AU2016401400A1 - A monitoring device and method for dynamic radial deformation and dynamic tension of wire ropes on double broken line multi-layer winding hoists for deep mines - Google Patents

A monitoring device and method for dynamic radial deformation and dynamic tension of wire ropes on double broken line multi-layer winding hoists for deep mines Download PDF

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AU2016401400A1
AU2016401400A1 AU2016401400A AU2016401400A AU2016401400A1 AU 2016401400 A1 AU2016401400 A1 AU 2016401400A1 AU 2016401400 A AU2016401400 A AU 2016401400A AU 2016401400 A AU2016401400 A AU 2016401400A AU 2016401400 A1 AU2016401400 A1 AU 2016401400A1
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wire rope
drum
tension
sensor
dynamic
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AU2016401400B2 (en
Inventor
Tong JIANG
Hao LU
Yuxing PENG
Dongxu Shi
Ganyu SHI
Dagang WANG
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
    • G01DMEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
    • G01D21/00Measuring or testing not otherwise provided for
    • G01D21/02Measuring two or more variables by means not covered by a single other subclass

Abstract

This invention is a monitoring device for dynamic radial deformation and dynamic tension of wire ropes on double broken line multi-layer winding hoists for deep mines, including base frame, driving system, tension and compression testing system, and dynamic deformation monitoring system. The driving system includes, among others, a motor. The motor is connected with the drum via coupler A, reducer and coupler B. The outer side of the drum baffle attaches to the brake disc. The tension and compression testing system includes a servo electric cylinder, etc. The S-type tension sensor connects the servo electric cylinder and wire rope fixture. The drum surface is fitted with a friction lining, and wire ropes are wound on the double broken line grooves of the friction lining surface. One end of the wire rope fixture is fastened via the wire rope U-shaped lock on the wire rope fixture. The back of the friction lining is fitted with multiple sensor mounting grooves along the axial direction of the drum. The weighing type pressure sensor is mounted in the sensor mounting groove. The dynamic deformation monitoring system includes a 2D laser sensor. The invention can simulate the characteristics of tensile force on wire ropes under multiple operating conditions and accurately test the deformation and tension of each layer of wire ropes.

Description

A Monitoring Device and Method for Dynamic Radial Deformation and Dynamic Tension of Wire Ropes on Double Broken Line Multi-Layer Winding Hoists for Deep Mines
Technical Field
The invention relates to a monitoring device and method for dynamic radial deformation and dynamic tension of wire ropes on double broken line multi-layer winding hoists for deep mines. The invention can simulate the characteristics of tensile force on wire ropes in a winding hoisting system under multiple operating conditions such as acceleration, constant speed, deceleration, sudden stop, etc. The invention can be used to probe into the real time radial deformation of each layer of rope on a drum, the compression force on different zones of the drum’s outer wall and the dynamic variation of rope tension.
Background
The whole process of mine production can't do without mine haulage and hoisting operations, so the quality of haulage and hoisting operations directly relates to whether mine production can be performed normally and highly effectively. Mine hoisting equipment is the “throat” of mine production and is large complex system integrating mechanical, electrical and hydraulic systems. Mine hoisting equipment is a lifeline of mine production and the hub where the mine’s underground production system is connected with the ground industrial square. Mine hoisting equipment is used mainly to hoist and convey ores, coal, materials, personnel and equipment. With larger and larger mining depth of mines and higher and higher requirements for safe and highly effective production of modern large mines, multi-layer winding hoists have become increasingly large. In addition, as the drum length increases, weight and rotational inertia increases, so there is a need for larger motors and layout spaces. The adoption of a multi-layer winding drum can save cost. Double broken line grooves are a groove form suitable for multi-layer winding and can effectively overcome the deficiencies of the traditional drum in multi-layer winding, avoid rope disorder and extend the service life of wire ropes. Due to their remarkable advantages such as large hoisting capacity, large hoisting height, high safety factor, low cost, etc., double broken line grooves have been applied in deep mine hoisting and ultra-deep mining hoisting more and more extensively. As the mining depth of mines increases, hoisting equipment inevitably develops towards the direction of large hoisting capacity and high hoisting speed in order to increase the haulage efficiency of hoists for deep and ultra-deep mines. This also presents higher requirements for safety and reliability of hoisting equipment.
