possible fire accident caused by the temperature rise on one side due to belt deviation can be avoided; on the other hand, the conveyor belt can be installed in advance before it is seriously damaged. Before an emergency shutdown occurs due to deviation, the user is reminded in advance so that appropriate adjustments can be made. This invention refers to the types and types of conveyor belt fire accidents in the past, and uses wireless temperature detectors and three-axis accelerometers to monitor the conveyor belt status. In addition to quickly and accurately detecting abnormal temperature rise of the conveyor belt, it also has the ability to detect the conveyor belt operating status and Deflection detection and other functions. In addition to information provision and deflection detection that can monitor the operating status of the conveyor belt, fire accidents can be avoided immediately and quickly by combining a water spray cooling system.
本發明提出一種輸送帶的監診方法，避免災害擴大。 本發明是透過無線偵溫器與三軸加速規為基礎，來辨識輸送帶異況高溫及運行狀態偵測的整合式技術。因此，本發明將可依據輸送帶的狀態，識別出所偵測的異況，以便於警報的分類及顯示，以便於迅速掌握狀況，進行對應措施，即時針對早期異況進行預警，有效控制事故的範圍。 The invention proposes a monitoring method for conveyor belts to avoid the expansion of disasters. This invention is an integrated technology based on wireless temperature detectors and three-axis accelerometers to identify abnormal high temperatures and detect operating conditions of conveyor belts. Therefore, the present invention will be able to identify the detected abnormalities based on the status of the conveyor belt, so as to facilitate the classification and display of alarms, so as to quickly grasp the situation, take corresponding measures, and immediately provide early warning for early abnormalities, effectively controlling the occurrence of accidents. Scope.
本發明能有效達到輸送帶早期異況辨識之結果。例如：由輸送帶與軸承接觸面摩擦引起之溫升、軸承潤滑不良所引起的溫升、輸送帶偏斜運轉、輸送帶溫升檢知等。因此，藉由本發明的輸送帶的監診方法，除可進行輸送帶全方位的異況確認，也可以進行輸送帶運轉狀態監診，以便於能提供使用者可靠且即時的警報訊息。 The invention can effectively achieve the result of early identification of abnormal conditions of the conveyor belt. For example: temperature rise caused by friction between the conveyor belt and the bearing contact surface, temperature rise caused by poor bearing lubrication, conveyor belt skew operation, conveyor belt temperature rise detection, etc. Therefore, through the conveyor belt monitoring method of the present invention, in addition to all-round abnormality confirmation of the conveyor belt, the operating status of the conveyor belt can also be monitored, so as to provide users with reliable and real-time alarm messages.
以上概述了數個實施例的特徵，因此熟習此技藝者可以更了解本發明的態樣。熟習此技藝者應了解到，其可輕易地把本發明當作基礎來設計或修改其他的製程與結構，藉此實現和在此所介紹的這些實施例相同的目標及/或達到相同的優點。熟習此技藝者也應可明白，這些等效的建構並未脫離本發明的精神與範圍，並且他們可以在不脫離本發明精神與範圍的前提下做各種的改變、替換與變動。 The features of several embodiments are summarized above, so that those skilled in the art can better understand the aspects of the present invention. Those skilled in the art should understand that they can easily use the present invention as a basis to design or modify other processes and structures to achieve the same goals and/or achieve the same advantages as the embodiments introduced here. . Those skilled in the art should also understand that these equivalent structures do not deviate from the spirit and scope of the present invention, and they can make various changes, substitutions and changes without departing from the spirit and scope of the present invention.
S1-S10:步驟 S1-S10: Steps
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