CA2987475C - Scraper conveyor sprocket wheel tooth abrasion monitoring device and method - Google Patents
Scraper conveyor sprocket wheel tooth abrasion monitoring device and method Download PDFInfo
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- CA2987475C CA2987475C CA2987475A CA2987475A CA2987475C CA 2987475 C CA2987475 C CA 2987475C CA 2987475 A CA2987475 A CA 2987475A CA 2987475 A CA2987475 A CA 2987475A CA 2987475 C CA2987475 C CA 2987475C
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- 208000002697 Tooth Abrasion Diseases 0.000 title claims abstract description 41
- 238000012806 monitoring device Methods 0.000 title claims abstract description 15
- 238000000034 method Methods 0.000 title abstract description 10
- 238000005299 abrasion Methods 0.000 claims abstract description 24
- 238000007405 data analysis Methods 0.000 claims abstract description 11
- 238000005259 measurement Methods 0.000 claims abstract description 11
- 230000003750 conditioning effect Effects 0.000 claims description 6
- 238000012937 correction Methods 0.000 claims description 4
- 238000001914 filtration Methods 0.000 claims description 4
- 238000005070 sampling Methods 0.000 claims description 4
- 230000000694 effects Effects 0.000 claims description 2
- 230000005856 abnormality Effects 0.000 abstract description 2
- 239000003245 coal Substances 0.000 description 6
- 238000010586 diagram Methods 0.000 description 4
- 238000012544 monitoring process Methods 0.000 description 4
- 230000005611 electricity Effects 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- BTCSSZJGUNDROE-UHFFFAOYSA-N gamma-aminobutyric acid Chemical compound NCCCC(O)=O BTCSSZJGUNDROE-UHFFFAOYSA-N 0.000 description 1
- 238000010921 in-depth analysis Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000005065 mining Methods 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
- G01B11/06—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/2416—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures of gears
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/255—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures for measuring radius of curvature
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- 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 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 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 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 modem 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
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 modem 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
2 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, 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.
According to an aspect of the invention, there is provided 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 top surfaces of sprocket wheel teeth, each vertical photoelectric sensing module comprises a vertical light source and a vertical 2a 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 side surfaces of the sprocket wheel teeth, each 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, wherein 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 abrasion conditions of the sprocket wheel teeth. ;
characterized by comprising the following steps:
firstly, a sampling frequency is allocated to both the 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 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, original dimensions Lõ_0 of corresponding parts of end surfaces of crests of the sprocket wheel teeth are measured, meanwhile, a high level length LD_o 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 kõ L0_0 41_0 is calculated;
2b 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 when a single sprocket wheel tooth passes, a ratio factor Ak = L2_042 is calculated, Ak = 1 if a scraper conveyer runs at constant speed, so is Ak defined as a correction factor to eliminate effect of changing rotational speed on sprocket wheel tooth abrasion loss measurement during measurement;
= Akxknx 1 is calculated, and thereby sprocket wheel tooth abrasion loss is ALD = LD-0 finally, an abrasion threshold J of the sprocket wheel teeth is set, wherein if the sprocket wheel tooth abrasion loss is AL,, < J , the sprocket wheel teeth can be used continuously and normally; if the sprocket wheel tooth abrasion is A/0 J, and an abrasion danger warning signal is outputted.
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 the 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 0 of corresponding parts of the end surfaces of the crests of the sprocket wheel teeth are measured, meanwhile, a high level length L
outputted by the vertical photoelectric sensing module and a low level 1.2 0 outputted by the horizontal photoelectric sensing module which correspond to a single sprocket wheel tooth are acquired, and a ratio factor I'D =4_0/4 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 I, and the low level length outputted by each horizontal photoelectric sensing module is L, , when a single sprocket wheel tooth passes, a ratio factor Ak = L2 0/4 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
In order to achieve the above, 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.
