CN110142084B - Crushing cavity wear monitoring method - Google Patents
Crushing cavity wear monitoring method Download PDFInfo
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- CN110142084B CN110142084B CN201910281688.8A CN201910281688A CN110142084B CN 110142084 B CN110142084 B CN 110142084B CN 201910281688 A CN201910281688 A CN 201910281688A CN 110142084 B CN110142084 B CN 110142084B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C25/00—Control arrangements specially adapted for crushing or disintegrating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C2/00—Crushing or disintegrating by gyratory or cone crushers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C23/00—Auxiliary methods or auxiliary devices or accessories specially adapted for crushing or disintegrating not provided for in preceding groups or not specially adapted to apparatus covered by a single preceding group
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C2210/00—Codes relating to different types of disintegrating devices
- B02C2210/01—Indication of wear on beaters, knives, rollers, anvils, linings and the like
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- Food Science & Technology (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
- Length Measuring Devices Characterised By Use Of Acoustic Means (AREA)
- Disintegrating Or Milling (AREA)
Abstract
The embodiment of the invention provides a crushing cavity wear monitoring method, and belongs to the technical field of crushing equipment operation state monitoring. The crushing cavity wear monitoring method comprises the following steps: acquiring a feedback signal with the cavity shape characteristics of the crushing cavity at each detection node at different positions of the crushing cavity, and performing the next step when the feedback signal meets a first preset monitoring condition; selecting a current detection node, and determining the local characteristics of the cavity shape of the crushing cavity according to the distance between the current detection node and an adjacent detection node, a feedback signal corresponding to the current detection node and a feedback signal corresponding to the adjacent detection node; and when the wear rate corresponding to the cavity local characteristics meets a second preset monitoring condition, jumping to a second step to form a cyclic monitoring process. The invention monitors the abrasion condition of the lining plate and the change condition of the structural shape of the crushing cavity by detecting the characteristics of the position and the characteristics of the current detected local area, can predict the service life of the lining plate and creates conditions for reasonably making the operation and maintenance plan of the crusher.
Description
Technical Field
The invention relates to the technical field of monitoring of running states of crushing equipment, in particular to a method and a structure for monitoring wear of a crushing cavity.
Background
The working mechanism of the crusher consists of a fixed lining plate and a movable lining plate, and the area between the working surfaces of the lining plates is a crushing cavity. In the crushing process, the movable lining plate swings relative to the fixed lining plate according to a certain rule to crush the materials in the crushing cavity, so that the particle size of the materials is continuously reduced until the materials are discharged out of the crushing cavity.
During crushing, the material in the crushing chamber will cause wear to the fixed and movable liners, which changes the shape of the crushing chamber, resulting in a deterioration of the quality of the crushed product. The method for evaluating the abrasion loss and the distribution area of the lining plate mainly comprises two methods, namely judging the abrasion condition of the lining plate by the ore crushing amount, the discharge granularity, the working time of the lining plate and the like; and secondly, the crushing equipment is disassembled, and the abrasion condition of the lining plate is accurately judged. Obviously, the first method can only carry out fuzzy estimation on the abrasion condition of the lining plate, and cannot determine the abraded part of the lining plate, so that effective guidance is difficult to provide for crushing production; the second method can obtain the direct result of the abrasion condition of the lining plate, but the disassembly crushing equipment has large workload and long construction period, and the production of the crushing procedure is seriously influenced.
The technology related to the invention in the aspect of automatic control of the crushing process mainly comprises the following steps:
the first crusher controller in China is a crusher controller combined with an automatic control technology by the Maanshan mine research institute, the controller realizes the load control and fault diagnosis and protection of the crusher, the fine crushing capacity and granularity are improved, and the crushing energy consumption and equipment faults are reduced.
The system realizes the monitoring of the oil level of a lubricating system, the cleanliness of lubricating oil and the temperature of a lubricating part, and the sensing of the pressure, the temperature, the flow, the pressure difference and the liquid level of a hydraulic system of the crusher, and can automatically adjust the size of a mine discharge port by using the hydraulic system. In addition, by developing a power controller, effective monitoring of crushing load is achieved.
Thirdly, a cone crusher control technology based on PLC and WINCC, the technology adopts a two-stage three-layer system structure combining an upper computer and a controller, and the upper computer mainly realizes functions of programming, configuration, monitoring and the like; the lower computer is composed of a PLC and controlled equipment, and realizes automatic adjustment of the ore discharge port and comprehensive monitoring of the crushing process.
And fourthly, the intelligent control system of the cone crusher takes Siemens S7-200smart PLC as a control core, adopts WINCC as upper machine configuration software, and has the functions of data acquisition, automatic process control, equipment running state information recording, storage, display, alarm and the like.
And fifthly, the crusher controller system based on the PLC uses a touch screen as a human-computer interface, a position transmitter is used for detecting the ore discharge port of the cone crusher, a temperature transmitter is used for detecting the temperature of lubricating oil, a pressure transmitter is used for detecting the pressure of the lubricating oil, and a power transmitter is used for detecting the power of the driving motor, the PLC outputs certain control quantity by applying a fuzzy control model according to collected data, the rotating speed of the ore feeding motor is adjusted by a frequency converter, the size of the ore discharge port is adjusted by a servo valve of a hydraulic system, and the control target of stable working load of the crusher is realized.
