Steel Cord  Conveyor Belt  Online Real-time Safety Monitoring System

Application Locale of TCK•W® Steel Cord Conveyor Belt Online Real-time Safety Monitoring System

System Introduction

TCK•W® steel cord conveyor belt on-line real-time safety monitoring system, which adopts the most advanced weak magnetism inspection technology, can detect accurately steel cord twitch,cord breakage, corrosion, hidden damages and etc in the splice field of conveyor belt, solving permanently major inspection problemof horizontal conveyor belt breakage.

This monitoring system can meet complicated working condition such as mining with high-yield, excavation of underground mine, busy logistics, continuous transportation and high-level management requirement of on-line real-time remote monitoring, is the most advanced inspection equipment at present.

TCK•W® can help customer to meet the values

1、Quantitative and positioning inspection for splice twitch, displacement: internal broken cord, corrosion.

2、Combining the production process and inspection process into one, that will reduce one process, increase operation time and raise the rate of equipment utilization

3、Reducing the idle energy consumption of equipment specially for testing steel cord, effect of energy saving is obvious.

4、The conveyor belt is always under the statues of monitoring for safety.

The diagram of Splice displacement and steel cords breakage in the same section of conveyor belt installed at main shaft of Zhulinshan Mining.

NoteⅡ:

1、Method for Measuring splice displacement value in splice area

When inspection software runs for the first time, it will collect all splice information of the conveyor belt (length, broken point position and etc) and save it to sample database. After that the system enters realtime inspection mode and compare the realtime calculated splice length L’ to sample splice length L. Finally obtain the splice length displacement value.

Formula is △L=| L’-L|=△L1+△L2

2、Method for Measuring flaw in non splice area

When inspection software runs for the first time, it will collect all splice information of the conveyor belt (scope, position and etc) and save it to sample database. The information will be regarded as known sample information of current status of conveyor belt. Then the system enters realtime inspection mode. If the known flaws take changes or new broken rope, corrosion appear, the PC will figure out the change of known flaws and Quantitative and positioning information of new flaws.

Zero Emission, Zero Energy Consumption, Daily Maintenance Free

① TCK•W®-GTSC Weak Magnetic Loading Device

-Nd-Fe-B configuration loading module, permanent magnet and intrinsic safe design.

-Wide-space and non-contact loading, Zero release and Zero energy.

-Modular units can be suitable for different specifications of steel cord conveyor belt.

-Stainless steel frame structure with the rain-proof, shock-proof, and oil-proof performance.

-All-weather operation and daily maintenance-free.

The normal running of conveyor belts is not affected by inspection, daily maintenance free

②TCK•W®-GTSC flameproof and intrinsically safe type testing unit

-Built-in horizontal + vertical weak magnetic sensor spatial response arrays.

-Modular units can be suitable for different specifications of steel cord conveyor belt and installed very easily.

-Wide-space and non-contact will make no affect of the normal production during the inspection.

-High-strength copper explosion-proof housings, stainless steel connecting brackets, on-line installation and automatic operation, daily maintenance-free.

High-speed data sampling, Telecommunication exchange

③TCK•W® intelligent data collection & conversion workstation

-Embedded low-power 32-bit industrial CPU, high speed data acquisition system, and large capacity storage.

-Intelligent multi-channel two-way automatic information communication mode.

-Modular multi-function unit combination, easy for updating.

-Shield-type information receiving & conversion and anti-interference design.

-In line with GB3836-2000 “Electrical Apparatus for Explosive Gas Atmospheres” standard, with mining product safety signs Exd[ib]I explosion-proof and intrinsically safe products.

Table Signal , High-precision Measuring

④ TCK•W®-GSG10(A) Photoelectrical Speed Measuring Device

-Adopt high-precision explosion-proof photoelectrical encoder and light aluminum frame.

-Anti-loosening mechanical structure, self-clamp-floating cantilever support, and friction wheel with multi-channel anti-slip rings ensure a reliable meter/speed measuring.

