AU2016401397A1 - Scraper conveyer sprocket wheel tooth abrasion monitoring device and method - Google Patents

Scraper conveyer sprocket wheel tooth abrasion monitoring device and method Download PDF

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Publication number
AU2016401397A1
AU2016401397A1 AU2016401397A AU2016401397A AU2016401397A1 AU 2016401397 A1 AU2016401397 A1 AU 2016401397A1 AU 2016401397 A AU2016401397 A AU 2016401397A AU 2016401397 A AU2016401397 A AU 2016401397A AU 2016401397 A1 AU2016401397 A1 AU 2016401397A1
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AU
Australia
Prior art keywords
sprocket wheel
photoelectric sensing
horizontal
vertical
reflective stickers
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AU2016401397A
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AU2016401397B2 (en
Inventor
Guohua Cao
Fan Jiang
Wei Li
Hao LU
Yuxing PENG
Gang Shen
Sunyang WU
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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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01BMEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00Measuring arrangements characterised by the use of optical techniques
    • G01B11/02Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
    • G01B11/06Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01BMEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00Measuring arrangements characterised by the use of optical techniques
    • G01B11/24Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
    • G01B11/2416Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures of gears
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01BMEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00Measuring arrangements characterised by the use of optical techniques
    • G01B11/24Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
    • G01B11/255Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures for measuring radius of curvature

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Control Of Conveyors (AREA)
  • Length Measuring Devices By Optical Means (AREA)
  • Escalators And Moving Walkways (AREA)

Abstract

The present invention discloses a scraper conveyer sprocket wheel tooth abrasion monitoring device and method. The device includes top reflective stickers, vertical photoelectric sensing modules, side reflective stickers, horizontal photoelectric sensing 5 module, and a data analysis module; the top reflective stickers are mounted on the top surface of sprocket wheel teeth, each vertical photoelectric sensing module includes a vertical light source and a vertical photoelectric sensing element, the side reflective stickers are mounted on the side surface of the sprocket wheel teeth, each horizontal photoelectric sensing module includes a horizontal light source and a horizontal photoelectric sensing 10 element, and the data analysis module includes an lower computer and an industrial personal computer. The method acquires thickness data reflecting the sprocket wheel teeth through lengths of high and low level signals in real time, and acquires real-time sprocket wheel tooth abrasion loss by comparing with an original thickness value. The present invention can implement the real-time measurement of sprocket wheel tooth abrasion loss 15 to prevent equipment abnormality, damage and economic loss as the result of the skipping of chains of a scraper conveyer caused by the severe abrasion of sprocket wheel teeth.