The research on the automatic control of the foreign crusher is much earlier than that in China, and the product automation degree of several crusher manufacturers such as Stevila corporation, mountain Vickers and Fullersmith is very high. The HP series crushers developed by the American & Olympic company, particularly the crushers with HP500 models and HP800 models, are widely introduced and applied in the crushing industry of China, and the crushing ratio and the crushing processing capacity are greatly improved.
Through the analysis, the existing crusher control technology only relates to the detection and control of the operation parameters, equipment state parameters and crushing process parameters of the crusher, and does not relate to the remote detection of the crushing lining plate.
With the effective integrated application of wireless sensing technology, automatic control technology and crushing equipment technology, the patents related to the technology mainly include:
a crusher remote intelligent monitoring system (CN 201410475207.4) based on ZigBee wireless technology is composed of a computer, a PC, coordinator nodes, RS232 and node wireless sensors, controllers and execution devices distributed all over a crusher are connected into a measurement and control network through a ZigBee wireless module, and a rubber belt conveyor, a feeder, a primary crusher, a circular vibrating screen and a secondary crusher are remotely controlled and managed. The patent technology realizes the remote control of the crushing operation rules, but does not relate to the intelligent detection technology of the abrasion of the lining plate.
The automatic control system (CN 201510292022.4) of the crusher comprises an acousto-optic monitoring module, an operating state monitoring module, a control operation module, a signal standardization module, a central control module, an optimization processing module, a historical database and the like. The operation parameters, the production process parameters, the equipment state parameters and the like of the crusher can be monitored and optimally controlled, and the intelligent control of the crusher is better realized. The patent technology also does not relate to intelligent detection technology of wear of the lining plate.
The above patent technologies related to the present invention do not relate to the actual monitoring of the wear amount of the lining plate and the analysis method of the change condition of the crushing cavity caused by the wear of the lining plate. Therefore, the wireless sensing technology and the ultrasonic distance measuring principle are adopted, the lining plate abrasion wireless monitoring technology is developed, and the change condition of the crushing cavity is researched, so that the problems to be solved by the technical personnel in the field are solved.
Disclosure of Invention
The embodiment of the invention aims to provide a crushing cavity wear monitoring method and a monitoring structure thereof, and aims to solve the technical problems that the service life of a lining plate cannot be updated and predicted according to the dynamic service condition of a crusher, the lining plate which is about to reach the wear limit cannot be replaced or maintained in advance, the local area characteristics among nodes cannot be monitored and detected, the crusher has high operation cost and high wear rate and the like in the prior art.
In order to achieve the above object, embodiments of the present invention provide a method and a structure for monitoring wear of a crushing chamber.
A monitoring method performed by a crushing chamber service node, the monitoring method comprising the steps of:
s1) obtaining feedback signals with the cavity shape characteristics of the crushing cavity of each detection node at different positions of the crushing cavity, and carrying out the next step when the feedback signals meet first preset monitoring conditions, wherein,
the detection nodes are provided with ultrasonic ranging sensors, transmitting wafers and receiving wafers of the ultrasonic ranging sensors are installed in blind holes on one side of the non-working face of the lining plate of the crushing cavity, the cavity shape characteristics of the crushing cavity comprise the thickness of the lining plate measured by each detection node of the crushing cavity, the first preset monitoring condition is set that the proportion of the thickness of the lining plate, which is smaller than or equal to the preset minimum residual thickness of the lining plate, to the total feedback signal quantity is within a preset proportion threshold range,
the service node is a computing device which comprises an ultrasonic distance measurement and transmission module and an upper computer, the ultrasonic distance measurement and transmission module comprises a first single chip microcomputer and a first radio frequency wireless communication module, the upper computer comprises a second single chip microcomputer and a second radio frequency wireless communication module, the first single chip microcomputer and the second single chip microcomputer are in wireless communication through the first radio frequency wireless communication module and the second radio frequency wireless communication module,
the ultrasonic ranging and transmitting module also comprises a transmitting circuit and a receiving circuit which are connected with the first singlechip, the transmitting circuit is coupled with the transmitting wafer, the receiving circuit is coupled with the receiving wafer,
the ultrasonic ranging and transmission module further comprises a counter,
the first singlechip drives the transmitting circuit to send a plurality of rectangular pulse high-voltage signals to the transmitting wafer, the transmitting wafer converts the rectangular pulse high-voltage signals to obtain ultrasonic pulse wave signals with the same frequency, and simultaneously the first singlechip controls the counter to start counting,
the ultrasonic distance measuring and transmitting module comprises a lining plate, a transmitting wafer, a receiving wafer, a signal amplifying circuit, a signal modulator, a first singlechip, a second singlechip, a counter and a distance measuring and transmitting module, wherein the transmitting wafer transmits an ultrasonic pulse signal obtained by conversion to the working surface of the lining plate to be reflected, the receiving wafer receives the reflected ultrasonic pulse signal and transmits the ultrasonic pulse signal to the receiving circuit, the ultrasonic distance measuring and transmitting module further comprises the signal amplifying circuit and the signal modulator, the signal amplifying circuit and the signal modulator amplify, filter and shape the electric pulse signal and convert the electric pulse signal into a countable rectangular wave signal with thickness value and pulse width, the first singlechip transmits external interrupt for stopping counting of the counter, and the counter stops counting,
the ultrasonic distance measurement and transmission module is used for calculating the ultrasonic propagation time slot of each detection node according to the counting of the counter, calculating the thickness of the lining plate measured by each detection node according to the ultrasonic propagation time slot and the propagation speed of each detection node,
the ultrasonic ranging and transmission module sends the feedback signal to the upper computer,
the feedback signal is a radio frequency signal and is used for transmitting the thickness of the lining plate measured by each detection node to the upper computer;
s2) selecting a current detection node, and determining a cavity shape local characteristic of the crushing cavity according to the distance between the current detection node and an adjacent detection node, the thickness of a lining plate measured by the current detection node and the thickness of the lining plate measured by the adjacent detection node, wherein the cavity shape local characteristic comprises the areas of wear areas corresponding to the current detection node and the adjacent detection node;
s3) when the wear rate corresponding to the cavity local feature meets a second preset monitoring condition, skipping to the step S2) to form a loop monitoring process, wherein the second preset monitoring condition is set that the wear rate is within a preset wear threshold range, and the wear rate is the area ratio of the area of the wear lining plate area to the area of the original lining plate area,
the area of the original lining plate area is determined according to the distance between the ultrasonic distance measuring sensors corresponding to the current detection node and the adjacent detection node and one side of the working surface of the lining plate and the original thickness of the lining plate at the position of the ultrasonic distance measuring sensors.