-Integrated anti-shake, pulse shaping, and equal accuracy tachometer etc. Industrial design with features of stable signal and high accuracy meter/speed measuring.

the warning indication for the safety state of conveyor belt

⑤TCK•W® Self-controlled sound/light alarm device

-Give the warning indication for the safety state of conveyor belt according to test data by EPLD phototube, DDY-6 buzz alarm and software control component.

-Green Light: Steel cord conveyor belt is in safe condition.

-Yellow Light: Steel cord conveyor belt has partial hidden dangers, and need to be monitored and maintained more intensively.

-Red Light: Steel cord conveyor belt is in extremely dangerous condition and emergency plan should be executed such as the belt should be shut down immediately and, changing new belt and etc.

the warning indication for the safety state of conveyor belt

⑥TCK•W® SMS safety report function device

-Based on the real-time monitoring results and historical statistics, the alarm information will be showed and locked in terminal interface.

-The corresponding alarm information can be remotely sent to manager’s mobile phone by SMS according to the system pre-lock.

⑦TCK•W® multi-channel terminal main control device

-Multi-channel step-by-step calling, synchronous and high speed data receiving & sending operation mode.

-Optional configuration for wire/wireless communication and cable/fiber access.

-Touch screen computer supports B/S (browser and server) dialogue operation mode.

-Designed command and control system software which supports multi-language user interface.

-Target archiving management system, available on-line real time collection, analysis and processing of testing data of conveyor belt.

-Reconstruct objective dynamic perspective image according to testing data.

-Synchronous segmented display of curve.

-Real-time sound/light alarm and remote SMS report.

-Support testing data retrieving and test report printing whenever needed.

-Test data self-evaluation system.

-Intelligent self-learning function.

-Self-diagnosis function for system fault and manual/auto switch operation mode.

-Compatible with the LAN or public network for information sharing.

-Embedded remote takeover capabilities that enables whole system remote debugging, maintenance and interaction.

-Provide a temporal trend analysis for various hidden dangers of conveyor belt.

-Provide flaw curve analysis, calculation on splice displacement, precise flaw location, real-time alarm, and comprehensive perceptive image.

Providing users with powerful service functions such as analysis of damage curves, the fine measurement of splice displacement, local defects in precise positioning, real-timeover limit warnings, holographic perspective image reconstruction and generation of test reports etc.

Technical Parameter

Table of Specifications and Parameters

Wire Rope W-PD Steel Cord Conveyor belt on-line real-time Monitoring System V4.0, is applied software specially developed by our Company for the realization of background management for steel cord conveyor belt on-line, continuous, real-time monitoring. The software system isbased on more reliable TCP (the Transmission Control Protocol) and more convenient UDP (the User Datagram Protocol) dual optimization transport mechanism, using the API (or Application Programming Interface) underlying function and B / S (i.e. browser and server) operation mode, multi-thread synchronization, as well as large-scale mask figure animation, and can follow dynamically the security status of steel cord all the way according to mass testing data, providing users with powerful service functions such as analysis of damage curves, the fine measurement of splice displacement, local defects in precise positioning, real-timeover limit warnings, holographic perspective image reconstruction and generation of test reports etc.

3、Over limit real-time warning prompts

The real-time alerting functions of W-PD Steel Cord Conveyor belt on-line real-time Monitoring System, is divided into sound and light alarm and SMS alarm from the alarm form, and alarm at any time and appointment alarm from alarm sending device.

Sound and light alarm, mainly for on-site inspections and main control room, users could check specific cause for alarm accordingly.

Test message reporting, designed for equipment supervising department or the persons in charge of safety operation; one time setting, ready to send daily report for equipment safety status automatically.

Real-time alarm, the system can issue a warning immediately based on presetting for over limit defects if over-limit flaw detected.

Appointment alarm: the system can generate a report based on analyzed results and send corresponding information at a scheduled time point.

