System structure and Composition

The system mainly consists of mobile inspection devices, precision tracks, motion controllers and drivers, image processing workstations, switches, engineer operation stations, high-speed Al cameras, fill lights, etc.
The structure of the system is shown in the following figure:

Major Function

1. Tail rope monitoring

a、 It can monitor the running trajectory of the tail rope at full speed of 16m/s in real time, and can monitor the running status of the tail rope in real time. When the running trajectory or swing of the tail rope exceeds the warning value, a warning can be given and the video and position emergency locking function can be triggered.
b、 Detection rate of tail rope distortion: tail rope loose strands can be detected, with a detection rate of 100% for tail rope loose strands at 10m and above, and a detection rate of>85% for tail rope loose strands at 1m~10m.

2. Head rope inspection

a、 During the full speed (0-16m/s) operation of the hoist, the steel wire rope can be detected without blind spots, and the appearance defect status of a single steel wire rope can be monitored in real time throughout the entire process. It can be automatically or manually switched to other steel wire rope detection at regular intervals, and can automatically determine the trend curve of changes in the steel wire rope twist length, wire breakage, deformation, corrosion, etc. It has a forecasting and warning function, and can query the trend of the steel wire rope's entire life cycle status by week, month, quarter, or year.
b、 The system can automatically complete the change in twist length of steel wire ropes at the same position, achieve intelligent comparison, and generate detection reports.
c、 The image information of wire rope breakage and the position of the hoist should be automatically calibrated, and the position error should be controlled within 100mm; It can automatically detect the number of broken wires on the surface of the steel wire rope with an accuracy rate of 100%.
d、 Detection accuracy: The metal cross-sectional area (LMA) error of the steel wire rope is less than ± 1%, and the diameter accuracy of the steel wire rope is 0.01mm.
e、 It can automatically detect and judge the deformation of the steel wire rope, that is, the diameter of the steel wire rope locally increases, the diameter of the steel wire rope locally decreases, or the steel wire rope is locally deformed or damaged.

3. Bottom coal pile coal detection

Real time detection of coal pile status at the bottom of the well, automatic alarm when reaching the set threshold, capturing photos and videos, and generating alarm records. At the same time, it can output linkage control signals to the lifting system, which can control the lifting machine to stop hooking.

4. Scrap residue detection

Real time detection of residual status during the unloading of the lifting bucket, automatic alarm when the unloading residual reaches the set threshold, capturing photos and videos, and generating alarm records. At the same time, it can output linkage control signals to the lifting system, which can control the lifting machine to stop hooking.