TWI880320B - Monitoring system for real-time monitoring of the operating status of conveying equipment - Google Patents

Abstract

A monitoring system for real-time monitoring of the operating status of a conveying device is installed on one side of the conveying device and includes a monitoring device and a cloud server with a data management unit and a human-machine interactive interface. The monitoring device includes a signal acquisition module with a sensing device and a signal conversion device, an abnormality detection module with an edge computing device, a data integration module, and a data transmission module. The sensing device detects the sound signal or thermal image signal of the conveying device and converts it into a digital signal through the signal conversion device. The edge computing device judges and calculates the digital signal to generate a detection indicator. The data integration module is used to collect and integrate digital signals and detection indicators. The data transmission module communicatively couples the data integration module and the cloud server, transmits the digital signal and detection index to the data management unit and presents them on the human-computer interaction interface.

Description

Monitoring system for real-time monitoring of the operating status of conveying equipment

The present invention relates to a monitoring system, and more particularly to a monitoring system for real-time monitoring of the operating status of a conveying device.

Blast furnace ironmaking technology is a continuous production process that produces iron from iron ore. Generally speaking, blast furnaces must be in continuous production, so ensuring a stable supply of raw materials is crucial.

In existing blast furnace ironmaking equipment, the conveying device responsible for conveying raw materials is mainly composed of a roller assembly and a conveyor belt surrounding the roller assembly. When the raw materials are placed on the conveyor belt, the conveyor belt can be driven by the roller assembly to transport the raw materials at the bottom of the furnace to the material bin on the top of the furnace, which is more than 80 meters high.

However, if the roller assembly is damaged during the conveying process, the conveyor belt and the roller assembly may continue to rub against each other, causing the conveyor belt to tear or fire, thereby affecting the continuous production of blast furnace ironmaking. Therefore, in the current operation process, manual regular inspections are often required to confirm the operating status between the conveyor belt and the roller assembly.

From the above description, it can be seen that improving the monitoring system used to monitor the operating status of the conveying device to reduce the cost of regular manual inspections is a problem that needs to be solved by relevant technical personnel in the relevant technical field.

Therefore, the purpose of the present invention is to provide a monitoring system for real-time monitoring of the operating status of a conveying device, which can reduce the cost of manual regular inspections.

Therefore, the monitoring system of the present invention for real-time monitoring of the operating status of a conveying device is suitable for being arranged on at least one side of a conveying device.

The monitoring system for real-time monitoring of the operating status of the transport device includes at least one monitoring device and a cloud server.

The at least one monitoring device includes a signal acquisition module, an abnormality detection module, a data integration module, and a data transmission module.

The signal acquisition module has a sensing device disposed on at least one side of the transport device and a signal conversion device. The sensing device can be used to detect at least one of a sound signal and a thermal image signal generated by the transport device, and convert the signal into a corresponding digital signal through the signal conversion device.

The abnormality detection module has an edge operation device connected to the signal conversion device for judging and operating the digital signal to generate a corresponding detection indicator.

The data integration module is connected to the abnormality detection module to collect and integrate the digital signal converted by the signal conversion device and the detection index generated by the edge computing device.

The data transmission module is communicatively coupled to the data integration module.

The cloud server is communicatively coupled to the data transmission module and includes a data management unit and a human-machine interaction interface connected to the data management unit. The data transmission module transmits the digital signal and the detection index to the data management unit and presents the digital signal and the detection index in the human-machine interaction interface.

The effect of the present invention is that by arranging the at least one monitoring device on at least one side of the conveying device, the sound signal, thermal image signal and digital signal of the conveying device can be detected in real time, and then through the cooperation of the abnormal detection module and the cloud server, the detection index can be systematically and objectively judged, and the digital information of the operation status of the conveying device can be established. It can also allow operators to monitor the conveying device and its abnormal warnings in real time, so as to reduce the cost of regular manual inspections.

Before the present invention is described in detail, it should be noted that similar components are represented by the same reference numerals in the following description.

