Based on the TCK weak magnetic detection technology, an online real-time automatic monitoring system for TCK steel cord conveyor belt was developed, which can locate, classify and quantitatively detect hidden faults such as internal broken wire, corrosion, joint displacement, and pressure injury in the conveyor belt. After practical application, the system not only has outstanding features such as high detection accuracy, simple operation, low power consumption, and zero pollution, but also plays an important technical role in preventing lateral breakage accidents while reducing the maintenance workload of steel cord conveyor belts. Additionally, it has created considerable economic benefits.

　　中图分类号：TM247;TM936 文献标识码：B 文章编号：1001—0874(2011)03—044—03

　　DevelopmentandApplicationofOn--LineReal—TimeAutomatic

　　MonitoringSystemofSteelWireRopeCoreConveyorBelt

　　GUODong—bing，LIHuin，DOUBo—lin

　　(1.JingchengLanyanCoalCo.，Ltd.，Jincheng048006，China;

　　2.LuoyangTixikaiSteelWireRopeDetectingTechnologyCo.，Ltd.，Luoyang471003，China)

　　Abstract：The on-line real-time automatic monitoring system of TCK steel wire rope core conveyor belt is being researched and developed based on TCK weak magnetic detecting technique，which can realize the positioning qualitative and quantitative detecting of hidden faults in the conveyor belt such as broken ropes，corrosion，joint displacement and crushing.By practical application，this system has the features of high accuracy，easy operation，low power consumption and zero contamination.This system reduces lateral direction belt broken accident while Reducing the detecting operating strength of steel core conveyor belt.And it creates obviously economy effect.

　　Keywords：online automatic monitoring weak magnetic detecting technique steel wire rope conveyor belt.

　　1 overview

　　The steel cord conveyor belt is constantly operating in a continuous mode under conditions of large volume, long distance, and heavy load, especially under adverse conditions. Frequent occurrences of joint movement, unexpected breakage of steel cords, severe misalignment of conveyor belts, and steel cord corrosion and fatigue often occur. Once a lateral breakage or longitudinal tear safety accident occurs, it will directly affect the safety production and economic benefits of enterprises. In the past 10 years, a large state-owned mining group in Henan has experienced 24 conveyor belt breakage accidents, resulting in cumulative production losses exceeding 1800 hours. Fifteen of these breakages occurred at the joint, accounting for 60% of the total. The accidents not only caused significant economic losses but also resulted in personal injuries. Due to the steel cord being embedded in the conveyor belt, if its detection is to be achieved, the key is to effectively sense and reliably extract the original damage signal of the steel cord. Conventional magnetic detection methods have low sensor sensitivity and require instruments to be in close proximity to the object being tested, making it impossible to achieve online monitoring of steel cord conveyor belts.

　　Using TCK's steel cord weak magnetic detection technology as the core, Jincheng Lanyan Coal Industry Company and Luoyang TCK Steel Cord Detection Technology Company jointly developed the TCK steel cord conveyor belt online real-time automatic monitoring system, successfully solving the technical difficulties related to on-line detection of steel cord conveyor belt joint displacement, broken cords, wear, corrosion, fatigue and other failures, creating a new safety supervision mode. This system can not only monitor the safety status of conveyor belt use in real-time, eliminate hidden dangers, improve the modern management level of coal mine steel cord conveyor belts, but also scientifically reduce conveyor belt usage costs and effectively improve conveyor belt operation efficiency.

　　2 Steel cord conveyor belt online automatic monitoring system

　　The technical key of the on-line automatic monitoring system for steel cord conveyor belts lies in the use of highly sensitive sensor technology. Due to the sensitivity of the TCK sensor, which can reach 50V/mT, it can sense the changes in the geomagnetic field. Its sensitivity is 250,000 times that of the Hall element and 71,400 times that of the Hall component. Therefore, its detection device adopts a "wide-range" non-contact detection, and the distance between it and the conveyor belt has reached 100mm. This fundamentally solves the key problem of on-line detection of conveyor belts, and thus realizes the on-line real-time quantitative, qualitative, and positioning detection of steel cord conveyor belts.