Wire ropes will be deformed during long-time working and especially the tensile force and tension on wire ropes in case of sudden change of operating conditions will easily result in fracture of wire ropes and thus hanging basket falling accidents and personnel casualties.
Due to the joint action of variable suspension length of hoisting ropes and inertial loads during hoisting with a friction hoist, the hoisting system will vibrate and ropes will also bear dynamic tension variation in the one-cycle hoisting process of ropes including hoisting acceleration, constant speed and deceleration. Especially during acceleration and deceleration of hoisting, the dynamic tension of ropes fluctuates greatly and the vibration frequency increases as the length of ropes decreases. Vibration changes the tensile force and tension on ropes and results in radial deformation of ropes. After long-cycle working, the service life of ropes is affected so as to cause serious hoist accidents. The force on each layer of rope is different, so if the deformation and tension of each layer of rope can be tested, mine accidents can be effectively prevented. Therefore, it is very important to put forward a dynamic monitoring device and method for radial deformation and tension of deep mine hoisting ropes and probe into the real time radial deformation of each layer of rope on a drum, the compression force on different zones of the drum’s outer wall and the dynamic variation of rope tension.
The existing hoist wire rope testing devices include the following: the utility model patent (patent No. ZL201220715786.1) has disclosed an online monitoring device for tension of multi-rope friction hoist wire ropes, and the tension of wire ropes can be acquired via a wireless transmitting module and pressure sensor and then transmitted to a wireless receiving module in wireless mode; not affected by the structure and running state of a hoist, the utility model patent can achieve real time monitoring of dynamic tension of hoist wire ropes, but it cannot test the radial deformation of each layer of wire rope. The utility model patent (patent No. ZL201420703971.8) has disclosed a tension monitoring system for mine hoists; the system can achieve remote real-time monitoring of tension of mine wire ropes and improve the safety of mine hoists. However, the accuracy of the three-point bending method used by the system to test wire rope deformation is not high and the system cannot accurately measure the tension on wire ropes. The invention (application No. 201510634389.X) has applied for disclosing a measuring method for tension of wire ropes in a hoisting system. The method is an indirect measuring method without direct contact with wire ropes and no damage to wire rope structure. The method cannot be used to measure the tension value of each layer of wire rope.
Summary
Objective of the invention: in order to overcome the deficiencies of the existing technologies, the invention provides a monitoring device and method for dynamic radial deformation and dynamic tension of wire ropes on double broken line multi-layer winding hoists for deep mines. The invention can simulate the characteristics of tensile force on wire ropes in a winding hoisting system under multiple operating conditions such as acceleration, constant speed, deceleration, sudden stop, etc. The invention can be used to probe into the real time radial deformation of each layer of rope on a drum, the compression force on different zones of the drum’s outer wall and the dynamic variation of rope tension.
In order to achieve the above objective, the invention uses the following technical scheme: a monitoring device for dynamic radial deformation and dynamic tension of wire ropes on double broken line multi-layer winding hoists for deep mines, including base frame, driving system, tension and compression testing system, and dynamic deformation monitoring system.
The said base frame includes motor and reducer bracket, servo electric cylinder bracket, 2D laser sensor fixture and 2D laser sensor bracket. The motor and reducer bracket and the servo electric cylinder bracket are fixed on the ground via anchor bolts. The 2D laser sensor fixture is fixed on the 2D laser sensor bracket via bolt A.
The said driving system includes motor, coupler A, reducer, and coupler B. The motor and reducer are fixed on the motor and reducer bracket via bolts. The output shaft of the motor is connected with the input shaft of the reducer via coupler A. The output shaft of the reducer is connected with the main shaft of the drum via coupler B. The outer side of the drum baffle at the end of the drum attaches to the brake disc of the disc brake.