Referring to FIG. 1 , an embodiment of the monitoring system for real-time monitoring of the operating status of a conveying device of the present invention is applicable to monitoring the conveying status of a blast furnace iron smelting equipment 1. The blast furnace iron smelting equipment 1 includes a blast furnace 10 and a conveying device 11 disposed on one side of the blast furnace 10. The conveying device 11 includes a roller assembly 111 and a conveyor belt 112 surrounding the roller assembly 111 and capable of carrying a raw material (not shown). The roller assembly 111 can drive the conveyor belt 112 to transport the raw material from a furnace bottom 101 adjacent to the blast furnace 10 at a lower position to a furnace top 102 of the blast furnace 10.

Specifically, the conveying device 11 is disposed obliquely on the side of the blast furnace 10 so that the raw material is obliquely conveyed from the furnace bottom 101 to the furnace top 102. In the present invention, as shown in FIG1 , the roller assembly 111 has a plurality of rollers disposed in two rows, the rollers located on the upper side of FIG1 are the carry idlers 113, and the rollers located on the lower side of FIG1 are the return idlers 114.

The monitoring system for real-time monitoring of the operating status of the conveying device of the embodiment of the present invention includes at least one monitoring device 21 and a cloud server 22 communicatively coupled to the at least one monitoring device 21. It should be noted that there is no particular limitation on the number of monitoring devices 21, and there may be only one monitoring device 21 or multiple monitoring devices 21. In this embodiment, as shown in FIG. 1 , multiple monitoring devices 21 are used as an example for explanation. The monitoring devices 21 are arranged at intervals on at least one side of the conveying device 11 along a conveying path of the conveying device 11. Specifically, at least one side of the conveying device 11 is provided with a bracket 3 separated from the conveying device 11, and the monitoring devices 21 are arranged at intervals from each other along the conveying path of the conveying device 11 at the top of the bracket 3 to be adjacent to the roller assembly 111 and the conveyor belt 112.

2 and 3 , each of the monitoring devices 21 includes a housing 20 , and a signal acquisition module 211 , an abnormality detection module 212 , a data integration module 213 , and a data transmission module 214 disposed in the housing 20 and electrically connected to each other.

The housing 20 is provided with a plurality of external detection ports, connection ports, and other function keys and display lights. Specifically, the size of the housing 20 is designed to be portable as shown in FIG. 2, so that its maximum side length is less than 15 cm and its thickness is not more than 5 cm. In this embodiment, the length, width, and thickness of the housing 20 are 12 cm, 10 cm, and 3.2 cm respectively, and a power port 201, a power switch 202, a status indicator 203, a thermal imaging port 204, a sound receiving hole 205, and an antenna transmission port 206 are provided on the housing surface.

Specifically, the power interface 201 can be used to connect an external power source to supply power to each module, and the operation of each module can be started or shut down through the power switch 202 (two buttons are used to represent the power switch in FIG. 2, representing OFF and ON respectively), and the operating status can be known from the status indicator 203.

The signal acquisition module 211 has a sensing device 215 disposed on at least one side of the transport device 11, and a signal conversion device 216. The sensing device 215 can be used to detect at least one of a sound signal and a thermal image signal generated by the transport device 11. The sensing device 215 of the signal acquisition module 211 includes an audio detection unit 217 and a thermal image acquisition unit 218.

The audio detection unit 217 can detect the sound signal generated by the transport device 11 through the sound receiving hole 205 provided in the housing 20. In this embodiment, the audio detection unit 217 is illustrated by a microphone capable of collecting external sounds. The thermal image capture unit 218 can capture the thermal image signal generated by the transport device 11 through the thermal image shooting port 204 provided in the housing 20. In this embodiment, the thermal image capture unit 218 is illustrated by a thermal imaging sensor capable of collecting infrared frequency spectrum. Specifically, the sound signal detected by the audio detection unit 217 of the sensing device 215 is an analog signal of sound intensity, and specifically, an analog signal of the voltage value corresponding to the sound intensity at each time point within a period of time; and the thermal image signal detected by the thermal image capture unit 218 is an analog signal of the voltage value corresponding to each image pixel within its field of view.

It should be noted that when the transport device 11 is operating, the signal acquisition module 211 can, depending on the situation, detect only the sound (that is, the sound signal) through the audio detection unit 217, or only detect the thermal image status (that is, the thermal image signal) through the thermal image acquisition unit 218, or detect both the sound and the thermal image at the same time.