　　(1) System Configuration

　　The TCK steel cord conveyor belt on-line real-time automatic monitoring system has five parts: TCK-GMS weak magnetic loading device, TCK—GMS flaw detection device, TCK-GMS travel encoder, TCK self-controlled acoustic and visual alarm device, and TCK multi-channel terminal main control device.

　　(2) System Technology Flow

　　TCK-GMS weak magnetic loading device. The monitoring system can mainly carry out weak magnetic planning for the steel cord core of the conveyor belt to stabilize the conveyor belt in a stable state ready for testing.

　　TCK-GMS flaw detection device. Extract the original signal of the technical state of the steel cord core of the conveyor belt, complete the conversion of the specified digital-to-analog and information encoding standards, carry out preliminary processing and information storage of the original data, and then transmit the steel cord core damage signal to the terminal main control device in real time through wired or wireless communication transmission methods.

　　TCK-GMS travel encoder. Mainly measure the speed and stroke of the steel cord core conveyor belt, and input high-density sampled pulse signals into the flaw detection device.

　　TCK self-controlled acoustic and visual alarm device. Alarm in real time based on the detection signal processing results of the flaw detection device. The green light indicates that the steel cord core conveyor belt is in a safe state; the yellow light indicates that the steel cord core conveyor belt has local hidden dangers that need to be strengthened attention and maintenance; the red light indicates that the steel cord core conveyor belt has significant dangerous conditions and is in a dangerous state, requiring immediate implementation of preset emergency plans such as stopping the vehicle for adjustment or replacement of a new belt.

　　TCK multi-channel terminal main control device. This is the central control system of the system, consisting of a central processing unit, hardware system, software system, and display terminal. It can comprehensively analyze the received detection signals, store the daily analysis results in a database for easy retrieval and query, and display the terminal to implement query or print the detection data analysis report, clearly and completely demonstrating the actual safety status and injury development trend of the steel cord core conveyor belt for users.

　　3 Main features and technical performance

　　(1) Main Features

　　Adopt TCK weak magnetic detection technology. It can complete high-reliability and high-precision quantitative and positioning online automatic detection of various injuries to steel cord conveyor belts.

　　High-sensitivity detectors are far away from the conveyor belt. It is not affected by factors such as conveyor belt speed changes, upper and lower vibrations, and wandering during conveyor belt operation. It adopts unit-type combined design, is not restricted by the conveyor belt width, and is flexible and easy to install. Its software adopts a functional modular design concept, has a user-friendly interface, and is easy to operate.

　　Meet the explosion-proof requirements in mines and other technical requirements in coal mines. It is not only suitable for use in coal mine shafts, but also for other harsh working conditions such as surface conditions. It does not require manual attendance, and the detection process is synchronized online in real time with the conveyor belt operation to ensure personal safety.

　　Realize data storage. It can complete real-time processing of raw data, real-time transmission, and real-time curve/image display, implement data compression and large data storage, facilitate historical records, post-analysis, and replay, and provide real-time detection conclusions, injury type analysis, and other information for steel cord conveyor belt injuries. It also has real-time acoustic and visual alarm prompting functions.

　　Have linkage functions. It can achieve linkage functions with user control equipment.

　　(2) Technical Performance

　　Accurate detection of steel cord conveyor belt injuries such as joints, broken wires, corrosion, etc. Through laboratory tests, comparisons, and statistical analysis, the real-time detection rate of the system for joints and broken wires reaches 100%, and it can accurately identify the joint grade and the number of broken wires. Other injury real-time detection rates are greater than 95%.

　　The quantitative detection error of metal cross-sectional area damage is small. By pre-burying steel cords in conveyor belt samples and then implementing online detection, the system's detection error for metal cross-sectional area loss within the range of 50% to 90% is less than 5%.