The said tension and compression testing system includes servo electric cylinder, S-type tension sensor, wire rope fixture, wire rope and weighing type pressure sensor. The electric cylinder is fixed on the electric cylinder bracket via bolts. One end of the S-type tension sensor is connected with the servo electric cylinder. The other end of the S-type tension sensor is connected with the wire rope fixture. The surface of the drum is fitted with a friction lining. The surface of the friction lining is provided with double broken line grooves. Wire rope is wound on the double broken line grooves. One end of the wire rope fixture is fastened via the wire rope U-shaped lock on the wire rope fixture. The back of the friction lining is fitted with multiple sensor mounting grooves matching with the appearance of the weighing type pressure sensor along the axial direction of the drum. The weighing type pressure sensor is mounted in the sensor mounting groove.
The said dynamic deformation monitoring system includes a 2D laser sensor. The 2D laser sensor aims at the monitoring hole on the drum baffle and brake disc.
Moreover, the said weighing type pressure senor includes weighing type pressure senor A and weighing type pressure senor C near the two ends of the drum and weighing type pressure senor B in the middle of the drum.
Furthermore, the position of the surface of the said drum corresponding with the sensor mounting groove is provided with a plane groove, and the weighing type pressure sensor is fixed with the plane groove via bolt B.
The monitoring method for dynamic radial deformation and dynamic tension of wire ropes on double broken line multi-layer winding hoists for deep mines according to the above monitoring device includes the following contents: a) The motor drives the drum to rotate and thus the wire rope is wound by three layers on the drum. Then shut down the motor. One end of the wire rope passes through the wire rope fixture and then is clamped by the wire rope U-shaped lock; the wire rope fixture is connected with one end of the S-type tension sensor; the other end of the S-type tension sensor is connected with the servo electric cylinder; b) Start the 21aser sensor, and ensure that the 2D laser sensor can monitor the first layer of rope body, the second layer of rope body and the third layer of rope body via the monitoring hole. Brake the drum via the disc brake. Control horizontal movement of the servo electric cylinder via the computer, so that the force on the wire rope reaches the set fatigue load. At this time, record the outer contour of three layers of rope bodies in real time using the 2D laser sensor; by comparing the recorded outer contour with the outer contour of three layers of rope bodies in case of not exerting force, calculate the deformation of each layer of wire rope; c) Release the disc brake, close the servo electric cylinder, and restart the motor. The motor drives the drum to rotate reversely till only one layer of wire rope is wound on the drum. Brake the drum via the disc brake, and re-clamp the wire rope via the wire rope U-shaped lock of the wire rope fixture; control horizontal movement of the servo electric cylinder via the computer to load the wire rope, so that the wire rope deformation monitored by the 2D laser sensor reaches the deformation of each layer of wire rope obtained in step b). Measure the pressure of a single wire rope in different zones via the weighing type pressure sensor; d) Calculate the corresponding tension value of each layer of wire rope according to the pressure value of each layer of wire rope obtained in step c); e) Shut down the servo electric cylinder, 2D laser sensor and weighing type pressure sensors at different positions and stop the test; f) Exert different loads to the wire rope by controlling the servo electric cylinder via the computer, and thus achieve different operating conditions of a hoist including acceleration, constant speed, deceleration and sudden stop. Study the tensile force characteristics, tension variation and radial deformation of wire ropes under multiple operating conditions according to the data measured by the 2D laser sensor, S-type tension sensor and weighting type pressure sensors at different positions.
Beneficial effects: the invention patent can simulate the characteristics of tensile force on wire ropes in a winding hoisting system under multiple operating conditions such as acceleration, constant speed, deceleration, sudden stop, etc. and accurately test the deformation and tension of each layer of wire rope, thereby judging whether to replace wire ropes more accurately and reducing mining disaster accidents caused by breaking of hoist wire ropes.