Then, the detected analog signals of the sound and thermal image voltage values are transmitted to the signal conversion device 216, and the sound signal and the thermal image signal are respectively converted into a digital signal (i.e., a sound digital signal and a thermal image digital signal) by the signal conversion device 216. In this embodiment, the signal conversion device 216 is illustrated by taking an analog-to-digital converter (ADC) as an example.

The abnormality detection module 212 has an edge computing device 219 connected to the signal conversion device 216. The edge computing device 219 can receive each digital signal (that is, the sound digital signal and the thermal image digital signal) transmitted by the signal conversion device 216 to judge and calculate each digital signal to generate a corresponding detection indicator (that is, a sound detection indicator and a thermal image detection indicator). Specifically, the edge computing device 219 of the present embodiment is equipped with a memory, which can temporarily store a sound digital signal and a thermal image digital signal being processed, and the detection index determined/calculated therein. After the determination/calculation is completed, the sound digital signal and the thermal image digital signal being processed, and the detection index will be transmitted to the cloud server 22 together, and the memory will be cleared to wait for the next detection task. Specifically, the sound digital signal is first converted into an audio time-frequency analysis data by the signal conversion device 216, and specific frequency and intensity characteristics are extracted from the audio time-frequency analysis data. The sound detection index is then generated through an artificial intelligence model calculation, and the sound detection index data is judged to be abnormal based on a specific sound threshold stored in the memory. The determination of the thermal image digital signal is to first filter out an abnormal digital signal in the thermal image digital signal through a statistical method (including but not limited to the average value and the median) to generate a representative temperature map, and then regard a maximum temperature in a region of interest (ROI) in the temperature map as the thermal image detection index. When the thermal image detection index is higher than a specific temperature threshold stored in the memory, the data of the thermal image detection index is determined to be abnormal. It should be noted here that the abnormal digital signal filtered out above is based on an abnormal noise caused by the thermal image acquisition unit 218 itself, causing the thermal image digital signal converted by the signal conversion device 216 to carry the abnormal digital signal.

Then, the sound detection index and the thermal image detection index can be transmitted to the data integration module 213 connected to the abnormal detection module 212. The data integration module 213 is mainly used to collect the sound digital signal and the thermal image digital signal converted by the signal conversion device 216, and the sound detection index and the thermal image detection index generated by the edge computing device 219, and integrate the two detection indicators and transmit them to the cloud server 22 through the data transmission module 214. In this embodiment of the present invention, the edge computing device 219 and the data integration module 213 are explained by taking a single board computer as an example.

The data transmission module 214 is communicatively coupled to the data integration module 213 and the cloud server 22. The cloud server 22 includes a data management unit 221 and a human-machine interaction interface 222 connected to the data management unit 221. The data transmission module 214 transmits the sound digital signal and the thermal image digital signal and the sound detection indicator and the thermal image detection indicator to the data management unit 221, and presents the sound digital signal and the thermal image digital signal and the sound detection indicator and the thermal image detection indicator in the human-machine interaction interface 222. Specifically, the data transmission module 214 transmits the sound digital signal and the thermal image digital signal and the sound detection index and the thermal image detection index to the data management unit 221 by wireless transmission through the antenna transmission port 206 provided on the housing 20. In this embodiment, the data transmission module 214 is a Wi-Fi wireless transmission module. As shown in FIG1 , the wireless transmission module (not shown) 214 of each monitoring device 21 is connected to a wireless signal receiving station 4 mounted at the bottom of the bracket 3 and located at at least one side of the transport device 11 to transmit the digital signal and the detection index monitored by each monitoring device 21 from the transport device 11 to the cloud server 22. The wireless signal receiving station 4 applicable to the embodiment of the present invention can be a Wi-Fi base station, a 5G base station, a LoRaWAN base station or a NB-IoT base station. In the embodiment of the present invention, the wireless signal receiving station 4 is illustrated by taking a Wi-Fi base station as an example, but is not limited thereto.

