AU2015321151B2 - Broken link detection method for drag flight conveyor - Google Patents

Broken link detection method for drag flight conveyor Download PDF

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Publication number
AU2015321151B2
AU2015321151B2 AU2015321151A AU2015321151A AU2015321151B2 AU 2015321151 B2 AU2015321151 B2 AU 2015321151B2 AU 2015321151 A AU2015321151 A AU 2015321151A AU 2015321151 A AU2015321151 A AU 2015321151A AU 2015321151 B2 AU2015321151 B2 AU 2015321151B2
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Australia
Prior art keywords
strain
link
sprocket teeth
chain
engaged
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AU2015321151A1 (en
Inventor
Guohua Cao
Wei Li
Hao LU
Yuxing PENG
Mingquan QIU
Gang Shen
Hang Zhang
Gongbo Zhou
Zhencai Zhu
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China University of Mining and Technology CUMT
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China University of Mining and Technology CUMT
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
    • B65G43/06—Control devices, e.g. for safety, warning or fault-correcting interrupting the drive in case of driving element breakage; Braking or stopping loose load-carriers

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  • Control Of Conveyors (AREA)
  • Escalators And Moving Walkways (AREA)

Abstract

Disclosed is a broken link detection method for a drag flight conveyor, wherein a strain sensor (3) is mounted on the largest force bearing face (1) of several wheel teeth of link wheels (6, 8) of the drag flight conveyor, the strain on the force bearing face (1) of the wheel teeth of the link wheels is collected, and when a link is broken in a certain link chain of the drag flight conveyor, a sudden change occurs in the wheel teeth strain of the link wheels (6, 8) engaged with this link chain in a short time, while no obvious change occurs in the wheel teeth strain of the link wheels (6, 8) engaged with the link chain in which no link is broken. By comparing the strain changes in the force bearing faces (1) of the wheel teeth of the link wheels (6, 8) engaged with different link chains, it can be determined timely whether a link is broken in a certain link chain of the drag flight conveyor so as to take necessary shut down measures, thereby preventing an incident in which serious damage to the device occurs caused by all the link chains being broken.

