Development Of State Monitoring And Fault Diagnosis System For Mining Belt Conveyor

This paper is one of the important sub-topics of Shanxi Province’s major scientific and technological project,"Development of Monitoring and Life Cycle Management System of Major Production Equipment for Coal Mine Based on Internet of Things".The project(No.20131101029)is proposed to solve the problems of incomplete functions,low reliability,low automation and intelligence of the existing monitoring and control system of belt conveyor.Under the condition of high speed and heavy load for a long time,the belt conveyor in coal mine is prone to slippage,deviation,overtemperature of drum,stacking of head coal,longitudinal tearing of belt conveyor,broken belt,motor,reducer,drum and other faults during operation.If it can not be found and handled in time,it will pose a serious threat to the property and personnel safety of enterprises.At present,the monitoring system produced abroad has some problems,such as high price,technical service inconvenient and poor compatibility and extensibility with the domestic system.The monitoring system of the domestic belt conveyor has many problems,such as high false alarm rate,multiple independent monitoring and protection systems for one belt conveyor,repeated collection of information and inconvenient operation,etc.Operators with low skill quality are extremely difficult to operate in narrow space and harsh environment.In addition,although the basic functions of the monitoring and control system developed at home and abroad can be realized,the amount of data collected is also large,but there is a lack of in-depth mining of monitoring data,no comprehensive use of advanced fault diagnosis technology,no fault diagnosis model,no Give full play to the value of the data.In view of the above shortcomings,this paper develops a monitoring,and fault diagnosis system for belt conveyor with high reliability,comprehensive function,high data utilization,standardized communication protocol,good extensibility and high automation.In this paper,the fault mechanism of common faults of belt conveyor is analyzed in detail,and the technical index and overall scheme of the system are determined according to the field investigation and application requirements as well as the deficiencies of the existing monitoring and control system.According to the technical index and overall scheme of the system,the monitoring and control quantity and system composition are determined: monitoring host,along-line management module,voice alarm module,I/O module,distribution control module(A~H),PLC,lower computer module,amplifier telephone module,along-line emergency stop module,terminal acquisition module.The functions of each module are defined,the hardware circuits of each functional module are designed and manufactured,and the corresponding software programs of each functional module are compiled.The background program is developed based on LabVIEW software platform,and the man-machine interface such as conveyor main control window,combined distribution box main control window,emergency stop position window,wiring details,history record,tape conveyor parameter setting,combined distribution box parameter setting and operation introduction are designed.The system has good man-machine interaction function.In addition,the fault mechanism of key components of belt conveyor is analyzed,signal processing methods such as noise reduction,fault feature extraction and intelligent recognition are studied,the overall scheme of fault diagnosis is determined,the relevant data processing,feature extraction and fault identification procedures are compiled,the fault diagnosis man-machine interface is made,and the on-line fault diagnosis of key components of belt conveyor is realized.In order to test the function of the system,first of all,the functions of hardware circuit and software program of each module are tested separately.Then,an experimental system is set up in the laboratory.The latch switch is used to simulate the switching sensor and the switching feedback signal,the signal generator is used to output 200-1000 Hz frequency signal analog output of frequency sensor,and the DC power supply is used to output the output signal of 0-5V DC voltage analog frequency sensor.Finally,the functions of real-time monitoring and display,start-stop control,voice alarm,data acquisition,communication,parameter setting,automatic address allocation and fault location of the system are tested on the platform of the experimental system.The test results show that all functions of the system are normal and meet the expected design requirements.In order to further test the functions of the system and the reliability and stability of the system in the actual use environment,the shell of each device is designed and assembled,and various sensors are connected according to the types and quantities of actual sensors.The equipment along the line is connected serially through 8-core pull-shielded cable for mining,and a practical experimental system is built on the spot.The functions of communication distance,power carrying capacity,condition monitoring,soft start,automatic tension,fault location and parameter setting were tested on the experimental platform built on site.In view of the problems and shortcomings exposed in the experiment,the software program of the system was improved by Accessing information,consulting tutors and relevant technicians,the hardware circuit of each module was improved,and the man-machine interface of the system was optimized.After many improvements and debugging,the field test was successfully completed.The test results show that the system integrates the monitoring and control system of belt conveyor with the combined distribution system and the key components fault diagnosis system.The system has high degree of integration and informatization,comprehensive function,convenient operation,high reliability and automation,and achieves the anticipated design requirements and practical application requirements.