The data management unit 221 can integrate the detection index into a detection position and a detection time corresponding to the conveying device 11. The human-machine interactive interface 222 can issue an alarm according to an abnormal condition of the detection index. As mentioned above, the abnormal condition has been judged in the edge computing device 219. Specifically, each monitoring device 21 has an identity code (ID), and each identity code represents the detection position of the corresponding monitoring device 21 at at least one side of the conveying device 11. When the artificial intelligence model of the edge computing device 219 of one of the monitoring devices 21 determines that the sound digital signal has an abnormal sound detection indicator data according to the specific sound threshold in its memory, or after filtering the abnormal digital signal of the thermal image digital signal, it determines in the temperature map that the thermal image digital signal has a thermal image detection indicator that is higher than the specific temperature threshold, then the abnormal sound detection indicator or the abnormal thermal image detection indicator can be detected. The data is transmitted to the data management unit 221 of the cloud server 22 via the data transmission module 214 of one of the monitoring devices 21 through the wireless signal receiving station 4, so as to integrate the detection position and detection time of one of the monitoring devices 21 corresponding to the conveying device 11 according to the abnormal sound detection indicator or the abnormal thermal image detection indicator, and the human-computer interaction interface 222 can issue an alarm according to the abnormal sound detection indicator or the abnormal thermal image detection indicator.

Referring to FIG. 4 , FIG. 4 shows a historical information viewing window of the human-machine interactive interface 222. The human-machine interactive interface 222 is connected to a database (not shown) of the cloud server 22, and the identification number of the monitoring devices 21 and the corresponding detection time can be selected through the menu 223 on the left side of the historical information viewing window, and the right side of the historical information viewing window will display the digital signal and detection index detected by the monitoring device 21 selected in the left menu 223, including the thermal image digital signal 224, the audio time-frequency analysis data 225, the sound detection index 226, and the thermal image detection index 227. In addition, a play button 228 is designed in the upper right corner of the historical information viewing window. After pressing the play button 228, the live audio recorded by the monitoring device 21 at the selected detection time can be reproduced. From the sound detection indicator 226 shown in FIG4, it can be seen that its horizontal axis and vertical axis represent time and state respectively, and the dotted line displayed in the sound detection indicator 226 represents the specific sound threshold in the memory, and exceeding the specific sound threshold (dotted line) in the sound detection indicator 226 represents an abnormal sound detection indicator value. In addition, from the thermal image detection indicator 227 shown in FIG. 4 , it can be seen that the horizontal axis and the vertical axis represent time and temperature respectively, and the dotted line displayed in the thermal image detection indicator 227 represents the specific temperature threshold, and exceeding the specific temperature threshold (dotted line) in the thermal image detection indicator 227 represents an abnormal thermal image detection indicator value.

Refer to FIG5 , which shows a real-time information viewing window of the human-machine interactive interface 222. As shown in FIG5 , the left side of the real-time information viewing window lists a schematic diagram of the blast furnace ironmaking equipment 1, and marks the installation position of each monitoring device 21. During the real-time detection process, after clicking the corresponding monitoring device 21 on the left side of the real-time information viewing window, the right side of the real-time information viewing window will instantly display the latest detection index of the monitoring device 21 clicked on the left side, and draw a data curve of the corresponding time point.

In summary, the monitoring system of the present invention is used for real-time monitoring of the operating status of the conveying device. Through the monitoring devices 21 spaced along at least one side of the conveying device 11 of the blast furnace ironmaking equipment 1, the operating status of the conveying device 11 can be detected all-time and in real time to obtain the sound and thermal image digital signals of the conveying device 11 and their detection indicators. The human-machine interaction interface 222 of the cloud server 22 can present systematic and objective detection indicators, so that the operator can remotely monitor the operating status of the conveying device 11 and its abnormal warnings in real time and reduce the cost of manual regular inspections, so the purpose of this invention can be achieved.

However, the above is only an embodiment of the present invention and should not be used to limit the scope of implementation of the present invention. All simple equivalent changes and modifications made according to the scope of the patent application of the present invention and the content of the patent specification are still within the scope of the present patent.