Description

SCRAPER CONVEYER SPROCKET WHEEL TOOTH ABRASION MONITORING DEVICE AND METHOD
BACKGROUND
Technical Field
The present invention relates to the technical field of the monitoring and safety guarantee of scraper conveyer equipment, and in particular to a scraper conveyer sprocket wheel tooth abrasion monitoring device and method.
Related Art A scraper conveyer is main production and conveying equipment for underground fully mechanized coal faces of coal mines, and assumes the important tasks of conveying coal, providing pushing supporting points for hydraulic supports and providing traveling tracks for coal mining machines, and their reliability directly affects the safe and efficient production of modern coal mines. A scraper chain is a mechanism, which can easily go wrong, of the scraper conveyer, and the failure accounts for about 40 percent of the total number of failures of the scraper conveyer. Once the scraper chain fails, the time needed by maintenance is long, and as a result, the production efficiency of large coal mines in our country is severely restricted. It is discovered in in-depth analysis that after sprocket wheel teeth are abraded severely, the skipping phenomenon of a chain of the scraper conveyer will take place when the chain is engaged with the sprocket wheel teeth, moreover, the risk of sprocket wheel tooth breakage exists, but there are no mature detection techniques for sprocket wheel tooth abrasion loss at home and abroad at present. Therefore it is necessary to monitor the abrasion condition of the sprocket wheel teeth in the running process of the scraper conveyer in real time.
SUMMARY
Objective of the invention: Aiming at the safety monitoring problem existing in the process of using a scraper conveyer, the present invention provides a scraper conveyer sprocket wheel tooth abrasion monitoring device and method to implement the real-time measurement of sprocket wheel tooth abrasion loss, providing technical support for the prevention of the chain skipping and sprocket wheel tooth chain breakage of the scraper conveyer caused by the severe abrasion of the sprocket wheel teeth.
In order to achieve the above-mentioned objective, the present invention adopts the following technical solution: disclosed is a scraper conveyer sprocket wheel tooth abrasion monitoring device, which includes top reflective stickers, vertical photoelectric sensing modules, side reflective stickers, horizontal photoelectric sensing modules, and a data analysis module; the top reflective stickers are mounted on the top surfaces of sprocket wheel teeth, each vertical photoelectric sensing module includes a vertical light source and a vertical photoelectric sensing element, the vertical light sources are configured to emit light toward the top reflective stickers, and the vertical photoelectric sensing elements are configured to sense the light reflected by the top reflective stickers and output level signals; the side reflective stickers are mounted on the side surfaces of the sprocket wheel teeth, each horizontal photoelectric sensing module includes a horizontal light source and a horizontal photoelectric sensing element, the horizontal light sources are configured to emit light toward the side reflective stickers, and the horizontal photoelectric sensing elements are configured to sense the light reflected by the side reflective stickers and output level signals; the data analysis module includes a lower computer and an industrial personal computer, the lower computer is configured to acquire level signals outputted by the vertical photoelectric sensing elements and the horizontal photoelectric sensing elements, and the industrial personal computer is configured to analyze the acquired level signals in order to obtain the abrasion conditions of the sprocket wheel teeth.
Preferably, the top reflective stickers have the same shape as the top surfaces of the sprocket wheel teeth, and the side reflective stickers have the same shape as the side surfaces of the sprocket wheel teeth.
Preferably, both tire vertical light sources and the horizontal light sources are point light sources.
Preferably, each vertical photoelectric sensing element is shaped like a circular arc, and the horizontal photoelectric sensing elements have the same shape as the side reflective stickers.
Preferably, each of the vertical photoelectric sensing modules and the horizontal photoelectric sensing modules also includes a signal conditioning unit for amplifying and filtering the outputted level signals.
