CN103434816A - Chain state monitoring and protecting system for scraper conveyor - Google Patents
Chain state monitoring and protecting system for scraper conveyor Download PDFInfo
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Abstract
The invention discloses a chain state monitoring and protecting system for a scraper conveyor. The system is characterized by comprising a micro controller unit, a wireless measuring unit, an AC (Alternating Current) sampling unit, an analog quantity conditioning unit, a display unit, a communication unit, a keying unit, a switching value unit and a driving unit. According to the invention, a modularized system structure is adopted; all the units are combined into one organic integral body; a wireless measuring technology is adopted to more directly and accurately monitor an operating state of a chain; the state of the chain is dynamically regulated according to the load condition; after chain clamping and breaking accidents occur, fault protection is carried out by sending an alarm signal to an integral switch, and fault alarm is carried out; safety and stability of operation of the scraper conveyor are improved; and production safety of an underground coal mine is ensured.
Description
Technical field
The present invention relates to a kind of scraper conveyer chain condition monitoring and fault protection system, be particularly useful for the high-power scraper conveyer chain condition monitoring of colliery down-hole combined mining working and protection.
Background technology
Slat conveyer is the main conveying coal equipment of Mechanized, and its serviceability directly affects continuity and the safety that driving surface is mined.Simultaneously, along with improving constantly of production efficiency, building energetically annual output ten-million-ton scale fully-mechanized mining working has become China's mine main development direction.This just requires fully-mechanized mining working surface conveyer installation transport capacity constantly to promote, and the emergency protection of slat conveyer has also been proposed to requirements at the higher level simultaneously.According to statistics, the fault of slat conveyer more than 40% all caused by chain, so chain is carried out condition monitoring and protects and can effectively reduce the slat conveyer probability failure.
The fully-mechanized mining working circumstance complication, be subject to the impact of the reasons such as laod unbalance, wall caving and hydraulic support grouping pushing and sliding during the slat conveyer operation, cause the chain tension skewness, make chain generation plastic deformation and elastic deformation, causing chain is not that tension was exactly pine.The too tight or too loose chain that all can make of chain can not normally mesh with sprocket wheel.The chain tension can cause that in chain, lateral wearing increases the weight of, and causes jumping chain or chain rupture; Chain is crossed the chain accumulation that Song Zehui causes the sprocket wheel bottom, causes the chain jamming accident.In addition, the horsepower output of chain tension meeting expanded motor, cause that the transmission device running temperatures such as motor, fluid coupling, retarder raise, and shorten service life of equipment greatly.
At present, domesticly mainly by oil cylinder working-pressure and these two kinds of methods of scraper conveyer chain tension force corresponding relation, overhang and scraper conveyer chain tension force corresponding relation, judge the tensioning state of scraper conveyer chain, thereby realize that automatic or manual controls chain tension.But, because these parameters are difficult in the slat conveyer operational process Measurement accuracy in real time, thus the general manual control mode that adopts during working control, fail to realize automatic control, can not meet the construction requirements of automatically working face.The domestic chain stretching device of controlling based on the constant voltage mode of now having developed, because it can not be along with the variation of chain tension is regulated in real time, so be not used widely.Nowadays, mine flight conveyer chain state still be take artificial observation as main, be that the workman relies on its practical experience after easy heap chain place is judged the tightness of chain, the manual regulation hydraulic ram is to reach the purpose of adjusting chain degree of tightness, therefore there are very large uncertainty and randomness, easily cause the chain fault.
The external research to the scraper conveyer chain condition monitoring early, but directly measure the tension variation occurred on chain is Research Challenges always, so still take indirect metering system as main, mainly comprise following three kinds of metering systems: (1) overhang and length tension relation; (2) power and length tension relation; (3) tail telescopic oil cylinder pressure and length tension relation.According to these three kinds of principles, German DBT company and U.S. JOY company have all developed corresponding chain stretching device.Due to after load changes, the relation of degree of dangling, power or telescopic oil cylinder pressure and tension force also can change thereupon, therefore these methods all can not change and dynamically adjust in real time chain tension according to external load, and this is also usually by ore deposit side, to be placed in the reason place of manual mode after the product import of why these several companies.