Description

Field of the Invention
The invention relates to a fault detection method for a scraper conveyor, in particular to a method for detecting chain breakage of a scraper conveyor.
Background Art
Scraper conveyors are widely applied in fully-mechanized mining in mines and transportation at harbors etc.. They employ a chain sprocket drive system in which sprocket are engaged with chains, and are equipment that utilizes a flexible traction mechanism for continuous transportation. Under the actual operation conditions of a scraper conveyor, the scraper chains bear heavy impact loads and may be worn or broken easily owing to many factors including the material of scraper chains, wearing, and corrosion, etc.. Hence, a chain breakage accident may happen easily once the load distribution is uneven. Chain breakage accidents are often seen in scraper conveyors operation, account for about 52.2% of the total accidents in scraper conveyors, and have a strong impact on safe operation of the scraper conveyors. The detection of chain breakage in scraper conveyors for different purposes, especially scraper conveyors used in mines where the operating environment is harsh and has heavy dust, has been a great technical challenge, because it is difficult to evaluate the state of the chains by conventional means, such as optical deformation detection and ultrasonic crack detection, etc.. At present, the existing chain breakage detection techniques for scraper conveyors mainly involve detection of the current flow through the drive motor and detection of the pressure on the hydraulic tension cylinder. But the two methods are only applicable to detection of breakage of all chains. Neither of the two methods can effectively detect the breakage of a part of the chains, because the current flow through the motor and the pressure on the hydraulic cylinder don't change obviously in such a case. However, when chain breakage occurs in a scraper conveyor, usually one chain is broken first, which results in suddenly increased stress on the other chains and excesses the allowable value. Consequently, the other chains are broken successively. The chain breakage generates high bounce force, which drives the scraper to bounce back, and may cause severe damage to the equipment. Hence, it is required to detect the breakage of one chain immediately and take appropriate emergency measures in order to avoid damage to the scraper conveyor resulted from chain breakage. But that objective is difficult to attain with the techniques in the prior art.
Contents of the Invention
Technical problem: The object of the present invention is to overcome the drawbacks in the existing detection techniques in the prior art and provide a method for detecting chain breakage of a scraper conveyor, which is easy to implement and has high sensitivity and accuracy, and not only can detect chain breakage of a scraper conveyor in real time, but also can accurately judge the specific broken chain, so that an alarm signal can be sent out and the equipment can be shut down before all chains are broken.
Technical scheme: The method for detecting chain breakage of a scraper conveyor disclosed in the present invention comprises the following steps:
(1) selecting sprocket teeth in the same phase on sprocket of the scraper conveyor that are engaged with different chains, judging the maximum strain areas of the sprocket teeth by stress analysis according to the rotation direction of sprocket shaft, and attaching strain sensors to the surfaces of the sprocket teeth in the same phase at positions where the strain is maximum, so that the strain sensors can rotate with the sprocket;
(2) during operation of the scraper conveyor, acquiring the strains on the stress surfaces of sprocket teeth of the sprocket that are engaged with different chains with the strain sensors, transmitting the detected strains to a signal analyzing device via a wireless transmission device, calculating the strain change rates Wj (%) on the stress surfaces of sprocket teeth of the sprocket at two sides in real time with the signal analyzing device and judging whether there is sudden strain change on the stress surfaces of the sprocket teeth, transmitting the analysis result through a cable to a server, and then transmitting the analysis result to an upper computer for further analysis and judgment; power is supplied to the strain sensors, signal analyzing device, and wireless transmission device from a power supply unit;
(3) comparing the strain change rates W) (%) on the stress surfaces of sprocket teeth of the sprocket that are engaged with different chains with a preset threshold J; (%) of strain change rate in real time with the upper computer; if a situation W)>Ji occurs at any time in 10 second interval while the strains on the stress surfaces of other sprocket teeth increase or meet | JF/|<10%, judging chain breakage has happened on the chain that is engaged with the sprocket teeth on which the strain has decreased suddenly by J; (%) or more in the 10s interval.
Beneficial effects: Since each chains of a scraper conveyor is engaged with a sprocket, the strain of the sprocket teeth of a sprocket directly reflects the stress on the corresponding chain; thus, when a chain is broken, the stress on the corresponding sprocket will have a sudden change, and the strain of the sprocket teeth of the sprocket will have a sudden change, while the strains of sprocket teeth of other sprockets that are not broken at the moment don't have a sudden change. Compared to the prior art, the method disclosed in the present invention employs strain sensors to measure the strains on stress surfaces of sprocket teeth of sprockets that are engaged with different chains. Thus, the detection means is more direct, and has higher sensitivity and accuracy. The method not only can detect chain breakage in a scraper conveyor timely, but also can judge the specific broken chain, so that an alarm signal can be sent out and the equipment can be shut down for chain reparation before all chains are broken. Therefore, the method disclosed in the prevent invention can avoid severe damage of the equipment and high economic loss resulted from breakage of all chains of the scraper conveyor.
Description of the Drawings
Fig. 1 is a flow chart of scraper chain breakage detection according to the present invention;
Fig. 2 is a schematic diagram of an embodiment of the present invention;
Fig. 3 is a constitutional diagram of the components in the fixing device according to the present invention.
