CN112623631A - Chain life prediction and chain breakage position judgment method for scraper conveyor - Google Patents
Chain life prediction and chain breakage position judgment method for scraper conveyor Download PDFInfo
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- CN112623631A CN112623631A CN202011493815.XA CN202011493815A CN112623631A CN 112623631 A CN112623631 A CN 112623631A CN 202011493815 A CN202011493815 A CN 202011493815A CN 112623631 A CN112623631 A CN 112623631A
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- scraper
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- scraper conveyor
- hall sensor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G19/00—Conveyors comprising an impeller or a series of impellers carried by an endless traction element and arranged to move articles or materials over a supporting surface or underlying material, e.g. endless scraper conveyors
- B65G19/18—Details
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G19/00—Conveyors comprising an impeller or a series of impellers carried by an endless traction element and arranged to move articles or materials over a supporting surface or underlying material, e.g. endless scraper conveyors
- B65G19/18—Details
- B65G19/20—Traction chains, ropes, or cables
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
- B65G43/02—Control devices, e.g. for safety, warning or fault-correcting detecting dangerous physical condition of load carriers, e.g. for interrupting the drive in the event of overheating
Abstract
The invention provides a method for predicting the service life of a scraper conveyor chain and judging a chain breakage position, and relates to the technical field of detection. The method of the invention uses the scraper provided with the magnetic block and the Hall sensor to jointly detect the broken chain of the scraper conveyor, the Hall sensor is arranged on the chain wheel shell at the head part and the tail part, the current time interval is judged by using the pulse signal of the scraper provided with the magnetic block and passing through the Hall sensor, the time interval is fed back to the industrial personal computer, the processing program in the industrial personal computer further judges whether the chain breakage phenomenon occurs on the scraper conveyor or not, and further judges whether the chain breakage phenomenon occurs on the double sides or the single side, and the side where the chain breakage phenomenon occurs can be used for prejudging whether the chain breakage hidden danger and the deflection phenomenon exist on the scraper, if the chain breakage hidden danger and the deflection phenomenon exist, the machine can be stopped and overhauled in time, the chain breakage phenomenon caused by the continuous operation of the scraper conveyor is prevented from occurring dangerously, and the problem that the service life prediction and the.
Description
Technical Field
The invention relates to the technical field of detection, in particular to a method for predicting the service life of a scraper conveyor chain and judging a chain breakage position.
Background
At present, in the process of using a scraper conveyor to transport in a coal mine, the scraper conveyor may have a chain breakage phenomenon, the working efficiency of underground coal mine mining work is influenced, the safety of underground workers is also damaged, a plurality of defects exist in engineering practice, if the chain breakage phenomenon is monitored manually, the real-time performance cannot be reached, the chain breakage phenomenon can only be judged when occurring, the current work cannot be pre-warned when the chain breakage phenomenon does not occur, the initiative is lacked, once the chain breakage occurs, a large amount of time needs to be consumed for maintenance, the time waste is caused to a large extent, and the safety and the reliability of the underground coal mine mining work are reduced.
Therefore, there is a need to design a better detection technique to solve the above problems.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a method for predicting the service life of a scraper conveyor chain and judging the chain breaking position, which aims at overcoming the defects of the prior art, and the method is characterized in that a scraper of a scraper conveyor is modified, magnetic blocks are arranged on the scraper of the scraper conveyor at fixed intervals to enable the scraper to have magnetism, a Hall sensor is used for monitoring the time interval between the magnetic scrapers passing through the Hall sensor, whether the chain breaking phenomenon or the chain breaking hidden danger exists in the current scraper conveyor is judged according to the change of the time interval, and the service life prediction and the chain breaking position judgment of the scraper conveyor are completed.
