带式输送机智能巡检机器人设计及工业性试验

Intelligent Inspection Robot Design and Industrial Testing for Belt Conveyor

  • 摘要: 针对带式输送机人工巡检效率低、漏检率高等问题,提出“轨道式巡检平台-多源感知-边缘决策”一体化智能巡检方案。系统采用状态机/事件驱动架构,集成红外热像、气体/温湿度、可见光与声学通道;在特征层完成时序对齐与去噪,在决策层引入加权投票与冲突消解。工业性试验表明:边缘决策平均响应延迟≤200 ms(急停通道≤50 ms),多源融合对“跑偏、托辊与电机过热、烟雾”三类事件综合识别F1≥0.90;单次巡检29 min,单次充电5.5 h,漏检率<2.17%,可替代1~2个巡检岗位;6个月直接经济效益49.65万元,人员暴露时长减少约175 人·h。方案在长距离带式输送机场景具备可推广性与工程实用价值。

     

    Abstract: Aiming at the problems of low efficiency, high missed detection rate and others in manual inspection of belt conveyors, an integrated intelligent inspection scheme of "track-type inspection platform-multi-source perception-edge decision-making" is proposed. The system adopts a state machine/event driven architecture to integrate infrared thermal imaging, gas/temperature and humidity, visible light, and acoustic channels; Complete time sequence alignment and denoising at the feature layer, and introduce weighted voting and conflict resolution at the decision-making layer. The industrial testing shows that the average response delay of edge decision-making is≤200 ms (emergency stop channel ≤50 ms), and multi-source fusion can comprehensively identify three types of events: "deviation, idler roller and motor overheating, and smoke" with F1≥0.90; With a single inspection of 29 minutes, single charging of 5.5 h, and a missed detection rate of <2.17%, which can replace 1-2 inspection positions; The direct economic benefit in 6 months is 496 500 yuan, and the personnel exposure time is reduced by about 175 people per hour. The scheme has generalability and practical engineering value in long-distance belt conveyor scenes.

     

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