Summary of the invention
The object of the present invention is to provide a kind of coal mine lower scraping plate conveyor chain condition monitoring and protection system, for solving, coal mine lower scraping plate conveyer chain bar state can not accurately be monitored in real time, chain can not be with the automatic adjust operation state of load variations, can not be in time after chain jamming and chain rupture fault occur chain be protected etc. to problem.By the characteristic quantity to slat conveyer running state, chain tension state and slat conveyer load condition detect online, information fusion and feature extraction; driver element is adjusted the scraper conveyer chain degree of tension makes it adjust in real time according to load variations; and to chain jamming, chain rupture diagnosing malfunction, protection and warning; thereby after occurring, fault stops in time the running of slat conveyer; guarantee the safe operation of slat conveyer, guarantee the production safety under coal mine.
Technical scheme provided by the invention is: a kind of scraper conveyer chain condition monitoring and protection system is characterized in that: comprise micro controller unit, wireless measurement unit, AC sampling unit, analog quantity conditioning unit, display unit, communication unit, push-button unit, switching value unit and driver element;
Described micro controller unit adopts dual-cpu structure, the real-time of controlling for the raising system;
Described wireless measurement unit, comprise induction force transducer, signal condition module, transmitter module, receiver module and antenna, wherein respond to force transducer and be arranged on scraper conveyer chain, for measuring the longitudinal deformation of chain link, and then obtain the suffered tension force of chain; By this unit, the chain tension information of measurement is sent to micro controller unit;
Described AC sampling unit comprises three phase current transformer, phase current modulate circuit and current acquisition module, this unit input is connected with three phase current transformer, wherein three phase current transformer is arranged on scraper conveyor tail motor point of incoming cables, for measuring current of electric, its output connects the phase current modulate circuit; Current acquisition module output interface connects the GPIO mouth of microcontroller, by virtual SPI mode, carries out reading of current value;
Described analog quantity conditioning unit, comprise tachogenerator, pressure sensor and stroke sensor, and wherein tachogenerator is arranged on the scraper conveyor tail motor, for measuring motor speed; Pressure sensor and stroke sensor are arranged in the scraper conveyor tail oil cylinder, for measuring oil cylinder working-pressure and oil cylinder stroke, and by establishing a communications link with hydraulic support, the position signal of Real-time Collection coalcutter; This unit be by the signal of collection through Isolation input protective circuit, Bessel filter, follow after circuit, bleeder circuit and pressure limited protection circuit are processed and be connected with the A/D pin of microcontroller;
Described display unit, comprise liquid crystal display and tangible color screen, and liquid crystal display is connected with the GPIO mouth of microcontroller, and tangible color screen is placed in explosion-resistant enclosure, by signalling methods, with microcontroller, is connected;
Described communication unit, by two-way RS-485 communication circuit and 1 road SPI communication circuit, formed, wherein between microcontroller, use the SPI mode to communicate by letter, microcontroller uses the RS-485 mode to communicate by letter with the receiver module of wireless measurement unit, and microcontroller and tangible color screen are used the RS-485 signalling methods;
Described push-button unit, be 4 * 8 matrix keyboards, and its output is connected with the GPIO mouth of microcontroller, and the working parameter of native system is arranged;
Described switching value unit, comprise coalcutter and slat conveyer actuation signal, scram button signal, and scram button is connected with the middle fracture 0 of microcontroller, and rest switch amount incoming signal is connected with the GPIO mouth of microcontroller;
Described driver element, that the control driving circuit of native system is connected with the GPIO mouth of microcontroller, by controlling electromagnetic priority valve, hydraulic efficiency pressure system is regulated, and then adjusted scraper conveyor tail, make chain maintain all the time a comparatively ideal tensioning state.
In the present invention, described micro controller unit comprises micro controller unit one and micro controller unit two, its CPU all adopts C8051F020 type micro controller system, micro controller unit one is responsible for data demonstration, key-press input, switching value input and is communicated by letter with micro controller unit two with receiver module, and the responsible collecting sensor signal of micro controller unit two, comprehensive judgement, output drive control and communicates by letter with micro controller unit one.
