The Design Of Steel Cord Conveyor Delt Non-Destructive Monitoring System Based On Linear Array Detector

In recent year, as the fast development in energy industry, the steel cord conveyor belt system have widely been large-scale transport equipment which used in coal, metallurgy, dock, power depart and etc, it having the characteristic of big obliquity, fast speed, huge transport ability, long transport distance and etc, which make the steel cord conveyor belt system to be the main transport equipment. The steel cord conveyor belt consists of many segments which being lie in given form then vulcanized, the head of steel cord belt are the weak places of those transport system. The incident of the head of steel cord belt tore would make person casualty and large economic loss. So it is necessary to develop the real-time and on-line steel cord conveyor belt non-destructive monitoring equipment.After investigation, we made a trial to make a protection device of steel cord belt based on the principle of Magnetic Flux Leakage (MFL). They achieved the expected target after a period of time of experience and use in coal field, and had been applied to fields in various mines. This product could find the broken rope injure in the steel cord conveyor belt and identify the signal of any header. It could locate the distance of the injury from origin of the steel cord conveyor belt after software having identified the place of injury. However, there are some shortcomings. At first, the steel cord condition in the belt can not be seen with this device based MFL, and only can see some simulation image on the display. Secondly, this device based MFL can reflect the condition of the steel cord qualitatively only, can not monitor the condition of the steel cord quantitatively. In other words, you do not know whether the steel rope broken completely, the reason is that where there is a broken steel rope there is a magnetic flux leakage. Because of these shortcomings, it also brings some problems to these operators. So, we are considering searching for new programs to avoid these deficiencies. At the some time, we know that X-Ray linear detector array has the characteristics of scanning fast and visual intuitive. The principle of x-Ray nondestructive monitoring is the same as medical perspective. The density difference between steel rope and rubber is too large, broken steel cord can be seen clearly in these steel rope cord perspective image. This greatly facilitates operators who in charge of the belt maintenance. At present, X-Ray non-destructive monitoring technology has been applied to tire test, workpiece defect detection, food detection of foreign matter and in some other fields, but real-time online monitoring equipment in the coal mine belt is a blank field. We worked out the solution of monitoring steel cord belt based on X-Ray non-destructive on the basis of evaluation and summary to MFL-based products. This solution brakes though the limitations of MFL-test and realizes the visual of internal structure of the belt. We can not see the injury of this belt before, now we can see the injury image clearly after this device being developed successfully. Operators can know the condition of those injuries in belt,it is a good advice to maintenance and replacement the steel cord conveyor belt. This thesis gives a blue print of steel cord conveyor belt a monitoring device based on X-Ray linear array detectors. We have designed communication software between X-Ray linear array detectors and host computer that carry out the large scale data and Real-time transmission based on X-Ray linear array detectors. It adopt image recovering , image enhancing,image transform and image splitting etc to process those images of conveyor belt. We find out the distinguishing method of steel cord broken off,steel cord rusting or steel cord dislocation. Image process software has been developed based on VC6.0 Integrated Development Environment. This device can achieve good effect for real-time monitoring and judge fault.This device passed some initial experiments. The capturing image quality of steel cord conveyor belt is good and image transmitting quality very good too. The software intelligent identifying steel cord defect has large effect to prevent malignant incident happening.