| Belt conveyor is widely used as transportation equipment in the industrial field such as mines metallurgy, chemical and thermal power, it is used mainly to transport the lumpish, granular or loose materials and pieces of goods. Belt often appears failures such as running-away, slip, tearing and scram at work, because the type of failure is multiple and the failure point is dispersed, making the searching of failure point becomes very difficult, bringing a great inconvenience for equipment maintenance and safe production. At present, the belt conveyor protection technology is not too mature, usually only rely on strengthening maintenance to reduce accidents, but the artificial maintenance can not completely avoid the malignant accident of belt break.In this paper, the cause and the method of the fault detection of the belt are studied, then processing and converting the signal of the fault sensor, and the filtering simulation experiment of the signal is carried out. The main function and design requirement of intelligent controller are introduced in this paper. On this basis, the overall design scheme of the intelligent controller is proposed, and a kind of intelligent controller with the function of the bit display is designed and developed.The intelligent controller can real-time monitor the working state of large belt conveyor system, when a failure occurs, it can send out sound and light alarm signal and display the type and location of failure by the LCD, and it can control the running state of the conveyor according to the type of the fault. This design uses STC89C52 RC microcontroller as the master MCU, it mainly consists of two parts which are the signal acquisition devices and the controllers, the collector can collect belt failure signal, every collector has two BCD code switches which can set the location of the failure. The controller uses LCD to display the type of failure and the location of failure point, it can send an alarm signal through sound and light alarm system, it can control the running state of the conveyor according to the type of the fault, it is easy to find and preclude failure, for improving production efficiency is beneficial. The controllers and each signal acquisition device achieve real-time communication through RS-485 bus, the communication interface chip is SN75176.This article’s software design uses the way of modular design, the system is divided into several functional modules to design, the functional modules include acquisition module, the controller module, BCD code switch module, RS-485 communication module, Using C language to write the program.Through the tests and experiments of hardware and software in the lab, the intelligent controller designed in this paper has the advantages of stable performance, fault alarm, display clear and flexible features in experimental operation. It has a certain practical application value. |
