Product Overview
At present, steel cord conveyor belts have been widely used in mining, ports, cement plants and other fields. Steel cord conveyor belts have the advantages of long conveying distance, large capacity, continuous transportation, reliable operation, and easy realization of automation and centralized control. Especially for high-yield and high-efficiency enterprises, steel cord conveyor belts have become one of the main conveying equipment in modern production at home and abroad. If the joint of the steel cord conveyor belt moves or the internal steel wire breaks during operation, it may cause the conveyor belt to reverse, damage the conveyor frame, and even cause casualties. Therefore, ensuring the safety of steel cord conveyor belt transportation is of paramount importance. Our company's KJ898 mine steel cord conveyor belt magnetic flaw detection system adopts the fifth-generation technology, which can accurately detect the movement and displacement of the steel wire rope core joint in the conveyor belt, and accurately identify problems such as broken wires, fatigue, and rust. It completely eliminates potential safety hazards. In addition, based on the fourth-generation product, this system adopts the "dual-loop time difference magnetic balance principle", effectively overcoming the influence of conveyor belt vibration and deviation on the detection results. To make the detection results intuitive and easy to understand, the fifth-generation product adopts the latest simulation technology. The software detection interface accurately reproduces the internal steel wire rope shape of the conveyor belt, just like an X-ray scan of the conveyor belt, making broken ends and joint movement clearly visible.
Product Functions
Online monitoring and accurate positioning: The sensor designed with dual-loop time-difference magnetic balance technology can accurately detect corrosion, broken wires, broken strands, offset, joint 抽动 (joint slippage), and other wire rope damages inside the conveyor belt.
Alarm: The alarm threshold can be manually set. When joint slippage or broken wires/strands reach the set threshold, the software will automatically alarm.
Display: The host computer software provides two display modes: User Mode and Precision Analysis Mode. The User Mode uses simulation technology to realistically display the actual status of the wire ropes inside the conveyor belt, which is intuitive. The Precision Analysis Mode is used for precise analysis of specific damages.
Data storage and detection report generation: The software automatically stores detection data and generates daily, monthly, and annual reports. Historical data can be saved for more than 5 years.
Data sharing: Detection data can be uploaded to the Internet, allowing users to understand the safety status of the conveyor belt anytime, anywhere.
One-to-multiple: One main unit can detect multiple conveyor belts and support manual/auto switching.
Anti-deviation: The sensor box is slightly wider than the belt to prevent missed detection caused by belt deviation.
Anti-jitter: The latest "dual-loop time-difference magnetic balance technology" is adopted to effectively overcome the impact of conveyor belt up-and-down jitter on detection accuracy.
Data review and photo comparison: Users can open multiple software windows at will to retrieve basic detection graphs, current detection graphs, and historical detection graphs for precise comparative analysis.
Quick joint positioning and synchronous browsing: The joint numbers displayed on the computer are consistent with the actual joint numbers. New joints can be customized by users, facilitating quick positioning of joint slippage.
Remote power on/off: When the monitoring software is opened to start detection, the system automatically powers on; when the conveyor belt stops running, the system automatically powers off. It also supports timed automatic detection for unattended operation.
Remote technical support: Detection results can be remotely transmitted to the manufacturer via the Internet, and analyzed by the manufacturer's experts.
SystemComposition
The system is composed of GSC2000P mine-used intrinsically safe steel cord conveyor belt flaw detection sensor, KDW127/12 mine-used flameproof and intrinsically safe DC regulated power supply, optical-electric converter, industrial control computer, host computer software, etc.
Flaw Detection Sensor: Inside, multiple flaw detection units and a 32-bit ARM single-chip microcomputer are densely arranged. Each flaw detection unit covers one or two steel ropes. The sensor converts defects in the steel ropes into analog signals and outputs them to the single-chip microcomputer. The single-chip microcomputer performs analog-to-digital conversion and signal processing, and converts the useful signals into CAN bus signals for transmission.
Mine-used Flameproof and Intrinsically Safe DC Regulated Power Supply: Composed of an intrinsically safe power supply, a servo single-chip microcomputer, and a data acquisition and communication module.
① The intrinsically safe power supply (12V/2A) supplies power to the sensor group and the single-chip microcomputer respectively.
② The servo single-chip microcomputer turns on/off the main power supply or stops the operation of the steel ropes according to commands from the host computer.
③ The data acquisition and communication module mainly receives signals from multiple sensor groups, processes and packages them, and transmits them to the host computer.
Optical-Electric Converter: Composed of an intrinsically safe power supply and a CAN communication data conversion interface, acting as a safety barrier.
① The intrinsically safe power supply provides power to the CAN communication data conversion interface.
② The communication data conversion interface converts CAN signals into USB interface signals for transmission to the computer.
Industrial Control Computer Station: Composed of a dedicated cabinet, an industrial control computer, dedicated steel rope data processing software, a printer, a text message notification module, etc. Its functions include data acquisition and processing, graphic display, data storage, defect type analysis and judgment, detection report generation, report printing, and notifying customers via text messages.
Technology Improvement
① Improve the accuracy of detecting weak signals.
② Enhance the signal resolution.
③ Reduce the output signal of the sensor to solve the problem of signal disconnection.
Replace three 98-series single-chip microcomputers with 32-bit ARM single-chip microcomputers to completely solve the asynchronization issue of single-chip microcomputers, eliminate display misalignment, and make the judgment of joint slippage more reliable.
① Solve the problem of automatic power on/off of the lower computer controlled by the upper computer, and extend the service life of sensors and the lower computer.
② Automatically stop the belt operation when joint slippage or broken wires exceed 10%.
① The single-chip microcomputer continuously collects signals to avoid signal loss caused by interruptions.
② The lower computer filters signals, discarding excessively large or small signals.
Solve the problem of automatic switching to realize true control of multiple devices via a single communication cable.
① Directly display broken wires and strands in the form of actual steel rope damage.
② Display joints in two ways simultaneously: signal mode and steel rope mode.
MeasurementGraph Description