1: Blast furnace ironmaking equipment 10: Blast furnace 101: Furnace bottom 102: Furnace top 11: Conveyor device 111: Roller assembly 112: Conveyor belt 113: Conveyor roller 114: Return roller 20: Housing 201: Power interface 202: Power switch 203: Status indicator 204: Thermal imaging port 205: Sound receiving hole 206: Antenna transmission port 21: Monitoring equipment 211: Signal acquisition module 212: Abnormal detection module 213: Data integration module 214: Data transmission module 215: Sensing device 216: Signal conversion device 217: Audio detection unit 218: Thermal image acquisition unit 219: Edge computing device 22: Cloud server 221: Data management unit 222: Human-computer interaction interface 223: Menu 224: Thermal image digital signal 225: Audio time-frequency analysis data 226: Sound detection index 227: Thermal image detection index 228: Play button 3: Bracket 4: Wireless signal receiving station

Other features and effects of the present invention will be clearly presented in the implementation method with reference to the drawings, wherein: FIG. 1 is a schematic diagram illustrating an embodiment of the monitoring system for real-time monitoring of the operating status of a conveying device of the present invention, which is installed on at least one side of a conveying device of a blast furnace ironmaking equipment; FIG. 2 is a schematic diagram illustrating a monitoring device of the embodiment of the present invention; FIG. 3 is a schematic diagram illustrating the system architecture of the embodiment of the present invention; FIG. 4 is a schematic diagram illustrating a historical information viewing window of a human-computer interaction interface of the embodiment of the present invention; and FIG. 5 is a schematic diagram illustrating a real-time information viewing window of the human-computer interaction interface of the embodiment of the present invention.

1: Blast furnace ironmaking equipment

10: Blast furnace

101: Bottom of the furnace

102: furnace top

11: Transport device

111: Roller assembly

112: Conveyor belt

113:Conveyor roller

114: Return roller

21: Monitoring equipment

22: Cloud Server

3: Bracket

4: Wireless signal receiving station

Claims (6)

A monitoring system for real-time monitoring of the operating status of a transport device, suitable for being arranged on at least one side of a transport device, comprising: At least one monitoring device, comprising: A signal acquisition module, having a sensing device arranged on the at least one side of the transport device, and a signal conversion device, the sensing device can be used to detect at least one of a sound signal and a thermal image signal generated by the transport device, and converted into a corresponding digital signal through the signal conversion device, An abnormality detection module, having an edge operation device connected to the signal conversion device, for judging and operating the digital signal to generate a corresponding detection indicator, A data integration module connected to the abnormal detection module to collect and integrate the digital signal converted by the signal conversion device and the detection indicator generated by the edge computing device, and A data transmission module communicatively coupled to the data integration module; and A cloud server communicatively coupled to the data transmission module and including a data management unit and a human-computer interaction interface connected to the data management unit, the data transmission module transmits the digital signal and the detection indicator to the data management unit, and presents the digital signal and the detection indicator in the human-computer interaction interface; The edge computing device can receive a sound digital signal from the signal conversion device to judge and calculate the sound digital signal to generate a sound detection indicator, and the edge computing device has a memory, which can temporarily store a sound digital signal being processed and the detection indicator judged and calculated by the edge computing device. After the judgment and calculation are completed, the sound digital signal being processed and its detection indicator will be transmitted to the cloud server together, and the memory will be cleared to wait for the next detection task; and The judgment of the sound digital signal is to first convert the sound digital signal converted by the signal conversion device into an audio time-frequency analysis data, extract specific frequency and intensity characteristics from the audio time-frequency analysis data, and then generate the sound detection index through an artificial intelligence model calculation, and judge whether the data of the sound detection index is abnormal according to a specific sound threshold stored in the memory. The monitoring system as described in claim 1, wherein the data management unit can integrate the detection indicator into a detection position corresponding to the conveying device and a detection time, and the human-machine interaction interface can issue an alarm based on an abnormal condition of the detection indicator. The monitoring system as described in claim 1, wherein the sensing device of the signal acquisition module includes an audio detection unit and a thermal image acquisition unit, the audio detection unit can detect the sound signal generated by the transport device, and the thermal image acquisition unit can capture the thermal image signal generated by the transport device. The monitoring system as described in claim 1 comprises a plurality of monitoring devices, which are arranged at intervals from each other along a conveying path of the conveying device. The monitoring system as described in claim 1, wherein the at least one monitoring device further includes a housing, and the signal acquisition module, the abnormality detection module, the data integration module, and the data transmission module are electrically connected to each other and arranged inside the housing. A monitoring system as described in claim 5, wherein the outer shell includes a power interface, a thermal imaging port, and a sound receiving hole, the power interface is used for connecting an external power source, the thermal imaging port and the sound receiving hole are used for the sensing device to detect the thermal imaging signal and the sound signal generated by the transmission device.

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