In the present invention, in described display unit, liquid crystal display is the 128*64 liquid crystal display, and tangible color screen is 10 cun tangible color screens.
Scheme specific implementation process provided by the invention is: the induction force transducer is installed on scraper conveyer chain, and the longitudinal deformation of measuring chain link obtains the suffered tension force of chain, and sends data to microcontroller by wireless communication mode; On the scraper conveyor tail motor, tachogenerator is installed, for measuring motor speed; Three phase current transformer is installed, for measuring current of electric in the motor point of incoming cables; Setting pressure sensor and stroke sensor in the scraper conveyor tail oil cylinder, for measuring oil cylinder working-pressure and oil cylinder stroke, and by establishing a communications link with hydraulic support, the position signal of Real-time Collection coalcutter; Scraper conveyor tail adopts removable tail, and hydraulic ram is installed in the tail both sides, and system is adjusted the tensioning degree of chain in real time by controlling hydraulic efficiency pressure system.Microcontroller is by gathering above sensor signal, after the actual load carried of slat conveyer running state, chain tension state and slat conveyer is comprehensively judged, the driver element of microcontroller is controlled hydraulic efficiency pressure system the stroke of scraper conveyor tail is adjusted, change the running state of chain, and after appearring in chain, chain jamming, chain rupture fault carry out emergency protection to combined switch, the concurrent alerting signal that is out of order by sending failure alarm signal; By microcontroller, the signal gathered is analyzed, is processed, shown and uploaded simultaneously, for operating personal provides the operation information of slat conveyer.
Concrete method of measurement described in the present invention is: by wireless measurement unit acquisition link annular change information, calculate the chain tension of slat conveyer, again by judging whether power assesses the chain running state with the load coupling, finally according to judged result, by driver element, hydraulic efficiency pressure system is controlled, and then adjusted the tensioning degree of chain; According to characteristic signals such as the rotating speed monitored, tension force, carry out information fusion simultaneously.When chain breaks down, send breakdown signal and to combined switch, it is protected, the concurrent alerting signal that is out of order; When the chain trouble free, according to the state of chain, adjust in real time.The deformation data of chain is by the collection of wireless measurement unit and send data to microcontroller, and microcontroller calculates the now tensile force of scraper conveyer chain; Be with the coal winning machine position difference rule that slope changes according to the slat conveyer load, in whole slat conveyer traffic coverage, driving surface is divided into to zones of different, the coefficient of weight that each zone is corresponding different, the load of slat conveyer calculates by fully loaded transportation volume, coefficient of weight and motor current value; Microcontroller is by gathering scraper conveyor tail motor current signal, motor speed signal and coalcutter, slat conveyer start stop signal, character pair information when itself and chain jamming, chain rupture accident are occurred is compared, comprehensively judge whether chain chain jamming or chain rupture fault occur, and by driver element, the scraper conveyer chain tensioning degree is dynamically adjusted, by communication unit, failure alarm signal is sent to combined switch, image data and failure alarm signal are uploaded to the ground maneuvers chamber.
Chain jamming described in the present invention, the concrete determination methods of chain rupture fault are:
During chain jamming, motor speed descends rapidly, and the data that the combining wireless measuring unit is beamed back judge that whether chain tension is normal, if now chain tension has exceeded normal measurement range, thinks slat conveyer generation chain jamming accident;
During chain rupture, motor speed first descends and rises, if the simultaneous chain tension first increases, reduces and is stabilized in minimal value, thinks slat conveyer generation chain rupture accident.
The present invention adopts modular system architecture, by micro controller unit, the wireless measurement unit, the AC sampling unit, the analog quantity conditioning unit, display unit, communication unit, push-button unit, switching value unit and driver element form an an organic whole, adopt the wireless measurement technology to monitor more directly and accurately the chain running state, dynamically adjust the state of chain according to load condition, chain jamming is appearring, carry out emergency protection by sending alerting signal to combined switch after chain rupture accident, and carry out fault alarm, improved the safety and stability of slat conveyer operation.
The accompanying drawing explanation
Fig. 1 is composition structured flowchart of the present invention;
Fig. 2 is integral structure schematic diagram of the present invention;
Fig. 3 is general procedure diagram of circuit of the present invention.
