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基于分布式光纤传感的散货码头带式输送机智能巡检系统

Research on intelligent inspection system for belt conveyor in bulk cargo terminal based on distributed optical fiber sensing

  • 摘要: 针对散货码头带式输送机传统人工巡检效率低、安全风险高,以及现有巡检机器人存在监测盲区、运维成本高、无法连续监测等问题,提出一种基于分布式光纤传感技术的全天候、全空间智能巡检系统。该系统构建了“感知–网络–平台–应用–用户”五层架构,融合分布式光纤声波传感(DAS)与分布式光纤测温(DTS)技术,实时采集输送机沿线的振动与温度信号。通过小波阈值降噪、多维特征提取与支持向量机(SVM)分类算法,建立了托辊损伤、皮带撕裂及溜槽堵料等故障的智能诊断模型。在某大型露天矿山带式输送机系统(全长1 255 m)中的现场应用表明:系统可实现全线实时监测,托辊故障检出率达100%,综合准确率约91.8%;皮带撕裂报警响应时间不超过5 s;溜槽积料状态识别准确有效。与巡检机器人方案相比,本系统具备本质安全、抗干扰能力强、运维成本低、无监测盲区等显著优势,不仅实现了输送机关键部件的深层故障诊断,还具有良好的可扩展性,为散货码头输送系统实现无人化、智能化运维提供了可靠的技术途径。

     

    Abstract: To address the low efficiency and high safety risks inherent in traditional manual inspection of belt conveyors in bulk cargo terminals, as well as the limitations of existing inspection robots(e.g., monitoring blind spots, high operational costs, and discontinuous coverage), this paper presents a comprehensive intelligent inspection system based on distributed optical fiber sensing technology. A five-layer architecture, “Perception–Network–Platform–Application–User, ” was designed and implemented. The system integrates Distributed Acoustic Sensing(DAS) and Distributed Temperature Sensing(DTS) to continuously acquire vibration and temperature signals along the conveyor line. An intelligent fault diagnosis model for idler damage, belt tearing, and chute blockage was established by combining wavelet threshold denoising, multi-dimensional feature extraction, and a Support Vector Machine(SVM) classifier. Field validation conducted on a 1,255-meter-long belt conveyor system in a large open-pit mine demonstrated that the system achieves real-time, full-line monitoring. It attained a 100% detection rate for idler faults with an overall diagnostic accuracy of approximately 91.8%, reduced the alarm response time for belt tearing to within 5 s, and reliably identified material accumulation in chutes. Compared to conventional inspection robot solutions, the proposed system exhibits distinct advantages, including intrinsic safety, strong interference immunity, lower long-term operational costs, and truly continuous, blind-spot-free monitoring. Beyond enabling deep fault diagnosis of critical conveyor components, the technology demonstrates excellent scalability, offering a viable and effective pathway toward the unmanned and intelligent operation and maintenance of bulk cargo terminal conveying systems.

     

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