Among the figures: 1 - stress area; 2 - cable of strain sensor; 3 - strain sensor; 4 - fixing device; 5 - signal processing system; 6 - first sprocket; 7. sprocket shaft; 8. second sprocket.
Detailed Description of the Embodiments
Hereunder the present invention will be further detailed in an embodiment, with reference to the accompanying drawings:
The steps of the chain breakage detection method are as follows:
(1) selecting sprocket teeth in the same phase on sprockets of the scraper conveyor that are engaged with different chains, judging the maximum strain areas of the sprocket teeth by stress analysis according to the rotation direction of sprocket shaft, and attaching strain sensors to the surfaces of the sprocket teeth in the same phase at positions where the strain is maximum, so that the strain sensors can rotate with the sprockets;
(2) during operation of the scraper conveyor, acquiring the strains on the stress surfaces of sprocket teeth of the sprockets that are engaged with different chains with the strain sensors, transmitting the detected strains to a signal analyzing device via a wireless transmission device, calculating the strain change rates Wj (%) on the stress surfaces of sprocket teeth of the sprockets in real time with the signal analyzing device and judging whether there is sudden strain change on the stress surfaces of the sprocket teeth, transmitting the analysis result through a cable to a server, and then transmit the analysis result to an upper computer for further analysis and judgment; power is supplied to the strain sensors, signal analyzing device, and wireless transmission device from a power supply unit;
(3) comparing the strain change rates W) (%) on the stress surfaces of sprocket teeth of the sprockets that are engaged with different chains with a preset threshold J; (%) of strain change rate in real time with the upper computer; if a situation W)>Ji occurs at any time in 10s interval while the strains on the stress surfaces of other sprocket teeth increase or meet |JFy|<10%, judging chain breakage has happened on the chain that is engaged with the sprocket teeth on which the strain has decreased suddenly by J; (%) or more in the 10s interval.
Embodiment: As shown in Fig. 1, regarding the method for detecting chain breakage of a scraper conveyor according to the present invention, several sets of strain sensors are attached to the roots of sprocket teeth of sprockets that are engaged with different chains to acquire the strains of the sprocket teeth. The detection process of the chain breakage detection system is as follows:
(1) initializing the chain breakage detection system, and setting a threshold J; (%) of strain change rate (e.g., .//=40%) via an upper computer;
(2) the strain sensors acquire strains of the sprocket teeth, and transmit the strain signal to a signal analyzing device via a wireless transmission device;
(3) the signal analyzing device calculates the strain change rate W) (%) of the sprocket teeth of the sprockets in real time, and transmits the analysis result to the upper computer;
(4) the upper computer makes a judgment: if a situation W)>Ji occurs at any time in 10s interval while the strains on the stress surfaces of other sprocket teeth increase or meet | JF7|<10%, judges chain breakage has happened on the chain that is engaged with the sprocket teeth on which the strain has decreased suddenly by J] (%) or more in the 10s interval. Once chain breakage is detected, the upper computer will immediately take actions, send out an alarm and shut down the equipment. Otherwise the upper computer will take no action but repeat the detection process circularly.
Fig. 2 is a schematic diagram of an embodiment of the present invention. An embodiment of the present invention is described here using a double-stranded nose scraper conveyor as an example. In a double-stranded nose scraper conveyor, the maximum deformation is located at the chainpit of sprockets. The sprocket wheel component that rotates in the direction indicated in Fig. 2, the stress area 1 is indicated by the hatched area. In the present invention, strain sensors 3 are attached to the roots of wheel teeth of the first sprocket 6 and the second sprocket 8 that are in the same phase as shown in the figures, to prevent damage to the strain sensors but facilitate the attachment of the strain sensors. Here, using wiring of a set of strain sensors as an example. To effectively avoid cable from damage by a vertical chain perpendicular to the sprocket shaft, the cable 2 of the strain sensor are led out from the middle of a cross chain slot between the wheel teeth of the sprocket, guided through an axial notch on the sprocket shaft, and finally connected to a data acquisition unit in a fixing device 4 on an end of the sprocket shaft. As shown in Fig. 3, the fixing device 4 is provide with data acquisition unit, a wireless router, and a power supply unit that supplies power to the data acquisition unit and the wireless router. The data acquisition unit acquires strain signals from the strain sensor 3 and converts the signal, and then transmits the signal via the wireless router in the fixing device 4. A wireless router in a signal processing system 5 receives the wireless signal from the fixing device 4, and transmits the signal to a signal analyzing device for analysis. The signal analyzing device calculates the strain change rate W) (%) on the stress surfaces of wheel teeth of the sprockets on the two sides and judges whether there is a sudden strain change on the stress surfaces of the wheel teeth in real time, and transmits the analysis result through a cable to a server. An upper computer in the signal processing system 5 carries out further analysis and judgment in real time on the basis of the data stored in the server. The upper computer compares the analysis result transmitted from the signal analyzing device and stored in the server (the strain change rates W) (%) on stress surfaces of sprocket teeth of the sprockets that are engaged with different chains) with a preset threshold^ (%) of strain change rate in real time. If a situation W)>Ji occurs at any time in 10s interval while the strains on the stress surfaces of other sprocket teeth increase or meet | FF'/|<10%, the upper computer will judge chain breakage has happened on the chain that is engaged with the sprocket teeth on which the strain has decreased suddenly by S (%) or more in the 10s interval. Once chain breakage is detected, the upper computer can shut down the equipment timely to prevent the occurrence of any severe safe accident resulted from breakage of all chains.