The specific embodiment
With specific embodiment, the present invention alleged scraper conveyer chain condition monitoring and protection system are described in further detail below in conjunction with accompanying drawing; the technical personnel in described field is after having read this specific embodiment; can realize technical solutions according to the invention, also can embody advantage of the present invention and good effect simultaneously.
As depicted in figs. 1 and 2; scraper conveyer chain condition monitoring of the present invention and protection system, comprise micro controller unit, wireless measurement unit, AC sampling unit, analog quantity conditioning unit, display unit, communication unit, push-button unit, switching value unit and driver element.
Micro controller unit adopts dual-cpu structure, comprise micro controller unit one and micro controller unit two, its CPU all adopts C8051F020 type micro controller system, micro controller unit one is responsible for data demonstration, key-press input, switching value input and is communicated by letter with micro controller unit two with receiver module, and the responsible collecting sensor signal of micro controller unit two, comprehensive judgement, output drive control and communicates by letter with micro controller unit one.The state value of measuring according to the actual payload calculated and wireless measurement unit, and, in conjunction with the communication information, the data of AC sampling unit and the collection of analog quantity conditioning unit are merged, judge and process, realize the monitoring to the scraper conveyer chain state.Adjust in real time the chain running state according to the variation of load, report to the police after chain jamming, chain rupture accident simultaneously and send breakdown signal to combined switch.By the push-button unit of native system, can be set the working parameter of slat conveyer.The underground work personnel can understand the operation conditions of scraper conveyer chain in time by system displaying device, and, by reserved communication interface, can realize the remote monitor and control to controller.
The wireless measurement unit comprises induction force transducer, signal condition module, transmitter module, receiver module and antenna, wherein responding to force transducer is arranged on scraper conveyer chain, for measuring the longitudinal deformation of chain link, and then obtain the suffered tension force of chain, then by the signal condition module, sensor signal is carried out to differential mode and amplify processing.The wireless measurement unit is used accurate voltage-stabilizing circuit to be powered, thereby guarantees accuracy and the precision of observed reading; Transmitter module transfers to receiver module by wireless telecommunications by the signal of signal condition module output, and receiver module sends data to micro controller unit one by serial communication.
Described AC sampling unit comprises three phase current transformer, phase current modulate circuit and current acquisition module, and this unit input is connected with three phase current transformer; Wherein three phase current transformer is arranged on scraper conveyor tail motor point of incoming cables, and for measuring current of electric, its output connects the phase current modulate circuit; Current acquisition module output interface connects the GPIO mouth of micro controller unit two, and micro controller unit two is by the conversion value in virtual SPI mode reading current acquisition module.This unit radical function is for gathering the instantaneous current value and calculating the alternating current effective value.
The analog quantity conditioning unit, comprise tachogenerator, pressure sensor and stroke sensor, and wherein tachogenerator is arranged on the scraper conveyor tail motor, for measuring motor speed; Pressure sensor and stroke sensor are arranged in the scraper conveyor tail oil cylinder, for measuring oil cylinder working-pressure and oil cylinder stroke, and by establishing a communications link with hydraulic support, the position signal of Real-time Collection coalcutter; This unit be by the tach signal of collection, pressure signal, position signal through Isolation input protective circuit, Bessel filter, follow after circuit, bleeder circuit and pressure limited protection circuit are processed and be connected with 12 A/D pins of micro controller unit two;
Display unit, comprise 128*64 liquid crystal display and 10 cun tangible color screens, liquid crystal display is connected with the GPIO mouth of micro controller unit one, shows measurement value sensor and the operational motion keys such as pressure, stroke, parameter value that can display setting and the parameter value of respective picture; Tangible color screen is placed in explosion-resistant enclosure, by the RS-485 signalling methods, with micro controller unit two, is connected, and can show in real time the information such as sensor collection value, cylinder action state and scrapper conveyor model, and capable of dynamic shows the cylinder movement process.