Optionally, in step S1), a feedback signal having a thickness of the lining plate measured from the wall of the crushing cavity to the currently corresponding detection node is obtained corresponding to each detection node, where the wall of the crushing cavity is an inner wall, and the thickness of the lining plate is specifically a distance from the wall of the crushing cavity to the currently corresponding detection node;
step S1), a minimum distance and a ratio threshold are preset, and then a first preset monitoring condition is set when the ratio of the minimum distance feedback signal number to the total feedback signal number is within the ratio threshold range, and when the feedback signal satisfies the first preset monitoring condition, step S2) is performed. The proportional threshold range may be designed in such a way that at least one of the feedback signals is present and the distance characteristic represented by the at least one feedback signal is less than or equal to the minimum distance.
A service node for monitoring a crushing chamber, the service node performing a service node in a monitoring method for the aforementioned crushing chamber service node, comprising:
the computing equipment is used for computing the measured thickness of each detection node at different positions of the crushing cavity;
the computing equipment comprises an upper computer and an ultrasonic distance measuring and transmitting module, wherein the upper computer is connected with the ultrasonic distance measuring sensor in the detection node through the ultrasonic distance measuring and transmitting module.
The ultrasonic distance measurement and transmission module comprises a first single chip microcomputer and a first radio frequency wireless communication module, the upper computer comprises a second single chip microcomputer and a second radio frequency wireless communication module, the first single chip microcomputer and the second single chip microcomputer are in wireless communication through the first radio frequency wireless communication module and the second radio frequency wireless communication module,
the ultrasonic ranging and transmitting module also comprises a transmitting circuit and a receiving circuit which are connected with the first singlechip, the transmitting circuit is coupled with the transmitting wafer, the receiving circuit is coupled with the receiving wafer,
the ultrasonic ranging and transmission module further comprises a counter,
the first singlechip drives the transmitting circuit to send a plurality of rectangular pulse high-voltage signals to the transmitting wafer, the transmitting wafer converts the rectangular pulse high-voltage signals to obtain ultrasonic pulse wave signals with the same frequency, and simultaneously the first singlechip controls the counter to start counting,
the ultrasonic distance measuring and transmitting module comprises a lining plate, a transmitting wafer, a receiving wafer, a signal amplifying circuit, a signal modulator, a first singlechip, a second singlechip, a counter and a distance measuring and transmitting module, wherein the transmitting wafer transmits an ultrasonic pulse signal obtained by conversion to the working surface of the lining plate to be reflected, the receiving wafer receives the reflected ultrasonic pulse signal and transmits the ultrasonic pulse signal to the receiving circuit, the ultrasonic distance measuring and transmitting module further comprises the signal amplifying circuit and the signal modulator, the signal amplifying circuit and the signal modulator amplify, filter and shape the electric pulse signal and convert the electric pulse signal into a countable rectangular wave signal with thickness value and pulse width, the first singlechip transmits external interrupt for stopping counting of the counter, and the counter stops counting,
the ultrasonic distance measurement and transmission module is used for calculating the ultrasonic propagation time slot of each detection node according to the counting of the counter, calculating the thickness of the lining plate measured by each detection node according to the ultrasonic propagation time slot and the propagation speed of each detection node,
the ultrasonic ranging and transmission module sends the feedback signal to the upper computer,
the feedback signal is a radio frequency signal and is used for transmitting the thickness measured by each detection node to the upper computer.
Optionally, the blind hole is further filled with a coupling agent.