Brief Description of the Drawings
Fig.l is the front view of the invention patent;
Fig.2 is the view of the invention patent from direction B;
Fig.3 is the partial enlarged view of Point I in Fig.2;
Fig.4 is the partial enlarged view of Point I in case of testing the tension of a single layer of wire rope;
Fig.5 is A-A broken-out section view of Fig.2;
Fig.6 is the partial enlarged view of Point II in Fig.5;
Fig.7 is the partial enlarged view of Point III in Fig.5;
Fig. 8 is the partial enlarged view of Point IV in Fig.5;
In the figures: 1. Motor and reducer bracket; 2. Motor; 3. Coupler A; 4. Reducer; 5. Coupler B; 6. Drum baffle; 7. Drum; 8. Bolt A; 9. 2D laser sensor; 10. 2D laser sensor fixture; 11. 2D laser sensor bracket; 12. Disc brake; 13. Brake disc; 14. Monitoring hole; 15. Wire rope U-shaped lock; 16. Wire rope fixture; 17. S-type tension sensor; 18. Servo electric cylinder; 19. Servo electric cylinder; 20. The first layer of rope body; 21. The second layer of rope body; 22. The third layer of rope body; 23. Weighing type pressure sensor A; 24. Wire rope; 25. Friction lining; 26. Weighing type pressure sensor B; 27. Weighing type pressure sensor C; 28. Plane groove; 29. Bolt B.
Detailed Description:
According to the drawings, the invention is further described as follows:
As shown in Fig.l and Fig. 2, a monitoring device for dynamic radial deformation and dynamic tension of wire ropes on double broken line multi-layer winding hoists for deep mines according to the invention includes base frame, driving system, tension and compression testing system, and dynamic deformation monitoring system.
The said base frame includes motor and reducer bracket 1, servo electric cylinder bracket 19, 2D laser sensor fixture 10 and 2D laser sensor bracket 11. The motor and reducer bracket 1 and servo electric cylinder bracket 19 are fixed on the ground via anchor bolts. The 2D laser sensor fixture 10 is fixed on the 2D laser sensor bracket 11 via bolt A8.
The said driving system includes motor 2, coupler A3, reducer 4, and coupler B5. The motor 2 and reducer 4 are fixed on the motor and reducer bracket 1 via bolts. The output shaft of the motor 2 is connected with the input shaft of the reducer 4 via the coupler A3. The output shaft of the reducer 4 is connected with the main shaft of the drum 7 via the coupler B5. The outer side of drum baffle 6 at the end of the drum 7 attaches to the brake disc 13 of the disc brake 12.
The said tension and compression testing system includes servo electric cylinder 18, S-type tension sensor 17, wire rope fixture 16, wire rope 24 and weighing type pressure sensor. The electric cylinder 18 is fixed on the electric cylinder bracket 19 via bolts. One end of the S-type tension sensor 17 is connected with the servo electric cylinder 18. The other end of the S-type tension sensor 17 is connected with the wire rope fixture 16. The surface of the drum 7 is fitted with friction lining 25. The surface of the friction lining 25 is provided with double broken line grooves. Wire rope 24 is wound on the double broken line grooves. One end of the wire rope fixture 16 is fastened via the wire rope U-shaped lock 15 on the wire rope fixture 16.
As shown in Fig.5 to Fig.8, the back of the friction lining 25 is fitted with multiple sensor mounting grooves matching with the appearance of the weighing type pressure sensor along the axial direction of the drum 7. The weighing type pressure sensor is mounted in the sensor mounting groove. The position of the surface of the said drum 7 corresponding with the sensor mounting groove is provided with plane groove 28, and the weighing type pressure sensor is fixed with the plane groove 28 via bolt B29. In the present embodiment the said weighing type pressure senor includes weighing type pressure senor A23 and weighing type pressure senor C27 near the two ends of the drum 7 and weighing type pressure senor B26 in the middle of the drum 7.
The said dynamic deformation monitoring system includes 2D laser sensor 9. The 2D laser sensor 9 aims at the monitoring hole 14 on the drum baffle 6 and brake disc 13.