4、Weak Magnetic scenograph of current conveyor belt status

As a result of adopted large capacity memory and data dynamic disposal technique, TCK•W® monitoring system can provide holographic schematic diagram of waveforms for conveyor belt current status which make the client clear about current status of conveyor belt.

Fig 4 shows the holographic waveforms schematic diagram of steel cords of main shaft conveyor belt. In this chart, it shows that splice type is typical two degree splice as well as flaw curves of non splice area.

Fig 4: Weak Magnetic scenograph of current conveyor belt status(局部)

7、 Analysis Of Conveyor Belt Safety Performance

The system is capable of remoting take-over and after-sales service System can access to the LAN / public network platform, and be embedded in remote take-over function. Easy remote debugging, software upgrades,fault diagnosis and other after-sales service functions. As long as the user needs, the remote take-over can be achieved via the Internet and other services like online commission, maintenance.

Installation plan for safety hazard solving of wire Rope conveyor belt online automatic monitoring system

Due to the modular design, W-PD steel cord conveyor belt on-line real-time safety monitoring system can simultaneously monitor two steel cord conveyor belts for their safe operation conditions. The system has a simple structure, easy installation; stable operation, reliable performance, hardware and software have a good versatility and scalability.

As shown above ,1.The loading devices are installed on the downside of the reverse belt; 2. Testing unit also installed in the lower belt but behind loading device; 3. Photoelectrical trechometer/speed measuring device installed at the upper surface of lower belt. As long as the return lower belt is flat belt and run more smoothly, we can facilitate the achievement of fixed installation; 4. Sound/light alarm; 5. Terminal control center installed in the controlling room.

Application of TCK•W® Monitoring System at Chengzhuang Mine of Jincheng Anthracite Mining Group Solved the problem of supervision and managementon steel cord conveyor belt

Small input and huge return

Chengzhuang Mine of Jincheng Anthracite Mining Group invested 0.8 million RMB to install Steel Cord Conveyor Belt Online Realtime Inspection System on their No. 1011 conveyor belt which did not only provide Hi-tech safeguard for conveyor belt operation, but also created considerable economic benefits for the enterprise. Every year this system creates obvious benefits of 35.09 million RMB and is also able to do inspection while the belt is running which saves the energy consumption of idle running for manual inspection. Only for this part, the system saved 0.432 million kw/h and effect of energy saving and consumption reducing is outstanding. Meanwhile this system is able to do early diagnosis, early repair and early prevention on conveyor belt breakdown; therefore it extends the service life of the belt, and lowers the maintenance cost significantly.

Steel Cord Conveyor Belt of Chengzhuang Mine can be monitored in real-time

-------——Published on Dec 7th of 2009, China Coal News

Reported by Zhao Pengpu and Liu Yaoping. A few days ago, the Steel Cord Conveyor Belt Online Real-time Automatic Inspection System that developed by JINCHENG BLUE FLAME COAL INDUSTRY CO.LTD. of Jincheng Coal Mining Group and TCK Wire Rope Inspection Technology Co., Ltd has been applied in Chengzhuang Mine successfully. It achieved purpose of conveying and inspecting at same time.

As the major transportation equipment in coal mining industry, if broken belt accident occurs on steel cord conveyor belt, it will directly endanger workers’ safety. Therefore BLUE FLAME COAL INDUSTRY CO.LTD invited TCK•W® Company to develop steel cord conveyor belt online automatic inspection system. After one and half years of cooperative research BLUE FLAME COAL INDUSTRY CO.LTD and TCK•W® Company developed the steel cord conveyor belt online automatic inspection system, which is able to avoid broken belt accidents.

China Luo Yang Wire Rope Inspection Technology Co.,Ltd.

Tel:86-379-65112379      E-mail:intl-dept@wmndt.com

Address:6/F,Buiding B2,Torch innovation Garden of Luoyang National High-Tech Development Zone ,Luoyang ,China.

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