Communication unit, by two-way RS-485 communication circuit and 1 road SPI communication circuit, formed, wherein between micro controller unit one and micro controller unit two, use the SPI mode to communicate by letter, micro controller unit one is used the RS-485 mode to communicate by letter with the receiver module of wireless measurement unit, and micro controller unit two is used the RS-485 signalling methods with tangible color screen.
Push-button unit, be 4 * 8 matrix keyboards, and its output is connected with the GPIO mouth of micro controller unit one, and the working parameter of native system is arranged.
The switching value unit, comprise coalcutter and slat conveyer actuation signal, scram button signal, and scram button is connected with the middle fracture 0 of micro controller unit one, and rest switch amount incoming signal is connected with the GPIO mouth of micro controller unit one.
Driver element, that the control driving circuit of native system is connected with the GPIO mouth of micro controller unit two, by controlling electromagnetic priority valve, hydraulic efficiency pressure system is regulated, and then adjusted scraper conveyor tail, make chain maintain all the time a comparatively ideal tensioning state.
As shown in Figure 2, three phase current transformer is the input end that secondary current that numerical value is less flows to three tunnel phase current modulate circuits by the once large current transformation in the slat conveyer motor, and acquisition of signal, the processing to phase current mainly realized in the AC sampling unit.The incoming signal of switching value unit comprises coalcutter start stop signal, scrapper conveyor motor start stop signal, emergent stop signal, the start stop signal of coalcutter and scrapper conveyor is as the condition precedent that whether chain is carried out to degree of tension control, only has when coalcutter and slat conveyer all normally move and just the chain tension degree of slat conveyer controlled; Emergent stop signal drives function for the output that stops controller.Driver element is realized the control to electromagnetic priority valve, and communication unit comprises the communication of slat conveyer substation and display unit, receiver module and mine remote control center, facilitates the running state of mine remote monitor and control slat conveyer.Push-button unit can be arranged the working parameter of native system.
Specific works process of the present invention is as follows:
(1) after powering on, at first carry out self check, the self check content comprises whether slat conveyer starts, whether coalcutter starts, whether sensor connects normally, force value and shift value no to scale etc. whether;
(2) after obtaining allowing actuation signal, can select start-up mode: pre-tensioner pattern, manual master mode, automatic control mode; After selecting corresponding modes, micro controller unit gathers the monitoring data of each sensor output, and to signal amplified, filtering, voltage protection is processed, and through the A/D interface conversion, is the discernible digital signal of micro controller unit two; After two pairs of signals of micro controller unit are judged, chain chain rupture, chain jamming state are assessed, controlled the driver element action and judge whether to send alerting signal according to assessment result, and showing the running state of current chain and oil cylinder.Under pre-tensioner pattern, optimum value when chain tension is adjusted to zero load; Under manual mode, by hand push button, according to the chain correlation behavior parameter gathered, regulated; Under automatic mode, micro controller unit, after the information fusion obtained by sensor, communication, is adjusted the state of scraper conveyer chain automatically by actuating unit;
(3) while needing emergent stopping when running into emergency case or fault, can carry out the emergent stopping operation by the scram button on the micro controller unit front panel, now the microprogrammed control unit control signal stops output, does not carry out any action, and display unit shows the anxious state that stops that enters; After emergency case or fault disappearance, the rotatable scram button transmission solution that pulls up is stopped signal, and micro controller unit recovers normal working, and display unit shows monitoring information simultaneously.
As shown in Figure 3, in the present invention, microcontroller adopts dual-cpu structure, primary data is processed and comprehensive judgement to take C8051F020 type micro controller system be core.Integrated two ADC modules in this micro controller system, wherein the ADC0 module is 8 Channel 12-Bit A/D converters, communication interface comprises UART0, UART1 and SPI.Two pairs of sensor informations of obtaining of micro controller unit one and micro controller unit are gathered, are nursed one's health and merged, and according to setting valve, operation chain state adjustment programme and chain jamming, chain rupture fault detection program are adjusted the tensioning degree of chain in good time.According to wireless measurement unit monitoring chain running state, and obtain effective monitor value by software filtering, control the actuating unit actions such as electromagnetic priority valve, hydraulic ram by driver element after the comprehensive judgement of microcontroller, realize the automatic adjusting to the scraper conveyer chain running state.Judge chain jamming, the chain rupture fault of chain by motor speed signal and chain tension signal; after occurring, fault closes in time the output of driver element; prevent the expansion of fault; micro controller unit two sends breakdown signal to the power control switch; carry out sound and light alarm simultaneously, realize the emergency protection to slat conveyer.