The monitoring method for dynamic radial deformation and dynamic tension of wire ropes on double broken line multi-layer winding hoists for deep mines according to the above monitoring device includes the following contents: a) The motor 2 drives the drum 7 to rotate and thus the wire rope 24 is wound by three layers on the drum 7. Then shut down the motor 2. One end of the wire rope 24 passes through the wire rope fixture 16 and then is clamped by the wire rope U-shaped lock 15; the wire rope fixture 16 is connected with one end of the S-type tension sensor 17; the other end of the S-type tension sensor 17 is connected with the servo electric cylinder 18; b) As shown in Fig.3, start the 2D laser sensor 9, and ensure that the 2D laser sensor 9 can monitor the first layer of rope body 20, the second layer of rope body 21 and the third layer of rope body 22 via the monitoring hole 14. Brake the drum 7 via the disc brake 12. Control horizontal movement of the servo electric cylinder 18 via the computer, so that the force on the wire rope 24 reaches the set fatigue load. At this time, record the outer contour of three layers of rope bodies in real time using the 2D laser sensor 9; by comparing the recorded outer contour with the outer contour of three layers of rope bodies in case of not exerting force, calculate the deformation of each layer of wire rope 24; c) As shown in Fig.4, release the disc brake 12, close the servo electric cylinder 18, and restart the motor 2. The motor 2 drives the drum 7 to rotate reversely till only one layer of wire rope 24 is wound on the drum 7. Brake the drum 7 via the disc brake 12, and re-clamp the wire rope 24 via the wire rope U-shaped lock 15 of the wire rope fixture 16; control horizontal movement of the servo electric cylinder 18 via the computer to load the wire rope 24, so that the wire rope deformation monitored by the 2D laser sensor 9 reaches the deformation of each layer of wire rope 24 obtained in step b). Measure the pressure of a single wire rope 24 in different zones via the weighing type pressure sensor; d) Calculate the corresponding tension value of each layer of wire rope 24 according to the pressure value of each layer of wire rope 24 obtained in step c). In this step, the pressure value is converted into the tension value according to the empirical formula for wire rope tension calculation; e) Shut down the servo electric cylinder 18, 2D laser sensor 9 and weighing type pressure sensors at different positions and stop the test; f) Exert different loads to the wire rope 24 by controlling the servo electric cylinder 18 via the computer, and thus achieve different operating conditions of a hoist including acceleration, constant speed, deceleration and sudden stop. Study the tensile force characteristics, tension variation and radial deformation of wire ropes under multiple operating conditions according to the data measured by the 2D laser sensor 9, S-type tension sensor 17 and weighting type pressure sensors at different positions.
The above description is only a preferred embodiment of the present invention. It should be pointed out that as far as general technicians in this technical field are concerned, they may implement some improvements and modifications on the premise of following the principle of this invention; however, such improvements and modifications shall be deemed to be within the coverage of protection of this invention.

Claims (4)

1. A monitoring device for dynamic radial deformation and dynamic tension of wire ropes on double broken line multi-layer winding hoists for deep mines is characterized in that it includes base frame, driving system, tension and compression testing system, and dynamic deformation monitoring system. The said base frame includes motor and reducer bracket (1), servo electric cylinder bracket (19), 2D laser sensor fixture (10) and 2D laser sensor bracket (11). The motor and reducer bracket (1) and servo electric cylinder bracket (19) are fixed on the ground via anchor bolts. The 2D laser sensor fixture (10) is fixed on the 2D laser sensor bracket (11) via bolt A(8). The said driving system includes motor (2), coupler A(3), reducer (4), and coupler B(5). The motor (2) and reducer (4) are fixed on the motor and reducer bracket (1) via bolts. The output shaft of the motor (2) is connected with the input shaft of the reducer (4) via the coupler A(3). The output shaft of the reducer (4) is connected with the main shaft of the drum (7) via the coupler B(5). The outer side of the drum baffle (6) at the end of the drum (7) attaches to the brake disc (13) of the disc brake (12). The said tension and compression testing system includes servo electric cylinder (18), S-type tension sensor (17), wire rope fixture (16), wire rope (24) and weighing type pressure sensor. The electric cylinder (18) is fixed on the electric cylinder bracket (19) via bolts. One end of the S-type tension sensor (17) is connected with the servo electric cylinder (18). The other end of the S-type tension sensor (17) is connected with the wire rope fixture (16). The surface of the drum (7) is fitted with friction lining (25). The surface of the friction lining (25) is provided with double broken line grooves. Wire rope (24) is wound on the double broken line grooves. One end of the wire rope fixture (16) is fastened via the wire rope U-shaped lock (15) on the wire rope fixture (16). The back of the friction lining (25) is fitted with multiple sensor mounting grooves matching with the appearance of the weighing type pressure sensor along the axial direction of the drum (7). The weighing type pressure sensor is mounted in the sensor mounting groove. The said dynamic deformation monitoring system includes 2D laser sensor (9). The 2D laser sensor (9) aims at the monitoring hole (14) on the drum baffle (6) and brake disc (13).