　　High positioning resolution. Verification of the alarm location of the measured damage point shows that the system's positioning resolution for steel cord damage is 1mm, which can accurately monitor the displacement of steel core joints.

　　Not affected by conveyor belt operating speed. The system uses spatial sampling methods, regardless of the speed of conveyor belt operation, to accurately complete the detection task.

　　Meet the detection needs of various width specifications of steel core conveyor belts. The implemented monitoring of the main conveyor belt for coal transportation at Chengzhuang Mine has a width of 1400mm, and actually uses two detection unit arranged side by side, each unit can cover an 800mm bandwidth, so for a large number of different width specifications of steel core conveyor belts, only need to use an appropriate number of units combined according to the actual situation to achieve online real-time monitoring of specific targets, which is both economical and practical for users.

　　4 Application effect

　　Since the application of the TCK steel cord conveyor belt online real-time automatic monitoring system in Chengzhuang Mine for more than a year, it has achieved an innovative监管model of paperless safety monitoring for the steel cord conveyor belt used in the mine, creating considerable economic and social comprehensive benefits.

　　(1) Increased production efficiency

　　The length of Chengzhuang Mine's belt conveyor is 2670in, with a total length of 5400m for the upper and lower belts. If inspected manually at a speed of 0.5m/s, a complete visual inspection takes at least 3 hours, and it is not possible to detect injuries such as joint movement, steel core fractures, severe corrosion and fatigue in the steel cord. Using X-ray imaging detection methods still cannot quickly and reliably assess the safety status of the entire conveyor belt, and often occupy normal production and maintenance time during the inspection, seriously affecting the production efficiency of the main inclined shaft belt conveyor. After adopting the online real-time automatic monitoring system, transportation and inspection are carried out simultaneously, which not only overcomes the inherent defects of previous appearance inspections, but also greatly extends the production time. It can transport 67200 tons of coal more per year, with an annual additional profit of 873.6 million yuan.

　　(2) Energy conservation and consumption reduction

　　The main energy consumption in the process of steel cord conveyor belt inspection mainly includes the power consumption of the conveyor and the cost of using detection equipment. The total no-load power load of the conveyor drive motor is 750kW. In the annual inspection process of 576 hours, it actually consumes 432000 kWh of electrical energy, which costs 230000 yuan at the industrial electricity price of 0.53 yuan/kWh. After applying the system, as the power consumption of the system is less than 200W, the electricity cost generated all year round can be almost neglected, avoiding not only the no-load power consumption of the conveyor, but also reducing the number of starts and stops of the conveyor and extending the service life of the equipment.

　　(3) Saving equipment costs

　　The system can perform real-time diagnosis and timely prediction for various safety hazards in conveyor belts, thus avoiding unnecessary waste caused by blind maintenance and replacement of conveyor belts. After using this system, it can also provide important technical basis for scrapping and updating steel cord conveyor belts, so as to reasonably extend the service life of conveyor belts and conveyor machines.

　　Conclusion 5

　　The TCK steel cord conveyor belt online real-time automatic monitoring system has been applied in Chengzhuang Mine of Jincheng Coal Industry Group Co., Ltd. for more than one year. It can monitor the safety status of steel cord conveyor belt in real time, reliably prevent belt breakage accidents, scientifically reduce the use cost of steel cord conveyor belt, and effectively improve the equipment operating efficiency. It not only achieves the leading level at home and abroad in technology, but also has a very prominent application prospect and value. The initial investment of the device is 300,000 yuan, which creates nearly 11 million yuan of direct economic benefits for the enterprise in one year.

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　　Author biography: Xiao Dongbing (1971-), male, senior engineer. Graduated from Shanxi University of Science and Technology (master's degree) in 1993, now engaged in technical work in Chengzhuang Mine of Jincheng Coal Industry Group Co., Ltd.