The foregoing is only preferred embodiment of the present invention, it is not limitation of the invention, relating in this manual other technology contents and technical term should understand and implement according to common practise and the habitual technological means of this area, also can enforcement be set by rational analysis ratiocination.
Claims (3)
1. a scraper conveyer chain condition monitoring and protection system, is characterized in that: comprise micro controller unit, wireless measurement unit, AC sampling unit, analog quantity conditioning unit, display unit, communication unit, push-button unit, switching value unit and driver element;
Described micro controller unit adopts dual-cpu structure, the real-time of controlling for the raising system;
Described wireless measurement unit, comprise induction force transducer, signal condition module, transmitter module, receiver module and antenna, wherein respond to force transducer and be arranged on scraper conveyer chain, for measuring the longitudinal deformation of chain link, and then obtain the suffered tension force of chain; By this unit, the chain tension information of measurement is sent to micro controller unit;
Described AC sampling unit comprises three phase current transformer, phase current modulate circuit and current acquisition module, and this unit input is connected with three phase current transformer; Wherein three phase current transformer is arranged on scraper conveyor tail motor point of incoming cables, and for measuring current of electric, output connects the phase current modulate circuit; Current acquisition module output interface connects the GPIO mouth of microcontroller, by virtual SPI mode, carries out reading of current value;
Described analog quantity conditioning unit, comprise tachogenerator, pressure sensor and stroke sensor, and wherein tachogenerator is arranged on the scraper conveyor tail motor, for measuring motor speed; Pressure sensor and stroke sensor are arranged in the scraper conveyor tail oil cylinder, for measuring oil cylinder working-pressure and oil cylinder stroke, and by establishing a communications link with hydraulic support, the position signal of Real-time Collection coalcutter; This unit be by the signal of collection through Isolation input protective circuit, Bessel filter, follow after circuit, bleeder circuit and pressure limited protection circuit are processed and be connected with the A/D pin of microcontroller;
Described display unit, comprise liquid crystal display and tangible color screen, and liquid crystal display is connected with the GPIO mouth of microcontroller, and tangible color screen is placed in explosion-resistant enclosure, by signalling methods, with microcontroller, is connected;
Described communication unit, by two-way RS-485 communication circuit and 1 road SPI communication circuit, formed, wherein between microcontroller, use the SPI mode to communicate by letter, microcontroller uses the RS-485 mode to communicate by letter with the receiver module of wireless measurement unit, and microcontroller and tangible color screen are used the RS-485 signalling methods;
Described push-button unit, be 4 * 8 matrix keyboards, and its output is connected with the GPIO mouth of microcontroller, and the working parameter of native system is arranged;
Described switching value unit, comprise coalcutter and slat conveyer actuation signal, scram button signal, and scram button is connected with the middle fracture 0 of microcontroller, and rest switch amount incoming signal is connected with the GPIO mouth of microcontroller;
Described driver element, that the control driving circuit of native system is connected with the GPIO mouth of microcontroller, by controlling electromagnetic priority valve, hydraulic efficiency pressure system is regulated, and then adjusted scraper conveyor tail, make chain maintain all the time a comparatively ideal tensioning state.
2. scraper conveyer chain condition monitoring according to claim 1 and protection system; it is characterized in that: described micro controller unit comprises micro controller unit one and micro controller unit two; its CPU all adopts C8051F020 type micro controller system; micro controller unit one is responsible for data demonstration, key-press input, switching value input and is communicated by letter with micro controller unit two with receiver module, and the responsible collecting sensor signal of micro controller unit two, comprehensive judgement, output drive control and communicates by letter with micro controller unit one.
3. scraper conveyer chain condition monitoring according to claim 1 and protection system, it is characterized in that: in described display unit, liquid crystal display is the 128*64 liquid crystal display, tangible color screen is 10 cun tangible color screens.
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