According to an aspect of the invention, there is provided 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 top surfaces of sprocket wheel teeth, each vertical photoelectric sensing module comprises a vertical light source and a vertical 2a 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 side surfaces of the sprocket wheel teeth, each 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, wherein 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 abrasion conditions of the sprocket wheel teeth. ;
characterized by comprising the following steps:
firstly, a sampling frequency is allocated to both the 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 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, original dimensions Lõ_0 of corresponding parts of end surfaces of crests of the sprocket wheel teeth are measured, meanwhile, a high level length LD_o 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 kõ L0_0 41_0 is calculated;
2b 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 when a single sprocket wheel tooth passes, a ratio factor Ak = L2_042 is calculated, Ak = 1 if a scraper conveyer runs at constant speed, so is Ak defined as a correction factor to eliminate effect of changing rotational speed on sprocket wheel tooth abrasion loss measurement during measurement;
= Akxknx 1 is calculated, and thereby sprocket wheel tooth abrasion loss is ALD = LD-0 finally, an abrasion threshold J of the sprocket wheel teeth is set, wherein if the sprocket wheel tooth abrasion loss is AL,, < J , the sprocket wheel teeth can be used continuously and normally; if the sprocket wheel tooth abrasion is A/0 J, and an abrasion danger warning signal is outputted.
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 the 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 0 of corresponding parts of the end surfaces of the crests of the sprocket wheel teeth are measured, meanwhile, a high level length L
outputted by the vertical photoelectric sensing module and a low level 1.2 0 outputted by the horizontal photoelectric sensing module which correspond to a single sprocket wheel tooth are acquired, and a ratio factor I'D =4_0/4 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 I, and the low level length outputted by each horizontal photoelectric sensing module is L, , when a single sprocket wheel tooth passes, a ratio factor Ak = L2 0/4 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
3 abrasion loss measurement during measurement; L, = Akx1c0x L, is calculated, and thereby sprocket wheel tooth abrasion loss is AL, ¨ LI) 0 ;
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 AL, < , and therefore the sprocket wheel teeth can be used continuously and normally; the sprocket wheel tooth abrasion loss goes beyond the limit when ALõ J, 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. I 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, I 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.
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 AL, < , and therefore the sprocket wheel teeth can be used continuously and normally; the sprocket wheel tooth abrasion loss goes beyond the limit when ALõ J, 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. I 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, I 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.
4 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
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
5 computer, the power supply supplies electricity to the lower computer and the industrial personal computer, the tower 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
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
6 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 Li outputted by the vertical photoelectric sensing module and a low level 1.2 õ outputted by the horizontal photoelectric sensing module which correspond to a single sprocket wheel tooth are acquired, and a ratio factor ;co= LD 04,0 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 4,1 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 042 t 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; LD Akxkpx LI is calculated, and thereby sprocket wheel tooth abrasion loss is ALI, = LD LD 1;
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 AL, <f , and therefore the sprocket wheel teeth can be used continuously and normally; the sprocket wheel tooth abrasion loss goes beyond the limit when AL, 3, 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
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 Li outputted by the vertical photoelectric sensing module and a low level 1.2 õ outputted by the horizontal photoelectric sensing module which correspond to a single sprocket wheel tooth are acquired, and a ratio factor ;co= LD 04,0 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 4,1 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 042 t 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; LD Akxkpx LI is calculated, and thereby sprocket wheel tooth abrasion loss is ALI, = LD LD 1;
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 AL, <f , and therefore the sprocket wheel teeth can be used continuously and normally; the sprocket wheel tooth abrasion loss goes beyond the limit when AL, 3, 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
7 embellishments, and these improvements and embellishments should also be regarded as the protection scope of the present invention.
