Beruflich Dokumente
Kultur Dokumente
MACEDO E.C.T
Dpto. Engenharia Elétrica
Univ. Federal da Paraíba
João Pessoa, Brasil
euler@cear.ufpb.br
Abstract — In many industrial applications the conveyor moment when it reaches the critical state, being anticipated
belts thickness monitoring became important. The transport to avoid unexpected stops and production losses.
of materials wears out the conveyor belt, that according to the
use frequency and material type lead it to reach critical
thicknesses and latter its rupture. This work has as main
contribution the development of a measurement system of the
conveyor belt thickness, using ultrasonic transducers for
distance measurement according to time-of-flight principle,
without necessity of contact and stop a process in execution by
conveyor belt. The experimental results was obtained through
a measuring setup with a conveyor belt driven by a motor with
speed control, ultrasonic transducers with frequency
operation of 40 kHz, conditioning circuits and a data
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15.9 mm Keywords—conveyor belt monitoring, ultrasonic transducer, Fig. 1. Conveyor belt wear trends. Font: Data provided by Compahia 15.9 mm
time-of-flight. Vale do Rio Doce.
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velocity in the test material is used to estimate the material Detecion method using ultrasound sensors:
thickness. For this procedure is required stop the process Several equipment based on ultrasonic transducers,
operation, to carry out the tests and therefore to determine with coupling, monitor the thickness of conveyor
the belt thickness. This procedure causes production losses belts used in mining environment. The principle of
due to programmed stops of the process. measurement uses the ultrasound signal that
overtake the rubber material and reflect on textile
canvas. Although this technique is quite accurate, it
is required to stop conveyor belt operations, and
discrete points is inspected, increasing then the
uncertainty in determining the average wear of
conveyor belt.
III. TIME OF FLIGHT ESTIMATION
The time of flight estimation is based on measurement of
signal propagation time between a transmitter and receiver
ultrasound transducer, TA and TB, as shown in Fig. 3. This
Fig. 2. Ultrasound test for thickness measurement. time is defined as the time of flight and is used to determine
the distance by means of expressions relating the
In this scenario, in order to introduce improvements in propagation time of ultrasound signals with the sound
thickness measurement process for conveyor belts that velocity in which the ultrasound wave propagates, in this
decreases / eliminates the stop times to perform case free air [7]:
measurements, in this work a system was developed to
×
estimate the conveyor belt thickness, using ultrasound 𝐿=
transducers, without coupling. For this purpose, a test setup
was constructed with a conveyor belt prototype composed of where: L is the distance between ultrasound transducer and
a 4 mm thick belt. The measurement technique is performed reflective surface, ToF is the Time of Flight, and C is the
using the time of flight principle to estimate the thickness of velocity of sound in the air given by (2), where TK is the
the conveyor belt. temperature in Kelvin [8]:
II. RELATED WORKS
𝐶 = 20.074 𝑇
The breaking of conveyor belts used in mining
applications brings serious problems in production safety, in
addition to the stop production and financial losses on the
part of the company. In this way monitoring systems of
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conveyor belts operational condition become excellent tools 0.625 in
15.9 mm of decision-making for the maintenance and/or planning of 15.9 mm
change of belts in the productive processes [3].
Among the belt conveyor monitoring systems for the
wear detection are:
Detection method using electromagnetic sensors [4]:
It uses an array of magnetic elements incorporated
in the conveyor belt housing and external sensors to
detect and monitor the conveyor belt parameters.
The sensor element is hold down against the belt
surface by a spring. Wear detection is performed Fig. 3. Configuration of ultrasonic transducers for distance measurement
based on time of flight.
according to the spring and sensor displacement.
Detection method based on radio frequency For the purpose of measuring ToF, the main techniques
identification (RFID) [5]: When there are tears in found in references [9], [10], [11] and [12] are briefly
the conveyor belt this will damage the antennas presented in this section: A. Threshold Detection; B. Phase
positioned along the belt and thus will be realized Difference; C. Cross-correlation.
the detection of the position in which the failure A. Threshold Detection
happened.