Through the technical scheme, the embodiment of the invention has the following beneficial effects:
by adopting an ultrasonic thickness measurement method and a wireless sensing technology, a multi-level wireless intelligent monitoring system consisting of ultrasonic thickness measurement of the lining plate at the bottom layer and analysis and monitoring of an upper computer is established, so that the requirement of measuring the thickness of the lining plate in a closed and narrow space can be met;
under the condition of not disassembling the crushing and grinding equipment, the abrasion condition of a lining plate inside the crushing and grinding equipment and the change condition of a crushing and grinding cavity structure can be monitored in real time, so that the problem of poor prediction accuracy of the service life of the lining plate of the current crushing and grinding equipment is solved;
the local detection area is constructed by detecting the distance between the nodes and the thickness from the detection node to the working surface of the lining plate, and the local abrasion problem of the area between part of the detection node and the adjacent detection node can be found immediately, so that workers can consider improving input materials or maintaining the lining plate in advance aiming at the local abrasion problem, and avoid serious crushing cavity faults or accidents;
the service life of the lining plate can be predicted and the structural degradation of the grinding cavity can be analyzed by combining the thickness of the lining plate, and a reliable basis is provided for quantitative analysis of the structural degradation of the grinding cavity according to the abrasion condition of the lining plate, so that conditions are created for accurately predicting the service life and the grinding efficiency of the lining plate and reasonably making a maintenance plan of grinding equipment.
Additional features and advantages of embodiments of the invention will be set forth in the detailed description which follows.
Drawings
FIG. 1 is a schematic view of a monitoring structure according to an embodiment of the present invention;
FIG. 2 is a schematic structural view of a mounting hole of a liner plate according to an embodiment of the present invention;
FIG. 3 is a schematic view of a crushing chamber and sensors disposed on a backing plate in accordance with an embodiment of the present invention;
FIG. 4 is a schematic diagram of a structural analysis of a crushing chamber according to an embodiment of the present invention;
fig. 5 is a schematic diagram of a liner intelligent monitoring process according to an embodiment of the invention.
Description of the reference numerals
1 moving cone lining board
11 initial contour line of working surface of moving cone lining plate
12 non-working surface of moving cone lining plate
13 moving cone lining plate ultrasonic sensor mounting hole
Actual contour line of 14 moving cone lining plate after working surface is worn
2 ultrasonic distance measuring sensor
21 transmitting wafer for ultrasonic ranging
22 ultrasonic ranging receiving wafer
3 coupling agent
4 ultrasonic distance measurement and transmission module
41 receiving circuit
42 signal amplifier
43 signal modulator
44 counter
45 AT89C51 singlechip A
46 radio frequency wireless communication module A
47 temperature acquisition circuit
48 power supply module
49 transmitting circuit
5 Upper computer
51 alarm module
52 radio frequency wireless communication module
53 AT89C51 singlechip B
54 memory module
55 display module
56 interaction module
6 fixed cone lining board
Initial contour line of working surface of 61 fixed cone lining plate
Non-working surface of 62 fixed cone lining board
63 fixed cone lining board ultrasonic sensor mounting hole
Actual contour line of working surface of 64 fixed-cone lining plate after abrasion
Detailed Description
The following detailed description of embodiments of the invention refers to the accompanying drawings. It should be understood that the detailed description and specific examples, while indicating embodiments of the invention, are given by way of illustration and explanation only, not limitation.
Example 1
A service node for monitoring a crushing chamber, comprising:
the calculating equipment is used for calculating the measured thickness of the lining plate of each detection node at different positions of the crushing cavity;
the computing equipment comprises an upper computer and an ultrasonic distance measuring and transmitting module, wherein the upper computer is connected with the ultrasonic distance measuring sensor in the detection node through the ultrasonic distance measuring and transmitting module.
The ultrasonic ranging and transmission module 4 comprises a first single chip microcomputer 45 and a first radio frequency wireless communication module 46, the upper computer 5 comprises a second single chip microcomputer 53 and a second radio frequency wireless communication module 52, the first single chip microcomputer 45 and the second single chip microcomputer 53 are in wireless communication through the first radio frequency wireless communication module 46 and the second radio frequency wireless communication module 52, the ultrasonic ranging and transmission module 4 further comprises a transmitting circuit 49 and a receiving circuit 41 which are connected with the first single chip microcomputer 45, the transmitting circuit 49 is coupled with the transmitting wafer 21, the receiving circuit 41 is coupled with the receiving wafer 22, the ultrasonic ranging and transmission module 4 further comprises a counter 44,
the first single chip microcomputer 45 drives the transmitting circuit 49 to send a plurality of rectangular pulse high voltage signals to the transmitting wafer 21, the transmitting wafer 21 converts the plurality of rectangular pulse high voltage signals into ultrasonic pulse wave signals with the same frequency, meanwhile, the first single chip microcomputer 45 also controls the counter 44 to start counting, the transmitting wafer 21 sends the converted ultrasonic pulse signals to reach the working surface of the lining plate for reflection, the receiving wafer 22 receives the reflected ultrasonic pulse signals and transmits the ultrasonic pulse signals to the receiving circuit 41, the ultrasonic distance measuring and transmitting module 4 further comprises a signal amplifying circuit 42 and a signal modulator 43, the signal amplifying circuit 42 and the signal modulator 43 perform signal amplification, filtering and shaping processing on the electric pulse signals and convert the electric pulse signals into rectangular wave signals with thickness value pulse width which can be counted, the first single chip microcomputer 45 sends an external interrupt for stopping counting of the counter, the counter 44 stops counting, the ultrasonic ranging and transmission module 4 is used for calculating ultrasonic propagation time slots of all detection nodes according to counting of the counter 44 and calculating thickness of the lining board measured by all the detection nodes according to the ultrasonic propagation time slots and the propagation speed of all the detection nodes, the ultrasonic ranging and transmission module 4 sends the feedback signal to the upper computer 5, and the feedback signal is a radio frequency signal and is used for transmitting the thickness of the lining board measured by all the detection nodes to the upper computer 5.