In order to solve the technical problems, the technical scheme adopted by the invention is as follows:
a method for predicting the service life of a chain of a scraper conveyor and judging the chain breakage position comprises the steps that magnetic blocks are installed on a scraper of the scraper conveyor, Hall sensors are arranged on the left side and the right side of the outer surfaces of a head chain wheel protective shell and a tail chain wheel protective shell of the scraper conveyor, and the chain breakage detection of the scraper conveyor is carried out by utilizing the time interval of the Hall sensors of adjacent scrapers with the magnetic blocks;
two Hall sensors are arranged on each side of the outer surface of the machine head chain wheel protection shell along the movement direction of the scraper conveyor, one Hall sensor is arranged on each side of the outer surface of the machine tail chain wheel protection shell, and the positions of the Hall sensors arranged on the left side and the right side are completely symmetrical relative to the scraper central line parallel to the short edge of the scraper;
the magnetic blocks arranged on the scraper are symmetrically arranged in the middle of the left end and the right end of the scraper; the distances between every two of the scraping plates provided with the magnetic blocks are completely the same; two magnetic blocks are respectively arranged at the left end and the right end of one scraper in the scrapers provided with the magnetic blocks, and the scraper is defined as the No. 1 scraper; the left end and the right end of each of the other scraping plates provided with the magnetic block are respectively provided with one magnetic block, and the two magnetic blocks are sequentially defined as a 2 nd scraping plate, a 3 rd scraping plate, an i th scraping plate, an n th scraping plate according to the direction from the machine head to the machine tail of the scraper conveyor;
when the next scraper blade provided with the magnetic block passes through the Hall sensor on the outer surface of the head chain wheel protective shell, the Hall sensors on the left side and the right side can sense the magnetic block again to send out pulses, and the pulses are fed back to the industrial personal computer through the A/D converter and the signal transceiver; the scraper conveyor runs at a constant speed in the running process, a modularized program is arranged in an industrial personal computer of the system, the time interval required when the magnetic blocks at the left end and the right end of two adjacent scrapers provided with the magnetic blocks pass through the Hall sensors on the corresponding side of the outer surface of the head chain wheel protective shell respectively under the current linear speed can be automatically calculated, the time intervals at the left side and the right side are respectively recorded and compared with the theoretical time interval, the running state of the current scraper conveyor is judged, and whether the scraper conveyor has the potential fault hazard currently or not and needs to be overhauled or not is determined;
the current running linear speed of scraper conveyor operation, motor power and rotational speed, real-time load are transmitted to the industrial computer by scraper conveyor self module, and the industrial computer can master the above parameter of scraper conveyor in real time to the running state according to the current scraper conveyor of judging sends control signal, by signal transceiver feedback to scraper conveyor, controls scraper conveyor's operation.
Furthermore, the transverse distance between the two magnetic blocks arranged at each end of the 1 st scraper blade is the same as the transverse distance between the two Hall sensors arranged on each side of the outer surface of the head chain wheel protective shell; when two hall sensor of the homonymy of aircraft nose sprocket protective housing surface detected pulse signal simultaneously, record as 1 st scraper blade and pass through, later install the scraper blade of magnetic path at every turn and when passing through the hall sensor of aircraft nose sprocket protective housing surface, the hall sensor who senses the magnetic path earlier can respond to the magnetic path and send pulse signal, and the inside procedure of industrial computer is from adding to the scraper blade serial number.
Further, when the 1 st scraper blade passes through the hall sensor of aircraft nose sprocket protective housing surface, the industrial computer can judge that the scraper blade that has passed through the afterbody or is about to pass through the afterbody is the several scraper blades according to aircraft nose sprocket protective housing surface and the distance between two adjacent scraper blades of installing the magnetic path with the distance of the hall sensor of afterbody sprocket protective housing surface.