Threshold Detection technique consists of transmitting a
Detection method based on X-rays [6]: The X-ray sine wave train and measuring the time required for its
has different attenuations for each material, and then detection (ToF) in the receiver transducer, through threshold
it is possible to detect different shapes, sizes and detection, as shown in Fig. 4. The measured time value until
objects with various physical and chemical the detection of the ultrasonic wave (tM) does not correspond
characteristics. However, several factors affect the directly to the reception time due to the delay imposed by
accuracy of detection, such as origin, frequency the dynamics of the transducers. The measured time can be
spectrum of X-rays and the distance between the expressed as the sum of the transmission time (ToF) with the
object examined and the origin of X-rays. detection time (tE), given by (3):
𝑡 = 𝑇𝑜𝐹 + 𝑡
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A calibration can be performed in order to determine the 𝑦(𝑛) = 𝐴𝑥(𝑛 − 𝜏) + 𝑤(𝑛)
detection time (tE) for a given distance.
where: A is the attenuation factor due to the trajectory of
B. Phase Difference
transmitted signal x(n) through the propagation medium, τ is
In phase difference technique, the phase difference the delay due to the path from the transmitter to the receiver
between the transmitted and received ultrasonic waves is (ToF) and w(n) represents the additive noise captured for
measured, as shown in Fig. 5. The phase difference verified receiver transducer and any other noise components
between transmitted and received signal is limited from 0 to generated by the electronics components and amplifiers. In
2π, and the number of wavelengths to be detected at the Fig. 6 the electrical signals of the transmitted and received
receiver must be calculated. The instantaneous phase at the ultrasound echo are shown.
transmitter and receiver is =2.f.ToF, where ToF is the
time of flight and f operation frequency of transducers. That Considering the transmission and reception sequences,
is, the ToF can be estimated indirectly from the phase the problem is to determine the time delay (τ) and, from this
difference measurement. result, the distance estimation (L). For this purpose,
correlation operation between the signals x(n) and y(n) is
used, where the position index of the maximum value from
result of the correlation operation is related to the time of
flight (ToF) measurement, as if illustrated in Fig. 7 [12]. The
correlation of two sequences is defined by (5):
1
x y = x(n-)
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0
0 0.5 1 1.5
t (s) -3
x 10
-1
Fig. 6. Ultrasound signal: transmitted x and rceived y.
2 3 4 5 6
t (s) x 10
-4 200
150
1
100
0
50
R(x,y)
AB 0
-1
2 3 4 5 6 -50
t (s) x 10
-4
-100
Fig. 5. ToF measurement using the Phase Difference (PD) technique.
-150
C. Cross-correlation
Cross-correlation is an operation between two discrete -200
0 500 1000 1500 2000 2500 3000 3500 4000
signals in order to evaluate the similarity between them, by k
extracting information from them. In this case, the Fig. 7. Correlation operation R(x,y).
information of interest is estimation of the time of flight
(ToF). For this purpose, we consider two digital sequences IV. MEASUREMENT CONFIGURATION: STUDY OF CASE
x(n) and y(n) to compare, where x(n) represents the samples
of the transmitted signal and y(n) the samples of the signal at In this section a conveyor belt thickness measurement
receiver. The received signal has a time delay relative to the will be displayed. Ultrasonic ToF estimation will be used to
transmitted signal like (4): measure the thickness using cross-correlation technique.
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A. Setup Measurement
In order to develop a belt conveyor monitoring system
from the construction of a laboratory setup, it was first
constructed a running machine with industrial
characteristics. Then, the mechanical adjustments were
made to all moving parts, the design and installation of a
three-phase motor and inverter used for its activation and
control, with installation of a local control to change rotation
direction and for speed control of the motor. Fig. 8 shows
the structure of the conveyor belt with some of its
components installed.
Fig. 9. Diagram of the conveyor belt drive setup.
B. Estimation Thechnique
Fig. 11 shows the configuration of the conveyor belt
Fig. 8. Setup measurement for thickness conveyor belt estimation.
wear measuring system, in which the conveyor belt with
Fig. 9 shows details for construction of the measurement wear L is shown.