Also disclosed is a scraper conveyer sprocket wheel tooth abrasion monitoring method based on the above-mentioned monitoring device, which includes the following steps: firstly, the same sampling frequency is allocated to vertical photoelectric sensing modules and horizontal photoelectric sensing modules, the vertical photoelectric sensing modules are set to output high levels when receiving light reflected by the top reflective stickers, and otherwise output low levels, and the horizontal photoelectric sensing modules are set to output high levels when receiving light reflected by the side reflective stickers, and otherwise output low levels; secondly, when sprocket wheel teeth do not have any abrasion, the original dimensions Ld_q of corresponding parts of the end surfaces of the crests of the sprocket wheel teeth are measured, meanwhile, a high level length Z,,_0 outputted by the vertical photoelectric sensing module and a low level L2 0 outputted by the horizontal photoelectric sensing module which correspond to a single sprocket wheel tooth are acquired, and a ratio factor kD - Ld_0/Zj 0 is calculated; then, when sprocket wheel tooth abrasion loss is measured actually, it is assumed that the high level length outputted by each vertical photoelectric sensing module is and the low level length outputted by each horizontal photoelectric sensing module is L2 , when a single sprocket wheel tooth passes, a ratio factor Ak - L2_0/L2_^ is calculated,
Ak = 1 if a scraper conveyer runs at constant speed, so Δ/c is defined as a correction factor to eliminate the affection of changing rotational speed on sprocket wheel tooth abrasion loss measurement during measurement;
is calculated, and thereby sprocket wheel tooth abrasion loss is
; finally, an abrasion threshold J of the sprocket wheel teeth is set, the sprocket wheel tooth abrasion loss does not go beyond the limit when
, and therefore the sprocket wheel teeth can be used continuously and normally; the sprocket wheel tooth abrasion loss goes beyond the limit when
, and an abrasion danger warning signal is outputted.
Beneficial effects: After the abrasion of the sprocket wheel teeth occurs, the structural dimensions of the sprocket wheel teeth in the running direction of the chains of the scraper conveyer become small, and the present invention acquires thickness data reflecting the sprocket wheel teeth in real time through high and low level signal lengths by a photoelectric sensing principle, and acquires real-time sprocket wheel tooth abrasion loss by comparing with the original thickness value. The present invention can implement the real-time measurement of sprocket wheel tooth abrasion loss to prevent equipment abnormality, damage and economic loss as the result of the skipping of chains of a scraper conveyer caused by the severe abrasion of sprocket wheel teeth.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a structural schematic diagram of the present invention;
Fig. 2 is a schematic mounting diagram of vertical photoelectric sensing modules of the present invention;
Fig. 3 is a schematic mounting diagram of horizontal photoelectric sensing modules of the present invention;
Fig. 4 is a schematic system configuration diagram of the present invention.
In the drawings, 1 and 7 are horizontal photoelectric sensing modules, 2 is a side reflective sticker, 3 and 6 are vertical photoelectric sensing modules, 4 and 5 are top reflective stickers, 8 is a left sprocket wheel, 9 is a right sprocket wheel, 10 is a data analysis module, 11 is a vertical photoelectric sensing element, 12 is a vertical light source, 13 is a horizontal photoelectric sensing element, and 14 is a horizontal light source.
DETAILED DESCRIPTION
The present invention is further explained in reference to the drawings.
As shown in Figs. 1, 2, 3 and 4, the present invention discloses a scraper conveyer sprocket wheel tooth abrasion monitoring device, which includes top reflective stickers, vertical photoelectric sensing modules, side reflective stickers, horizontal photoelectric sensing modules, and a data analysis module.
The top reflective stickers are mounted on the top surfaces of sprocket wheel teeth, the top reflective stickers have the same shape as the top surfaces of the sprocket wheel teeth, each vertical photoelectric sensing module includes a vertical light source and a vertical photoelectric sensing element, the vertical light sources are point light sources, the vertical light sources are configured to emit light toward the top reflective stickers, each vertical photoelectric sensing element is shaped like a circular arc, and the vertical photoelectric sensing elements are configured to sense the light reflected by the top reflective stickers and output level signals. Each vertical photoelectric sensing module also includes a signal conditioning unit for amplifying and filtering the outputted level signals. A power supply supplies electricity to the vertical light sources and the signal conditioning units.
The side reflective stickers are mounted on the side surfaces of the sprocket wheel teeth, the side reflective stickers have the same shape as the side surfaces of the sprocket wheel teeth, each horizontal photoelectric sensing module includes a horizontal light source and a horizontal photoelectric sensing element, the horizontal light sources are point light sources, the horizontal light sources are configured to emit light toward the side reflective stickers, the horizontal photoelectric sensing elements have the same shape as the side reflective stickers, and the horizontal photoelectric sensing elements are configured to sense the light reflected by the side reflective stickers and output level signals. Each horizontal photoelectric sensing module also includes a signal conditioning unit for amplifying and filtering the outputted level signals. The power supply supplies electricity to the horizontal light sources and the signal conditioning units.