Further, the specific method for judging the current running state of the scraper conveyor by the industrial personal computer is as follows:
when the scraper chain is in the original length state, defining the time interval of two adjacent scrapers provided with magnetic blocks passing through a Hall sensor on the outer surface of the head chain wheel protective shell as the time A required by the scraper conveyor chain to pass in the normal state; when the scraper chain is subjected to maximum deformation and is in a stretching limit state, defining the time interval of two adjacent scrapers provided with magnetic blocks passing through a Hall sensor on the outer surface of a head chain wheel protective shell as the time B required by the scraper conveyor chain to pass in the maximum stretching state; errors exist in the measuring process, the signal transmission process, the installation of the Hall sensors, the scraper modification process and the magnetic block installation process, so that errors inevitably exist in time intervals obtained after the Hall sensors on the left side and the right side sense pulses and the industrial personal computer record time, and the difference value of the time intervals sensed by the Hall sensors on the left side and the right side of two adjacent scrapers provided with the magnetic blocks under the state of the maximum error is defined as the maximum passing time error C on the two sides of the scraper conveyor; if the abrasion of the scraper chain on one side is large, the scraper chain on the other side is obviously elongated, the abrasion of the scraper chain on the other side is small, the elongation is not obvious, the scraper of the scraper conveyor can obviously deflect, and the difference value of the time intervals sensed by the Hall sensors on the left side and the right side of the adjacent two scrapers provided with the magnetic blocks under the condition is defined as the passing time difference D of the two sides of the scraper conveyor in the maximum deflection state of the scraper;
when the industrial personal computer calculates that two adjacent scrapers provided with magnetic blocks pass through the Hall sensors on the outer surface of the machine head chain wheel protective shell, the magnetic blocks at the left end and the right end of the two scrapers respectively pass through the time interval required by the Hall sensors on the corresponding sides, and the time interval between the magnetic block at the left end of the ith scraper passing through the Hall sensors on the outer surface of the machine head chain wheel protective shell and the magnetic block at the left end of the (i + 1) th scraper passing through the Hall sensors on the outer surface of the machine head chainLeft of iDefining the time interval of the magnet at the right end of the ith scraper blade passing through the Hall sensor on the outer surface of the head chain wheel protective shell and the magnet at the right end of the (i + 1) th scraper blade passing through the Hall sensor on the outer surface of the head chain wheel protective shell as ti Right sideWill separate the time tLeft of iAnd ti Right sideIs recorded as Δ ti；
If tLeft of iA and t ≦ Ai Right sideWhen A is less than or equal to A, the current scraper conveyor state is normal;
if tLeft of i>A or ti Right side>A, judging whether to judge delta tiC is less than or equal to C, if yes, the current scraper conveyor is in a normal state, and t is appearedLeft of i>A or ti Right side>A is the detection error, the scraper conveyor still works normally, if not, whether the delta t is judgedi>D, if so, the current scraper conveyor has a unilateral chain breakage phenomenon, and one side with longer time interval has a chain breakage phenomenon, otherwise, the current scraper conveyor has a deflection phenomenon;
if tLeft of i>A and ti Right side>A, then judge whether t isLeft of i>B and ti Right side>B, if yes, the current scraper conveyor has a double-side chain breakage phenomenon, and if t, the current scraper conveyor has a double-side chain breakage phenomenonLeft of i>B or ti Right side>B, breaking the chain at one side of the current scraper conveyor, and having hidden danger at the other side, if tLeft of iB and t ≦ Bi Right sideB ≦ B, determine if Δ tiC is less than or equal to C, if yes, the potential chain breakage hazards exist on two sides of the current scraper conveyor, and if not, whether delta t is judgedi≦DIf the chain is broken, the chain is broken at one side of the scraper conveyor, and if the chain is broken at the other side of the scraper conveyor, the chain is broken at one side with longer time interval.
Further, through the above judgment, if the abnormality occurs between the ith scraper blade and the (i + 1) th scraper blade, the time interval T between the operation of the current scraper conveyor at the linear speed v and the operation of the ith scraper blade passing through the hall sensor on the outer surface of the head chain wheel protective shell is determined according to the current linear speed v of the scraper conveyor at the timeiTime interval T between hall sensor of the (i + 1) th scraper passing through outer surface of machine head chain wheel protective shell and hall sensor of the (1) th scraper passing through outer surface of machine head chain wheel protective shelli+1Using displacement equal to velocity times time, i.e. si＝vTiAnd si+1＝vTi+1Pushing out s on the scraper chainiTo si+1The scraper conveyor is abnormal.
Further, if the load change of the scraper conveyor is obvious, the speed change inevitably occurs, at the moment, the required time A for the scraper conveyor chain to pass through in a normal state, the required time B for the scraper conveyor chain to pass through in a maximum stretching state, the maximum error C of the passing time of the two sides of the scraper conveyor scraper and the passing time difference D of the two sides of the scraper conveyor scraper in a maximum deflection state all change, at the moment, the industrial personal computer calculates the time interval that two adjacent scrapers provided with magnetic blocks pass through the Hall sensor on the outer surface of the head chain wheel protective shell under a new speed condition, if the Hall sensor is arranged between the two adjacent scrapers provided with the magnetic blocks, and then, starting to use new time monitoring from the next scraper provided with the magnetic block passing through the Hall sensor, abandoning the current monitoring result, and starting to record time from the next magnetic block passing through the Hall sensor to judge the running state of the scraper conveyor.