The detection node is provided with an ultrasonic ranging sensor 2, a transmitting wafer 21 and a receiving wafer 22 of the ultrasonic ranging sensor 2 are installed in blind holes on one side of the non-working surface of a lining plate of the crushing cavity, the transmitting wafer 21 is coupled with a transmitting circuit 49 in the ultrasonic ranging and transmission module 4, and the receiving wafer 22 is coupled with a receiving circuit 41 in the ultrasonic ranging and transmission module 4.
The utility model provides an on-line monitoring system of welt thickness, includes moving cone welt 1, fixed cone welt 6, ultrasonic ranging sensor 2, couplant 3, ultrasonic ranging and transmission module 4 and host computer 5. Ultrasonic ranging sensor 2 comprises emission wafer 21 and receiving wafer 22, ultrasonic ranging sensor 2 installs in the blind hole 13 of 1 non-working face one side of welt 1 in the blind hole 13 of welt with insert couplant 3 between the ultrasonic ranging sensor 2, ultrasonic ranging sensor 2's emission wafer 21 is connected with ultrasonic ranging and transmission module 4's transmitting circuit 49, ultrasonic ranging sensor 2's receiving wafer 22 is connected with ultrasonic ranging and transmission module 4's receiving circuit 41, host computer 5 pass through wireless communication mode with ultrasonic ranging is connected with transmission module 4.
The working surface 11 of the moving cone lining plate 1 and the working surface 61 of the fixed cone lining plate 6 form an initial crushing cavity before abrasion or an actual crushing cavity after abrasion.
The couplant 3 is filled in the gap between the lining plate blind hole 13 and the ultrasonic ranging sensor 2.
The input end of a transmitting circuit 49 in the ultrasonic ranging and transmission module 4 is connected with an AT89C51 singlechip 45, and the output end is connected with a transmitting wafer 21; the input end of a receiving circuit 41 in the ultrasonic ranging and transmission module 4 is connected with the receiving wafer 22, the receiving circuit 41, the signal amplifier 42, the signal modulator 43 and the counter 44 are sequentially connected, the output ends of the receiving circuit 41, the signal amplifier 42, the signal modulator 43 and the counter 44 are all connected with an AT89C51 single chip microcomputer 45, and the radio frequency wireless communication module 46, the temperature acquisition module 47 and the power supply module 48 are also connected with the AT89C51 single chip microcomputer 45.
The alarm module 51, the radio frequency wireless communication module 52, the storage module 54, the display module 55 and the interaction module 56 in the upper computer 5 are all connected with the AT89C51 single chip microcomputer 53.
The ultrasonic thickness measuring method for the lining plate under the same conception is executed through the online monitoring system for the thickness of the lining plate, and comprises the following steps of:
firstly, ultrasonic distance measuring sensors arranged on the non-working surface sides of a moving cone lining plate 1 and a fixed cone lining plate 6 are controlled by an AT89C51 singlechip 45 to emit ultrasonic waves, and start counting t, wherein the ultrasonic waves are transmitted to the surface of the lining plate through a coupling agent 3 and are transmitted in the lining plate AT a certain wave speed C; when the ultrasonic wave is transmitted to the working surface of the lining plate, the ultrasonic wave is reflected, the reflected ultrasonic wave is received by the ultrasonic receiver, meanwhile, the AT89C51 single chip microcomputer 45 realizes external interruption, and the counter stops counting;
secondly, respectively calculating the ultrasonic propagation time slots delta t of each measuring point on the moving cone lining plate 1 and the fixed cone lining plate 6i；
Third, according to the propagation time slot delta tiEach on the lining plate 1 of the calculation movable coneThickness of measuring point
And the thickness of each measuring point on the fixed cone lining board 6
Fourthly, transmitting the thickness of each measuring point of the moving cone lining plate 1 and the fixed cone lining plate 6 to the upper computer 5 in a wireless communication mode;
the intelligent analysis method for the service life of the lining plate under the same conception is executed through the online monitoring system for the thickness of the lining plate, and comprises the following steps of:
firstly, respectively determining the abrasion loss of each measuring point on a moving cone lining plate 1 and a fixed cone lining plate 6 by comparing the actual lining plate thickness with the initial lining plate thickness;
secondly, respectively determining the residual life of the moving cone lining plate 1 and the fixed cone lining plate 6 according to the abrasion loss of each measuring point;
and thirdly, transmitting the residual service life of each measuring point of the moving cone lining plate 1 and the fixed cone lining plate 6 to the upper computer 5 in a wireless communication mode.
The crushing cavity structure analysis method based on the same conception is executed through the online monitoring system of the thickness of the lining plate, and comprises the following steps of:
firstly, drawing an initial crushing cavity structure before abrasion according to initial structures of a moving cone lining plate 1 and a fixed cone lining plate 6;
secondly, periodically drawing a worn crushing cavity structure according to the thickness of each measuring point on the moving cone lining plate 1 and the fixed cone lining plate 6;
thirdly, comparing the actual worn crushing cavity structure with the crushing cavity structure before wear, and analyzing the change condition of the worn crushing cavity structure;
and fourthly, providing a basis for reasonably formulating an overhaul plan of the crusher or the ball mill on the basis of the comprehensive abrasion conditions of the movable cone lining plate 1 and the fixed cone lining plate 6 and the change conditions of the geometrical structure of the crushing cavity.