The data analysis module includes a lower computer and an industrial personal computer, the power supply supplies electricity to the lower computer and the industrial personal computer, the lower computer is configured to acquire level signals outputted by the vertical photoelectric sensing elements and the horizontal photoelectric sensing elements, and the industrial personal computer is configured to analyze the acquired level signals in order to obtain the abrasion conditions of the sprocket wheel teeth.
In the present embodiment, a set of vertical photoelectric sensing modules and top reflective stickers and a set of horizontal photoelectric sensing modules and side reflective stickers are arranged at sprocket wheels corresponding to each of chains at the head and tail of a scraper conveyer. The vertical photoelectric sensing modules and the horizontal photoelectric sensing modules are mounted overhead through fixed tube supports and the like, and the sprocket wheel teeth and the chains which are opposite to the spaces do not fit each other when running; the side reflective stickers are respectively mounted on the left side surfaces of left sprocket wheel teeth and the right side surfaces of right sprocket wheel teeth, and the top reflective stickers are respectively mounted on the crests of the left teeth of a left sprocket wheel and the crests of the right teeth of a right sprocket wheel.
The scraper conveyer carries out the conveyance of materials by means of the rotating sprocket wheels driving the chains to move; after the severe abrasion of the sprocket wheel teeth occurs, the skipping phenomenon of the chains will take place, causing the tension imbalance between the chains of the scraper conveyer, and ultimately, failures, such as chain breakage and scraper bending, are caused, affecting the normal running of the scraper conveyer and the effective implementation of the conveying function. After the abrasion of the sprocket wheel teeth occurs, the structural dimensions of the sprocket wheel teeth in the running direction of the chains of the scraper conveyer become small, and the present invention acquires thickness data reflecting the sprocket wheel teeth in real time through high and low level signal lengths by a photoelectric sensing principle, and acquires real-time sprocket wheel tooth abrasion loss by comparing with an original thickness value.
Also disclosed is a scraper conveyer sprocket wheel tooth abrasion monitoring method based on the monitoring device, which includes the following steps: firstly, the same sampling frequency is allocated to vertical photoelectric sensing modules and horizontal photoelectric sensing modules, the vertical photoelectric sensing modules are set to output high levels when receiving light reflected by the top reflective stickers, and otherwise output low levels, and the horizontal photoelectric sensing modules are set to output high levels when receiving light reflected by the side reflective stickers, and otherwise output low levels; secondly, when sprocket wheel teeth do not have any abrasion, the original dimensions Ld 0 of corresponding parts of the end surfaces of the crests of the sprocket wheel teeth are measured, meanwhile, a high level length L,_0 outputted by the vertical photoelectric sensing module and a low level L2 0 outputted by the horizontal photoelectric sensing module which correspond to a single sprocket wheel tooth are acquired, and a ratio factor
is calculated; then, when sprocket wheel tooth abrasion loss is measured actually, it is assumed that the high level length outputted by each vertical photoelectric sensing module is L, , and the low level length outputted by each horizontal photoelectric sensing module is L2_x when a single sprocket wheel tooth passes, a ratio factor
is calculated,
Ak = 1 if a scraper conveyer runs at constant speed, so Ak is defined as a correction factor to eliminate the affection of changing rotational speed on sprocket wheel tooth abrasion loss measurement during measurement;
is calculated, and thereby sprocket wheel tooth abrasion loss is
; finally, an abrasion threshold J of the sprocket wheel teeth is set, the sprocket wheel tooth abrasion loss does not go beyond the limit when
, and therefore the sprocket wheel teeth can be used continuously and normally; the sprocket wheel tooth abrasion loss goes beyond the limit when
, and an abrasion danger warning signal is outputted.
What is described above is merely the preferred embodiments of the present invention, it should be pointed out that under the premise of not departing from the principle of the present invention, those skilled in the art can also make a plurality of improvements and embellishments, and these improvements and embellishments should also be regarded as the protection scope of the present invention.