8
Claims (5)
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 top surfaces of sprocket wheel teeth, each 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 side surfaces of the sprocket wheel teeth, each 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, wherein 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 abrasion conditions of the sprocket wheel teeth;
characterized by comprising the following steps:
firstly, a sampling frequency is allocated to both the vertical photoelectric sensing modules and the 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 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, original dimensions L D-0 of corresponding parts of end surfaces of crests of the sprocket wheel teeth are measured, meanwhile, a high level length L D-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 k = L 0-01 1,,-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 L1-1 and the low level length outputted by each horizontal photoelectric sensing module is L2-1 when a single sprocket wheel tooth passes, a ratio factor .DELTA.k = L2-0/L2-1 is calculated, .DELTA.k = 1 if a scraper conveyer runs at constant speed, so is .DELTA.k defined as a correction factor to eliminate effect of changing rotational speed on sprocket wheel tooth abrasion loss measurement during measurement; L D-1 = .DELTA.k × k D × L 1-1 is calculated, and thereby sprocket wheel tooth abrasion loss is .DELTA.L D = L D-0 ¨ L D-1;
finally, an abrasion threshold J of the sprocket wheel teeth is set, wherein if the sprocket wheel tooth abrasion loss is .DELTA.L D < J , the sprocket wheel teeth can be used continuously and normally; if the sprocket wheel tooth abrasion loss is .DELTA.L D >= J , an abrasion danger warning signal is outputted.
the side reflective stickers are mounted on side surfaces of the sprocket wheel teeth, each 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, wherein 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 abrasion conditions of the sprocket wheel teeth;
characterized by comprising the following steps:
firstly, a sampling frequency is allocated to both the vertical photoelectric sensing modules and the 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 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, original dimensions L D-0 of corresponding parts of end surfaces of crests of the sprocket wheel teeth are measured, meanwhile, a high level length L D-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 k = L 0-01 1,,-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 L1-1 and the low level length outputted by each horizontal photoelectric sensing module is L2-1 when a single sprocket wheel tooth passes, a ratio factor .DELTA.k = L2-0/L2-1 is calculated, .DELTA.k = 1 if a scraper conveyer runs at constant speed, so is .DELTA.k defined as a correction factor to eliminate effect of changing rotational speed on sprocket wheel tooth abrasion loss measurement during measurement; L D-1 = .DELTA.k × k D × L 1-1 is calculated, and thereby sprocket wheel tooth abrasion loss is .DELTA.L D = L D-0 ¨ L D-1;
finally, an abrasion threshold J of the sprocket wheel teeth is set, wherein if the sprocket wheel tooth abrasion loss is .DELTA.L D < J , the sprocket wheel teeth can be used continuously and normally; if the sprocket wheel tooth abrasion loss is .DELTA.L D >= J , an abrasion danger warning signal is outputted.
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. 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. 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. 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.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201610325560.3 | 2016-05-17 | ||
| CN201610325560.3A CN105865352B (en) | 2016-05-17 | 2016-05-17 | Device and method for monitoring wear of sprocket gear of scraper conveyor |
| 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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| Publication Number | Publication Date |
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| CA2987475A1 CA2987475A1 (en) | 2017-11-23 |
| CA2987475C true CA2987475C (en) | 2019-12-31 |