Example 2
Based on embodiment 1, as shown in fig. 1, the invention discloses an intelligent lining board, which comprises a moving cone lining board 1, a fixed cone lining board 6, an ultrasonic distance measuring sensor 2, a coupling agent 3, an ultrasonic distance measuring and transmitting module 4 and an upper computer 5. Ultrasonic ranging sensor 2 comprises emission wafer 21 and receiving wafer 22, ultrasonic ranging sensor 2 installs in the blind hole 13 of 1 non-working face one side of welt 1 in the blind hole 13 of welt with insert couplant 3 between the ultrasonic ranging sensor 2, ultrasonic ranging sensor 2's emission wafer 21 is connected with ultrasonic ranging and transmission module 4's transmitting circuit 49, ultrasonic ranging sensor 2's receiving wafer 22 is connected with ultrasonic ranging and transmission module 4's receiving circuit 41, host computer 5 pass through wireless communication mode with ultrasonic ranging is connected with transmission module 4.
The input end of a transmitting circuit 49 in the ultrasonic ranging and transmission module 4 is connected with an AT89C51 singlechip 45, and the output end is connected with a transmitting wafer; the input end of a receiving circuit 41 in the ultrasonic ranging and transmission module 4 is connected with the receiving wafer 22, the receiving circuit 41, the signal amplifier 42, the signal modulator 43 and the counter 44 are sequentially connected, the output ends of the receiving circuit 41, the signal amplifier 42, the signal modulator 43 and the counter 44 are connected with an AT89C51 single chip microcomputer 45, a radio frequency wireless communication module 46, a temperature acquisition module 47 and a power supply module 48 are also connected with the AT89C51 single chip microcomputer 45, and the power supply module 48 supplies power for the AT89C51 single chip microcomputer 45.
The alarm module 51, the radio frequency wireless communication module 52 (i.e. the second radio frequency wireless communication module), the storage module 54, the display module 55 and the interaction module 56 in the upper computer 5 are all connected with the AT89C51 single chip microcomputer 53.
The ultrasonic online monitoring method suitable for the thickness of the lining plate under the same conception comprises the following steps:
firstly, measuring point arrangement: a plurality of mounting holes 63 are respectively processed at specific positions of the mounting hole 13 of the moving cone lining plate 1 and the fixed cone lining plate 6, and the ultrasonic distance measuring sensor 2 is mounted in the holes, as shown in fig. 2 and 3 respectively;
step two, setting parameters: the original thickness (h) of each measuring point of the moving cone lining plate 1 and the fixed cone lining plate 6 is set through an interactive module 56 of the upper computer 50)i(i ═ 1,2, …, n), threshold value Δ h for minimum residual thicknessi(i ═ 1,2, …, n), and the propagation velocity c of ultrasonic waves in high-ductility cast steel ZGMn13 at an ambient temperature of 20 ℃0；
Thirdly, the ultrasonic thickness measurement and service life analysis method of the lining plate is as follows:
And 4, correcting the propagation speed: while the transmission time of the ultrasonic pulse signal in the lining plate is determined, the AT89C51 single chip microcomputer 45 in the ultrasonic ranging and transmission module 4 controls the temperature acquisition circuit 47 to detect the temperature of the position of the ultrasonic ranging sensor 2 (i.e. to obtain a temperature signal), and corrects the transmission speed of the ultrasonic wave AT each measuring point according to the relation between the temperature and the propagation speed as shown in formula 1, namely:
ci＝c0·ΔTi·μ(i＝1,2,…,n) (1)
in the formula, c0Is the propagation velocity (m/s), Δ T, of the ultrasonic waves at an ambient temperature of 20 DEG Ci＝(Ti-20)℃,ΔTiMu is the coefficient of variation of sound velocity for temperature difference, i.e. the sound velocity increases by 0.17% for every 1 ℃ rise of ambient temperature.
fourthly, counting the abrasion loss of each measuring point of the lining plate: the thickness h of each measuring point on the moving cone lining plate 1 and the fixed cone lining plate 6 is respectively measurediAnd its original thickness (h)0)i(i is 1,2, …, n) and the point thickness h is measurediThe value reaches the threshold value delta h of the minimum residual thickness of the measuring pointi( i 1,2, …, n) then the pad limit has been reached at that point, while memory 54 records and stores that point j ( j 1,2, …, m; and m ≦ n).
Fifthly, analyzing the service life of the lining plate: number of test points when the wear limit of the lining board is reached
And meanwhile, the measuring points are distributed below the working surfaces of the moving cone lining plate 1 and the fixed cone lining plate 6, and the alarm module 51 in the upper computer 5 gives an alarm for the service life of the moving cone lining plate 1 or the fixed cone lining plate 6.