Claims (6)

  1. CLAIMS What is claimed is:
    1. A scraper conveyer sprocket wheel tooth abrasion monitoring device, characterized by comprising top reflective stickers, vertical photoelectric sensing modules, side reflective stickers, horizontal photoelectric sensing modules, and a data analysis module, wherein the top reflective stickers are mounted on the top surfaces of sprocket wheel teeth, the vertical photoelectric sensing module comprises a vertical light source and a vertical photoelectric sensing element, the vertical light sources are configured to emit light toward the top reflective stickers, and the vertical photoelectric sensing elements are configured to sense the light reflected by the top reflective stickers and output level signals; the side reflective stickers are mounted on the side surfaces of the sprocket wheel teeth, the horizontal photoelectric sensing module comprises a horizontal light source and a horizontal photoelectric sensing element, the horizontal light sources are configured to emit light toward the side reflective stickers, and the horizontal photoelectric sensing elements are configured to sense the light reflected by the side reflective stickers and output level signals; the data analysis module comprises a lower computer and an industrial personal computer, the lower computer is configured to acquire level signals outputted by die vertical photoelectric sensing elements and the horizontal photoelectric sensing elements, and the industrial personal computer is configured to analyze the acquired level signals in order to obtain the abrasion conditions of the sprocket wheel teeth.
  2. 2. The scraper conveyer sprocket wheel tooth abrasion monitoring device according to claim 1, characterized in that the top reflective stickers have the same shape as the top surfaces of the sprocket wheel teeth, and the side reflective stickers have the same shape as the side surface of the sprocket wheel teeth.
  3. 3. The scraper conveyer sprocket wheel tooth abrasion monitoring device according to claim 1, characterized in that both the vertical light source and the horizontal light source are point light sources.
  4. 4. The scraper conveyer sprocket wheel tooth abrasion monitoring device according to claim 1, characterized in that the vertical photoelectric sensing element is shaped like a circular arc, and the horizontal photoelectric sensing elements have the same shape as the side reflective stickers.
  5. 5. The scraper conveyer sprocket wheel tooth abrasion monitoring device according to claim 1, characterized in that each of the vertical photoelectric sensing modules and the horizontal photoelectric sensing modules also comprises a signal conditioning unit for amplifying and filtering the outputted level signals.
  6. 6. A scraper conveyer sprocket wheel tooth abrasion monitoring method based on the monitoring device according to claim 1, characterized by comprising the following steps: firstly, the same sampling frequency is allocated to vertical photoelectric sensing modules and horizontal photoelectric sensing modules, the vertical photoelectric sensing modules are set to output high levels when receiving light reflected by top reflective stickers, and otherwise output low level, and the horizontal photoelectric sensing modules are set to output high levels when receiving light reflected by the side reflective stickers, and otherwise output low levels; secondly, when sprocket wheel teeth do not have any abrasion, the original dimensions Ld_0 of corresponding parts of the end surfaces of the crests of the sprocket wheel teeth are measured, meanwhile, a high level length LD_0 outputted by the vertical photoelectric sensing module and a low level L2_0 outputted by the horizontal photoelectric sensing module which correspond to a single sprocket wheel tooth are acquired, and a ratio factor
    is calculated; then, when sprocket wheel tooth abrasion loss is measured actually, it is assumed that the high level length outputted by each vertical photoelectric sensing module is Z,and the low level length outputted by each horizontal photoelectric sensing module is I, ., when a single sprocket wheel tooth passes, a ratio factor
    is calculated,
    if a scraper conveyer runs at constant speed, so is
    defined as a correction factor to eliminate the affection of changing rotational speed on sprocket wheel tooth abrasion loss measurement during measurement;
    is calculated, and thereby sprocket wheel tooth abrasion loss is
    ; finally, an abrasion threshold J of the sprocket wheel teeth is set, die sprocket wheel tooth abrasion loss does not go beyond the limit when
    , and therefore the sprocket wheel teeth can be used continuously and normally; the sprocket wheel tooth abrasion loss goes beyond the limit when
    , and an abrasion danger warning signal is outputted.
AU2016401397A 2016-05-17 2016-12-07 Scraper conveyer sprocket wheel tooth abrasion monitoring device and method Active AU2016401397B2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
CN201610325560.3A CN105865352B (en) 2016-05-17 2016-05-17 A kind of Chain Wheel of Flight Bar Conveyor gear teeth tool-wear monitoring device and method
CN201610325560.3 2016-05-17
PCT/CN2016/108845 WO2017197876A1 (en) 2016-05-17 2016-12-07 Apparatus and method for wear monitoring of teeth of sprockets of scraper conveyor

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AU2016401397A1 true AU2016401397A1 (en) 2017-12-07
AU2016401397B2 AU2016401397B2 (en) 2018-08-30

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AU (1) AU2016401397B2 (en)
CA (1) CA2987475C (en)
WO (1) WO2017197876A1 (en)
ZA (1) ZA201802656B (en)

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CN106404570B (en) * 2016-09-26 2019-01-01 中国矿业大学 Heavily loaded Chain Wheel of Flight Bar Conveyor fatigue under scrubbing monitoring device and method under vibratory impulse
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AU2016401397B2 (en) 2018-08-30
CN105865352B (en) 2018-09-18
WO2017197876A1 (en) 2017-11-23
ZA201802656B (en) 2019-02-27
CA2987475A1 (en) 2017-11-23
CA2987475C (en) 2019-12-31
CN105865352A (en) 2016-08-17

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