45 pt setup, represented in a block diagram with follow 45 pt
0.625 in
Initially, the system is calibrated by determining a initial 0.625 in
15.9 mm
characteristics: i) Running machine: stainless steel wire distance (L0) between the ultrasonic transducers and base on 15.9 mm
conveyor; ii) Motor: WEG three-phase induction motor, 220 which is the conveyor belt (running machine), which was
/ 380V, 6-pole, 1 HP; iii) Inverter: Manufacturer Santerno, measured with a caliper.
model: LE 100; iv) Control: buttons for control rotation
direction and speed of conveyor belt, and potentiometer for Thereafter, the distance measurement (L) between the
linear velocity control; v) conveyor belt with a reference ultrasonic transducers and conveyor belt surface is
thickness of 4.5 mm. performed using Eq. (1). It is observed that the distance L
will depend on the estimation of the ToF and temperature
The Fig. 10 shows a functional diagram for acquisition for compensation of the sound velocity in free air given in
and measurement of the ultrasound signals, as well as the Eq. (2). In this work, the cross-correlation technique
ToF estimation. TR40-10 ultrasonic transducers whose presented in section III was chosen, mainly due to its
operating frequency is 40 kHz with 6 kHz bandwidth were robustness in ToF estimation, even in environments with
used, with a push-pull amplifier for the transmitter and an low SNR (Signal to Noise Ratio) levels.
inverter mode amplifier with variable gain for the receiver.
For signals acquisition, a multichannel data acquisition Then, during the operation or use of the distance belt, the
system (DAQ) AGILENT U2331A, configured with a wear of the conveyor belt L =L0 - L is monitored by the
sample rate of 400000 samples/s was used. The excitation of developed system, thus obtaining the estimation of belt
transmitter ultrasound transducer has done by a signal wear, measured in millimeters, L.
generator with operating frequency at 40 kHz (Agilent
33220A). The estimation ToF and thickness was performed
in offline mode on computer, after data collection.
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B. Situation 1: Thickness Measuring of Conveyor belt Fig. 14. Measurement of conveyor belt thickness in motion.
The first measurement was to measure the distance
between the ultrasonic transducers and the smooth surface of Table II contains the results of thickness monitoring in
conveyor belt, as shown in Fig. 13. This figure shows the reference point 22 ( ∆𝐿 = 𝐿 − 𝐿 ), considering the
displacement of the data acquisition system, which allows movement of conveyor belt with two different motor speeds,
performing a transverse measurement of various reference 15.1 Hz and 20 Hz. With the increase of conveyor rotation
points on the conveyor belt without motion. speed, vibrations appears in the structure of conveyor and
harm the operation of ultrasonic transducers and accuracy in
estimating the thickness of conveyor belt. To minimize this
effect, digital signal processing techniques can be used for
signal filtering as a step before the ToF estimation is
performed.
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TABLE II. THICKNESS MONITORING FOR 22 REFERENCE POINT. Conference on Ubiquitous Robots and Ambient Intelligence (URAI),
2016.
ToF Lo T L
Frequency (s) (mm) (°C) (mm) [3] Y. Yanli, M. Changyun, L. Xianguo and M. Xiuzhuang, “On-line
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15.1 455.00 79.05 26.5 3.45
[4] Y. Pang and G. Lodewijks, “A novel embedded conductive detection
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Service Operations and Logistics, and Informatics. 2006, pp. 803-
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VI. CONCLUSIONS [5] T. Nicolay, A. Treib and A. Blum, “RF identification in the use of
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Systems and Knowledge Discovery, 2008, pp. 617-621.
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[7] R. Pallas-Areny, “Sensors and Signal Conditioning,” 2nd Edition,
the surface of conveyor belt can be obtained with the cross- John Wiley and Sons, 2001.
correlation technique, with a standard deviation of [8] J. C. Kaimal and J. A. Businger, “A Continuous Wave Sonic
approximately 1.5 mm, on the conveyor belt without Anemometer-Thermometer,” Journal of Applied Meteorology, 1963,
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processing tools for the signals pre-processing, as a previous 58, Issue: 7, Pages: 2189-2195.
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45 pt 45 pt
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