矿用带式输送机托辊故障检测方法研究

    Research on fault detection methods for idlers of mine belt conveyors

    • 摘要: 针对带式输送机托辊故障检测中识别精度低、抗干扰能力弱及运行稳定性不足等问题,提出一种基于特征信号融合(TFM)与多输入一维卷积神经网络(MI-1DCNN)的智能诊断方法。该方法首先通过拾音器采集托辊运行音频,并采用db4小波基与无偏风险估计阈值进行降噪,以提高信噪比并抑制背景干扰;在此基础上,提取信号的时域特征、频域特征以及梅尔频率倒谱系数(MFCC)与其一阶、二阶差分系数,经归一化融合构建TFM特征集;将该特征集输入具有多尺度卷积核的MI-1DCNN模型,利用多路径特征融合机制与Softmax分类器实现托辊状态的精确辨识。实验基于某煤矿现场采集数据展开,结果显示:本文方法对故障托辊的平均识别准确率达98.65%,相较于改进小波阈值-BP-RBF网络与MFCC-KNN-SVM方法,分别提升了1.50%与1.03%。在工业试验中,该方法仍具备98.4%的识别准确率,展现出良好的鲁棒性与应用潜力。

       

      Abstract: Addressing the issues of low recognition accuracy, weak anti-interference capability, and insufficient operational stability in the fault detection of belt conveyor idlers, an intelligent diagnosis method based on feature signal fusion (TFM) and multi-input one-dimensional convolutional neural network (MI-1DCNN) is proposed. This method first collects the operating audio of the idlers through a microphone and employs db4 wavelet basis and unbiased risk estimation threshold for noise reduction, aiming to enhance the signal-to-noise ratio and suppress background interference. On this basis, the time-domain features, frequency-domain features, and Mel Frequency Cepstral Coefficients (MFCC) along with their first-order and second-order differential coefficients are extracted and normalized to construct a TFM feature set. This feature set is then input into the MI-1DCNN model equipped with multi-scale convolutional kernels. The precise identification of the idler state is achieved through the multi-path feature fusion mechanism and Softmax classifier. Experiments conducted based on data collected from a coal mine site demonstrate that the proposed method achieves an average recognition accuracy of 98.65% for faulty idlers, representing an improvement of 1.50% and 1.03% compared to the improved wavelet threshold-BP-RBF network and MFCC-KNN-SVM methods, respectively. In industrial tests, the method still maintains a recognition accuracy of 98.4%, exhibiting strong robustness and potential for application.

       

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