Research on fault monitoring of belt conveyor based on FBG sensor
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摘要:
带式输送机的故障监测有助于预防安全事故、提高生产效率以及实现设备智能化运行。从带式输送机常见故障分析、综合保护系统组成、光纤型传感器阵列设计与分析、核心敏感元件设计与选材等方面，对基于FBG传感器的带式输送机故障监测进行了深入研究。首先针对传统监测手段无法定量感知、实时性不足、数据融合能力薄弱等问题，提出了一种基于光纤光栅(FBG)的带式输送机综合保护系统，明确了光纤型传感器阵列的设计是系统搭建的重要前提。其次，在分析带式输送机常见故障形成原因和表现形式的基础上，以FBG–等强度悬臂梁为核心敏感元件设计了一系列故障监测传感器，组成了带式输送机综合保护系统的光纤型传感器阵列，实现了故障的实时定量监测。接着，通过理论分析和Ansys有限元仿真，对FBG–等强度悬臂梁的尺寸结构设计和材料选择进行了深入研究，在传感模型中分析了灵敏度和精度的影响因素，并据此确定了敏感元件的结构尺寸，优选了尼龙6作为制作材料。最后，通过试验对FBG–等强度悬臂梁的结构有效性、灵敏度和稳定性进行了验证。在灵敏度试验中，敏感元件表现出良好的线性响应特性，理论灵敏度$S = 52.978\;0\;{\text{N/nm}}$，实际灵敏度$S_{}^* = 38.115\;7\;{\text{N/nm}}$；在重复性试验中，平均重复性误差仅为1.002%，表现出良好的重复性和稳定性；温度敏感性试验和温度补偿试验则验证了光纤光栅在温度测量中的线性相关性，从而进一步揭示了温度补偿对提升传感灵敏度的必要性，即便在微小温度变化环境下，补偿机制仍能有效提高灵敏度0.6%。所设计的光纤型传感器阵列解决了现有带式输送机运行故障无法实时定量感知的问题，为实现设备智能化感知与控制提供了坚实的数据基础。研究成果不仅能有效降低带式输送机故障率，提高生产效率，更推动了煤矿行业向自动化、智能化方向的发展。
Abstract:The fault monitoring of belt conveyors serves as a pivotal tool in preventing safety incidents, enhancing production efficiency, and facilitating the intelligent operation of equipment. This comprehensive study delves into the multi-sensor fault monitoring of belt conveyors utilizing Fiber Bragg Gratings (FBGs), examining aspects such as common fault analysis, the composition of integrated protection systems, the design and analysis of fiber-optic sensor arrays, and the design and material selection of core sensing elements.Firstly, to address the shortcomings of traditional monitoring methods, including the inability to quantify faults, inadequate real-time performance, and weak data fusion capabilities, an FBG-based integrated protection system for belt conveyors is proposed. This system underscores the cruciality of designing a fiber-optic sensor array as a fundamental prerequisite for system establishment.Secondly, building upon an analysis of the root causes and manifestations of common faults in belt conveyors, a series of fault monitoring sensors are devised, with FBG-based equal-strength cantilever beams serving as the core sensing elements. These sensors constitute the fiber-optic sensor array within the integrated protection system, enabling real-time and quantitative fault monitoring.Thirdly, theoretical analyses and Ansys finite element simulations are conducted to thoroughly investigate the dimensional design and material selection of FBG-based equal-strength cantilever beams. The influencing factors on sensitivity and accuracy are analyzed within the sensing model, guiding the determination of the structural dimensions of the sensing elements. Nylon 6 is selected as the optimal material for fabrication.Finally, experimental validation is performed to assess the structural effectiveness, sensitivity, and stability of the FBG-based equal-strength cantilever beams. In sensitivity tests, the sensing elements exhibit exceptional linear response characteristics, with a theoretical sensitivity of