The steps for analyzing the structural change of the crushing cavity in combination with fig. 4 are as follows:
step one, calculating the area of a wearing area of a lining plate:
(1) calculating the area of the original lining plate area: according to the distance between the ultrasonic distance measuring sensor 2 and the working surface of the moving cone lining plate 1
And the original thickness of the lining plate at the position of the sensor 2
From which the respective sum of (A)1、A2、A"1、A"2)、 (A2、A3、A"2、A"3)、(A3、A4、A"3、A"4) Area S of the quadrangleA(1-2)、 SA(2-3)、SA(3-4)；
According to the distance between the ultrasonic distance measuring sensor 2 and the working surface side of the fixed cone lining plate 6
And the original thickness of the lining plate at the position of the sensor 2
From which the respective sum of (B)1、B2、B"1、B"2)、(B2、23、B"2、B"3)、(B3、B4、B"3、B"4) Area S of the quadrangleB(1-2)、SB(2-3)、SB(3-4)。
(2) Calculating the area of the wear region of the lining plate: according to the abrasion loss of the ultrasonic distance measuring sensor 2 on one side of the working surface of the moving cone lining plate 1
In combination with the spacing of the measuring points
From which the respective sum of (A)1、A2、A′1、A′2)、(A2、A3、A′2、A′3)、 (A3、A4、A′3、A′4) Area S 'of the rectangle'A(1-2)、S′A(2-3)、S′A(3-4)。
According to the abrasion loss of the ultrasonic distance measuring sensor 2 on one side of the working surface of the fixed cone lining plate 6
In combination with the spacing of the measuring points
From which the respective sum of (B)1、B2、B′1、B′2)、 (B2、B3、B′2、B′3)、(B3、B4、B′3、B′4) Area S 'of the rectangle'B(1-2)、 S′B(2-3)、S′B(3-4)。
Secondly, calculating the wear rate of the crushing cavity: firstly, respectively calculating the wear rates eta of the lower region, the middle region and the upper region of the moving cone lining plate 1A1＝S′A(1-2)/SA(1-2)、ηA2＝S′A(2-3)/SA(2-3)、ηA3＝S′A(3-4)/SA(3-4)(ii) a Secondly, respectively calculating the wear rates eta of the lower region, the middle region and the upper region of the fixed cone lining plate 6B1＝S′B(1-2)/SB(1-2)、ηB2＝S′B(2-3)/SB(2-3)、ηB3＝ S′B(3-4)/SB(3-4)。
Thirdly, analyzing the structure of the crushing cavity and giving an alarm: the wear rate eta of the moving cone lining plate 1A1、ηA2、ηA3And the wear rate eta of the fixed cone lining plate 6B1、ηB2、ηB3And respectively comparing the abrasion loss with the threshold value of the abrasion loss, if the abrasion rate of each area is greater than the corresponding threshold value, the structure of the crushing cavity is mutated, and the upper computer sends out an alarm.
A monitoring method based on a service node and a detection node can be designed as shown in fig. 5, and includes:
step one, setting wave velocity and working threshold parameters of a crushing cavity, wherein the working threshold parameters of the crushing cavity comprise a lining plate thickness threshold and a preset abrasion threshold;
step two, when the detection node receives the distance measurement instruction, the detection node transmits an ultrasonic signal;
step three, the detection node receives reflected ultrasonic signals corresponding to the ultrasonic signals which are just transmitted;
step four, the service node determines a feedback signal with the cavity shape characteristic of the crushing cavity according to a transmission time slot formed by the transmitted ultrasonic signal and the reflected ultrasonic signal;
step five, the service node calculates the thickness of a lining plate of the current detection node corresponding to the current feedback signal according to the feedback signal;
step six, recycling the step two to the step five until the thicknesses of the lining plates at the positions of all the selected detection nodes are obtained;
step seven, judging whether the thickness of the obtained lining plate is larger than a lining plate thickness threshold value or not, if so, alarming that the lining plate is worn, and if not, performing the next step;
step eight, calculating the areas with the characteristics of local areas of the lining plates according to the obtained thickness of the lining plates and the current distance between adjacent nodes, and calculating the wear rate of the crushing cavity according to the areas;
and step nine, judging whether the wear rate exceeds a preset wear threshold value, if so, alarming that the lining plate is worn, if not, recording all current data, and optionally, calculating the service life condition of the lining plate according to the current wear rate to obtain a predicted maintenance date.
Although the embodiments of the present invention have been described in detail with reference to the accompanying drawings, the embodiments of the present invention are not limited to the details of the above embodiments, and various simple modifications can be made to the technical solutions of the embodiments of the present invention within the technical idea of the embodiments of the present invention, and the simple modifications all belong to the protection scope of the embodiments of the present invention.
It should be noted that the various features described in the above embodiments may be combined in any suitable manner without departing from the scope of the invention. In order to avoid unnecessary repetition, the embodiments of the present invention do not describe every possible combination.
Those skilled in the art will understand that all or part of the steps in the method according to the above embodiments may be implemented by a program, which is stored in a storage medium and includes several instructions to enable a single chip, a chip, or a processor (processor) to execute all or part of the steps in the method according to the embodiments of the present application. And the aforementioned storage medium includes: a U-disk, a removable hard disk, a Read-Only Memory (ROM), a Random Access Memory (RAM), a magnetic disk or an optical disk, and other various media capable of storing program codes.
In addition, any combination of various different implementation manners of the embodiments of the present invention is also possible, and the embodiments of the present invention should be considered as disclosed in the embodiments of the present invention as long as the combination does not depart from the spirit of the embodiments of the present invention.