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| CA2987475A Expired - Fee Related CA2987475C (en) | 2016-05-17 | 2016-12-07 | Scraper conveyor sprocket wheel tooth abrasion monitoring device and method |
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| Country | Link |
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| CN (1) | CN105865352B (en) |
| AU (1) | AU2016401397B2 (en) |
| CA (1) | CA2987475C (en) |
| WO (1) | WO2017197876A1 (en) |
| ZA (1) | ZA201802656B (en) |
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| CN105865352B (en) * | 2016-05-17 | 2018-09-18 | 中国矿业大学 | Device and method for monitoring wear of sprocket gear of scraper conveyor |
| 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 |
| CN106653503A (en) * | 2017-02-15 | 2017-05-10 | 江苏森源电气股份有限公司 | Gear one-way energy storage mechanism not limited by pawl |
| CN108051171B (en) * | 2017-12-24 | 2020-03-17 | 太原理工大学 | Coal-throwing impact testing device for coal mining machine |
| CN107934406A (en) * | 2018-01-08 | 2018-04-20 | 南通奥普机械工程有限公司 | The buffering chain sprocket structure of scraper-type reclaimer |
| CN109059756B (en) * | 2018-06-14 | 2019-12-20 | 太原理工大学 | Scraper conveyor chain wheel abrasion measuring device and method based on focusing morphology recovery |
| KR102136870B1 (en) * | 2018-12-26 | 2020-07-22 | 대한민국 | A vehicle for mud-flat |
| KR102136867B1 (en) * | 2018-12-26 | 2020-07-22 | 대한민국 | Wheels for vehicle on land and mud |
| JP6874100B1 (en) * | 2019-11-29 | 2021-05-19 | 東芝エレベータ株式会社 | Passenger conveyor and wear detector |
| CN111350804B (en) * | 2020-02-25 | 2021-08-03 | 江苏大学 | Chain wheel abrasion on-line monitoring system and grain combine chain transmission system |
| CN112528511B (en) * | 2020-12-17 | 2023-12-12 | 中国矿业大学 | Method for evaluating abrasion reliability of chain wheel of scraper conveyor |
| WO2022188283A1 (en) * | 2021-03-08 | 2022-09-15 | 中国矿业大学 | Scraper chain monitoring system and method based on measurement of light transmission amount of torsion spring |
| CN113351352A (en) * | 2021-06-30 | 2021-09-07 | 郑州三和水工机械有限公司 | Intelligent detection and alarm device for abrasion degree of sand making machine |
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| EP0083047B1 (en) * | 1981-12-24 | 1987-02-04 | Bayerische Motoren Werke Aktiengesellschaft, Patentabteilung AJ-3 | Test method for mechanical working parts, and device for carrying out this method |
| CN2196290Y (en) * | 1994-04-27 | 1995-05-03 | 中国科学院上海冶金研究所 | Work piece angle and length measuring apparatus |
| JP2000337825A (en) * | 1999-05-31 | 2000-12-08 | Nisshin Flour Milling Co Ltd | Measuring apparatus for shape of tooth profile on brake roll |
| US7269997B2 (en) * | 2004-06-03 | 2007-09-18 | Snap-On Incorporated | Non-contact method and system for tire analysis |
| DE102004033432B4 (en) * | 2004-07-10 | 2012-07-12 | Schenck Process Gmbh | Device for measuring status data on a rolling wheelset of a rail-bound vehicle |
| EP1926968A1 (en) * | 2005-09-19 | 2008-06-04 | Gutehoffnungshütte Radsatz GmbH | Method for contactless dynamic detection of the profile of a solid body |
| JP4997378B2 (en) * | 2006-03-03 | 2012-08-08 | 学校法人 芝浦工業大学 | Damage detection method and device for gear tooth surface or rolling surface of bearing |
| CN101469971B (en) * | 2007-12-26 | 2010-11-03 | 上海西屋开关有限公司 | Method and apparatus for detecting contact head abrasive loss of vacuum circuit breaker |
| CN202320395U (en) * | 2011-08-04 | 2012-07-11 | 大连民族学院 | Steel rail abrasion detection device |
| CN104316004B (en) * | 2014-11-13 | 2017-05-10 | 大连交通大学 | Wheel set tread image data dynamic acquisition system based on edge diffracted ray light source |
| CN105865352B (en) * | 2016-05-17 | 2018-09-18 | 中国矿业大学 | Device and method for monitoring wear of sprocket gear of scraper conveyor |
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- 2016-12-07 AU AU2016401397A patent/AU2016401397B2/en active Active
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| AU2016401397B2 (en) | 2018-08-30 |
| CN105865352B (en) | 2018-09-18 |
| WO2017197876A1 (en) | 2017-11-23 |
| CA2987475A1 (en) | 2017-11-23 |
| CN105865352A (en) | 2016-08-17 |
| ZA201802656B (en) | 2019-02-27 |
| AU2016401397A1 (en) | 2017-12-07 |
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