Claims (3)

  1. Claims
    1. A method for detecting chain breakage of a scraper conveyor, wherein, comprising the following steps:
    (1) selecting sprocket teeth in the same phase on sprockets of the scraper conveyor that are engaged with different chains, judging the maximum strain areas of the sprocket teeth by stress analysis according to the rotation direction of sprocket shaft, and attaching strain sensors to the surfaces of the sprocket teeth in the same phase at positions where the strain is maximum, so that the strain sensors can rotate with the sprockets;
  2. (2) during operation of the scraper conveyor, acquiring the strains on the stress surfaces of sprocket teeth of the sprockets that are engaged with different chains with the strain sensors, transmitting the detected strains to a signal analyzing device via a wireless transmission device, calculating the strain change rates W (%) on the stress surfaces of sprocket teeth of the sprockets in real time with the signal analyzing device and judging whether there is sudden strain change on the stress surfaces of the sprocket teeth, transmitting the analysis result through a cable to a server, and then transmitting the analysis result to an upper computer for further analysis and judgment; power is supplied to the strain sensors, signal analyzing device, and wireless transmission device from a power supply unit;
  3. (3) comparing the strain change rates W) (%) on the stress surfaces of sprocket teeth of the sprockets that are engaged with different chains with a preset threshold J; (%) of strain change rate in real time with the upper computer; if a situation W)>Ji occurs at any time in 10s interval while the strains on the stress surfaces of other sprocket teeth increase or meet |JF7|<10%, judging chain breakage has happened on the chain that is engaged with the sprocket teeth on which the strain has decreased suddenly by Ji (%) or more in the 10s interval.
    1/2 ΐ Initialization ;
    Yxxxxxxxxxxxs>xxxxxxxxxxxxx^
    Set a threshold J! (%) of strain change ratio | Acquire and transmit strain data
    Stain analysis |
    Calculate the strain change ratio W, (%) in real time
    Ύ,
    In every 10s interval: and the strains on the stress surfaces of other . .2>x ''''xx sprocket teeth increase or meet | W21< 10%?
    Ύ..
    ^\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\^^^^ | Breakage has happened on the chain where Wi>Ji occurs
    Fig. 1 $
    2/2
    Fig. 2
    Fig. 3
AU2015321151A 2014-09-26 2015-05-12 Broken link detection method for drag flight conveyor Ceased AU2015321151B2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
CN201410503491.1 2014-09-26
CN201410503491.1A CN104229427B (en) 2014-09-26 2014-09-26 A kind of slat conveyer chain rupture method of inspection
PCT/CN2015/078724 WO2016045389A1 (en) 2014-09-26 2015-05-12 Broken link detection method for drag flight conveyor

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AU2015321151A1 AU2015321151A1 (en) 2017-02-02
AU2015321151B2 true AU2015321151B2 (en) 2018-04-19

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WO (1) WO2016045389A1 (en)

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CN105173616B (en) * 2015-09-06 2017-08-25 中国矿业大学 A kind of scraper conveyer chain break detection system and method
CN105784241B (en) * 2016-03-07 2018-04-13 中国矿业大学 A kind of scraper conveyer chain tension force evaluation method
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CN112781871B (en) * 2020-12-21 2022-12-06 哈尔滨启棱航空科技有限公司 Chain detection method based on chain detection tool
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WO2016045389A1 (en) 2016-03-31
CN104229427B (en) 2016-03-02
AU2015321151A1 (en) 2017-02-02
CN104229427A (en) 2014-12-24

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