Claims (1)
1. A monitoring method performed by a service node of a crushing chamber, the monitoring method comprising the steps of:
s1) obtaining feedback signals with the cavity shape characteristics of the crushing cavity of each detection node at different positions of the crushing cavity, and carrying out the next step when the feedback signals meet first preset monitoring conditions, wherein,
the detection nodes are provided with ultrasonic ranging sensors (2), transmitting wafers (21) and receiving wafers (22) of the ultrasonic ranging sensors (2) are installed in blind holes on one side of the non-working surface of the lining plate of the crushing cavity, the shape characteristics of the crushing cavity comprise the thickness of the lining plate measured by each detection node of the crushing cavity, the first preset monitoring condition is set that the proportion of the thickness of the lining plate, which is smaller than or equal to the preset minimum residual thickness of the lining plate, to the total feedback signal is within a preset proportion threshold range,
the service node is a computing device, the computing device comprises an ultrasonic ranging and transmission module (4) and an upper computer (5), the ultrasonic ranging and transmission module (4) comprises a first single chip microcomputer (45) and a first radio frequency wireless communication module (46), the upper computer (5) comprises a second single chip microcomputer (53) and a second radio frequency wireless communication module (52), the first single chip microcomputer (45) and the second single chip microcomputer (53) are in wireless communication through the first radio frequency wireless communication module (46) and the second radio frequency wireless communication module (52),
the ultrasonic ranging and transmission module (4) further comprises a transmitting circuit (49) and a receiving circuit (41) which are connected with the first single chip microcomputer (45), the transmitting circuit (49) is coupled with the transmitting wafer (21), the receiving circuit (41) is coupled with the receiving wafer (22),
the ultrasonic ranging and transmission module (4) further comprises a counter (44),
the first single chip microcomputer (45) drives the transmitting circuit (49) to send a plurality of rectangular pulse high-voltage signals to the transmitting wafer (21), the transmitting wafer (21) converts the rectangular pulse high-voltage signals into ultrasonic pulse wave signals with the same frequency, and meanwhile, the first single chip microcomputer (45) also controls the counter (44) to start counting,
the ultrasonic distance measurement and transmission module (4) further comprises a signal amplification circuit (42) and a signal modulator (43), the signal amplification circuit (42) and the signal modulator (43) amplify, filter and shape the electric pulse signals, and convert the electric pulse signals into countable rectangular wave signals with thickness value pulse width, the first single chip microcomputer (45) sends out external interrupt for stopping counting of the counter, and the counter (44) stops counting,
the ultrasonic ranging and transmission module (4) is used for calculating the ultrasonic propagation time slot of each detection node according to the counting of the counter (44), calculating the thickness of the lining plate measured by each detection node according to the ultrasonic propagation time slot and the propagation speed of each detection node,
the ultrasonic ranging and transmission module (4) sends the feedback signal to the upper computer (5),
the feedback signal is a radio frequency signal and is used for transmitting the thickness of the lining plate measured by each detection node to the upper computer (5);
s2) selecting a current detection node, and determining a cavity shape local characteristic of the crushing cavity according to the distance between the current detection node and an adjacent detection node, the thickness of a lining plate measured by the current detection node and the thickness of the lining plate measured by the adjacent detection node, wherein the cavity shape local characteristic comprises the areas of worn lining plate areas corresponding to the current detection node and the adjacent detection node;
s3) when the wear rate corresponding to the cavity local feature meets a second preset monitoring condition, skipping to the step S2) to form a loop monitoring process, wherein the second preset monitoring condition is set that the wear rate is within a preset wear threshold range, and the wear rate is the area ratio of the area of the wear lining plate area to the area of the original lining plate area,
the area of the original lining plate area is a quadrilateral area determined according to the distance between the ultrasonic distance measuring sensors (2) corresponding to the current detection node and the adjacent detection node and one side of the working surface of the lining plate and the original thickness of the lining plate at the position of the ultrasonic distance measuring sensors (2).
Priority Applications (2)
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| CN201910281688.8A CN110142084B (en) | 2019-04-09 | 2019-04-09 | Crushing cavity wear monitoring method |
| BE20205231A BE1027148B1 (en) | 2019-04-09 | 2020-04-08 | ABRASIVE MONITORING METHOD AND STRUCTURE FOR A FRACTION CAVE |
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| CN201910281688.8A CN110142084B (en) | 2019-04-09 | 2019-04-09 | Crushing cavity wear monitoring method |
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| CN112317109B (en) * | 2020-09-27 | 2022-02-18 | 鞍钢集团矿业有限公司 | Cone crusher fault pre-judging method |
| CN113731617B (en) * | 2021-09-22 | 2023-07-28 | 湖北实美科技有限公司 | Crusher lining plate abrasion loss detection and self-compensation control system |
| DE112022000512T5 (en) | 2021-09-29 | 2024-02-29 | Nikolay Ovcharenko | Method and device for controlling the operation of shredding plants |
| CN114950615B (en) * | 2022-04-29 | 2023-10-03 | 成都大宏立机器股份有限公司 | Automatic compensation control method for conical break discharge port |
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| BE1027148B1 (en) | 2021-06-22 |
| BE1027148A1 (en) | 2020-10-23 |
| CN110142084A (en) | 2019-08-20 |
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