52.9780 N/nm and an actual sensitivity of38.1157 N/nm. In repeatability tests, an average repeatability error of merely 1.002% is recorded, demonstrating robust repeatability and stability. Temperature sensitivity and compensation tests verify the linear correlation of FBGs in temperature measurement, emphasizing the necessity of temperature compensation for enhancing sensing sensitivity. Even under minor temperature variations, the compensation mechanism effectively boosts sensitivity by 0.6%.The designed fiber-optic sensor array resolves the challenge of real-time and quantitative fault perception in current belt conveyor operations, providing a solid data foundation for intelligent sensing and control. This research not only contributes to reducing belt conveyor failure rates and enhancing production efficiency but also propels the coal mining industry towards automation and intelligence. -
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图 2 运行故障与部件健康状态关系
Figure 2. Relationship diagram between operational failures and component health status
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图 3 基于FBG的带式输送机综合保护系统结构示意
Figure 3. Schematic diagram of the comprehensive protection system for belt conveyors based on fiber bragg grating
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图 13 等强度悬臂梁应变随压力、距离变化分布曲线
Figure 13. Distribution curves of strain in an equal-strength cantilever beam varying with pressure and distance
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图 14 等强度悬臂梁应变均值随压力变化曲线
Figure 14. Variation curve of mean strain in an equal-strength cantilever beam with changing pressure
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图 17 等强度悬臂梁压力与应变变化曲线
Figure 17. Variation curves of strain with applied force in an equal-strength cantilever beam
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图 18 等强度悬臂梁压力与光纤光栅中心波长 偏移量变化曲线
Figure 18. Variation curves of central wavelength shift in fiber bragg gratings with applied force in an equal-strength cantilever beam
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图 19 等强度悬臂梁压力与应变重复性试验变化曲线
Figure 19. Variation curves of repetitive stress and strain tests on cantilever beams with uniform strength
表 1 材料选择与尺寸设计
Table 1 Table of material selection and dimension design
材料 ${F_0}$/N ${F_{\max }}$/N 最优尺寸 最大量程应变 评价 bmax/mm bmin/mm h/mm ${L_0}$/mm 304不锈钢 100 100 93 2 1.5 29.4 $4.5{ \times }{10^{ - 4}}$ 尺寸不合理 易切削黄铜 100 100 55.14 2 2.52 28.9 $4.0{ \times }{10^{ - 4}}$ 尺寸不合理 3003–铝合金 100 100 39.5 3 5.1 27.9 $2.55{ \times }{10^{ - 4}}$ 应变过小 1345铝合金 100 100 25.6 3 7.5 26.9 $1.8{ \times }{10^{ - 4}}$ 应变过小 尼龙101 100 100 25.6 2 5.2 27.8 $2.3{ \times }{10^{ - 2}}$ 应变过大 尼龙6/10 100 100 62.05 2 2.25 29.1 $6.3{ \times }{10^{ - 3}}$ 尺寸不合理 尼龙6 100 100 45.73 2 3 28.7 $1.5{ \times }{10^{ - 2}}$ 应变较大 
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表 2 最终材料选择与尺寸设计
Table 2 Table of final material selection and dimension design
材料 ${F_0}$/N ${F_{\max }}$/N 最优尺寸 最大量程应变 评价 bmax/mm bmin/mm h/mm ${L_0}$/mm 尼龙6 1 000 100 24.8 5 12.1 24.9 ${\text{2}}{{.2\times }}{10^{ - 3}}$ 尺寸、应变均合理
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表 3 等强度悬臂梁受力与光纤光栅中心波长偏移量数据拟合
Table 3 Table of data fitting between the applied force on an equal-strength cantilever beam and the central wavelength shift of fiber bragg gratings
试样 拟合函数 拟合系数 传感灵敏度/(N·nm−1) 平均灵敏度$S_2^*$/(N·nm−1) 试样1 y=0.023 3x−0.060 7 0.998 2 42.918 5 38.115 7 试样2 y=0.028 0x−0.103 1 0.998 4 35.714 3 试样3 y=0.028 0x−0.041 9 0.998 1 35.714 3
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表 4 温度补偿试验数据拟合
Table 4 Table of data fitting for temperature compensation experiments
试验内容 拟合函数 拟合系数 灵敏度/(10−6 N−1) 实际应变 y=21.596 1x−52.406 9 0.998 6 21.596 1 温补前测量应变 y=19.521 2x−50.864 5 0.998 3 19.521 2 温补后测量应变 y=19.641 3x−49.575 7 0.998 4 19.641 3
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