2. A monitoring device for dynamic radial deformation and dynamic tension of wire ropes on double broken line multi-layer winding hoists for deep mines according to claim 1, wherein the said weighing type pressure senor includes weighing type pressure senor A(23) and weighing type pressure senor C(27) near the two ends of the drum (7) and weighing type pressure senor B(26) in the middle of the drum (7).
3. A monitoring device for dynamic radial deformation and dynamic tension of wire ropes on double broken line multi-layer winding hoists for deep mines according to claim 2, wherein the position of the surface of the said drum (7) corresponding with the sensor mounting groove is provided with plane groove (28), and the weighing type pressure sensor is fixed with the plane groove (28) via bolt B(29).
4. The monitoring method for dynamic radial deformation and dynamic tension of wire ropes on double broken line multi-layer winding hoists for deep mines according to the above monitoring device is characterized in that the method includes the following contents: a) The motor (2) drives the drum (7) to rotate and thus the wire rope (24) is wound by three layers on the drum (7). Then shut down the motor (2). One end of the wire rope (24) passes through the wire rope fixture (16) and then is clamped by the wire rope U-shaped lock (15); the wire rope fixture (16) is connected with one end of the S-type tension sensor (17); the other end of the S-type tension sensor (17) is connected with the servo electric cylinder (18); b) Start the 2D laser sensor (9), and ensure that the 2D laser sensor (9) can monitor the first layer of rope body (20), the second layer of rope body (21) and the third layer of rope body (22) via the monitoring hole (14). Brake the drum (7) via the disc brake (12). Control horizontal movement of the servo electric cylinder (18) via the computer, so that the force on the wire rope (24) reaches the set fatigue load. At this time, record the outer contour of three layers of rope bodies in real time using the 2D laser sensor (9); by comparing the recorded outer contour with the outer contour of three layers of rope bodies in case of not exerting force, calculate the deformation of each layer of wire rope (24); c) Release the disc brake (12), close the servo electric cylinder (18), and restart the motor (2). The motor (2) drives the drum (7) to rotate reversely till only one layer of wire rope (24) is wound on the drum (7). Brake the drum (7) via the disc brake (12), and re-clamp the wire rope (24) via the wire rope U-shaped lock (15) of the wire rope fixture (16); control horizontal movement of the servo electric cylinder (18) via the computer to load the wire rope (24), so that the wire rope deformation monitored by the 2D laser sensor (9) reaches the deformation of each layer of wire rope (24) obtained in step b). Measure the pressure of a single wire rope (24) in different zones via the weighing type pressure sensor; d) Calculate the corresponding tension value of each layer of wire rope (24) according to the pressure value of each layer of wire rope (24) obtained in step c); e) Shut down the servo electric cylinder (18), 2D laser sensor (9) and weighing type pressure sensors at different positions and stop the test; f) Exert different loads to the wire rope (24) by controlling the servo electric cylinder (18) via the computer, and thus achieve different operating conditions of a hoist including acceleration, constant speed, deceleration and sudden stop. Study the tensile force characteristics, tension variation and radial deformation of wire ropes under multiple operating conditions according to the data measured by the 2D laser sensor (9), S-type tension sensor (17) and weighting type pressure sensors at different positions.
AU2016401400A 2016-09-26 2016-12-07 A monitoring device and method for dynamic radial deformation and dynamic tension of wire ropes on double broken line multi-layer winding hoists for deep mines Ceased AU2016401400B2 (en)

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CN201610850593.XA CN106482782B (en) 2016-09-26 2016-09-26 Dynamic radial deformation and dynamic tension monitoring device and the method for the two-fold wire type multi-lay winding steel wire rope of hoist of deep-well
CN201610850593X 2016-09-26
PCT/CN2016/108883 WO2018053944A1 (en) 2016-09-26 2016-12-07 Device and method for monitoring dynamic radial deformation and dynamic tension of steel rope of deep-well double-broken-line multilayer winding hoist

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