Adopt the produced beneficial effect of above-mentioned technical scheme to lie in: the scraper conveyor chain life prediction and chain breakage position judgment method provided by the invention has the advantages that the scraper provided with the magnetic block and the Hall sensor are used in a combined manner to detect the chain breakage of the scraper conveyor, whether the chain breakage phenomenon occurs on the scraper conveyor can be judged, if the chain breakage phenomenon occurs, the current chain breakage is bilateral chain breakage or unilateral chain breakage, and if the chain breakage phenomenon occurs on the unilateral chain breakage, the current chain breakage phenomenon occurs on which side; and when the chain breakage phenomenon does not occur to the scraper conveyor, whether the chain breakage hidden danger exists in the current state or not and whether the deflection phenomenon exists in the scraper conveyor or not can be judged in advance, if the chain breakage hidden danger and the deflection phenomenon exist, the scraper conveyor can be stopped and overhauled in time, the chain breakage phenomenon caused by continuous operation of the scraper conveyor is prevented, danger is generated, the problem that the service life of the scraper conveyor is short of real-time performance in chain breakage monitoring and prediction is solved, and casualties and property loss are greatly reduced.
Drawings
FIG. 1 is a schematic diagram of a modified general structure of a scraper conveyor provided in an embodiment of the present invention;
FIG. 2 is a schematic diagram of mounting magnetic blocks of a scraper blade 1 and a scraper blade 2 according to an embodiment of the present invention;
FIG. 3 is an S-N curve of a scraper chain according to an embodiment of the present invention;
fig. 4 is a block diagram of a process of predicting the life of a scraper conveyor chain and warning chain breakage according to an embodiment of the present invention.
In the figure: 1. a squeegee; 2. a chain wheel protective housing; 3. an A/D converter; 4. a signal transceiver; 5. a scraper chain; 6. a Hall sensor; 7. a magnetic block.
Detailed Description
The following detailed description of embodiments of the present invention is provided in connection with the accompanying drawings and examples. The following examples are intended to illustrate the invention but are not intended to limit the scope of the invention.
The embodiment provides a method for predicting the service life of a chain of a scraper conveyor and judging a chain breakage position.
As shown in fig. 1 and 2, two hall sensors are mounted on each side of the outer surface of the head sprocket protective shell along the moving direction of the scraper conveyor, one hall sensor is mounted on each side of the outer surface of the tail sprocket protective shell, and the hall sensors mounted on the left side and the right side are symmetrical relative to the central line of the scraper parallel to the short side of the scraper. The magnetic blocks arranged on the scraper are symmetrically arranged in the middle of the left end and the right end of the scraper. The distances between every two of the scrapers provided with the magnetic blocks are completely the same. Two magnetic blocks are respectively arranged at the left end and the right end of one scraper blade in the scraper blades provided with the magnetic blocks, the scraper blade is defined as a 1 st scraper blade, and the transverse distance between the two magnetic blocks arranged at each end is the same as the transverse distance between the two Hall sensors arranged at each side of the outer surface of the chain wheel protective shell of the machine head. The left end and the right end of other scraper blades provided with the magnetic blocks are respectively provided with one magnetic block, and the two magnetic blocks are sequentially defined as a 2 nd scraper blade, a 3 rd scraper blade, an i th scraper blade, an n th scraper blade according to the direction from the head to the tail of the scraper conveyor. When two hall sensor of the homonymy of aircraft nose sprocket protective housing surface detected pulse signal simultaneously, record as 1 st scraper blade and pass through, later install the scraper blade of magnetic path at every turn and when passing through the hall sensor of aircraft nose sprocket protective housing surface, the hall sensor who senses the magnetic path earlier can respond to the magnetic path and send pulse signal, and the inside procedure of industrial computer is from adding to the scraper blade serial number.
When the scraper blade of installing the magnetic path passes through the hall sensor of aircraft nose sprocket protective housing surface, the hall sensor of the left and right sides can respond to the magnetic path and send pulse signal, and this pulse signal passes through signal transceiver after AD converter conversion processing and feeds back to the industrial computer, and when the next scraper blade of installing the magnetic path passes through the hall sensor of aircraft nose sprocket protective housing surface, the magnetic path is sent out the pulse to the hall sensor of the left and right sides hall sensor meeting secondary induction again to feed back to the industrial computer via AD converter and signal transceiver. The scraper conveyor runs at a constant speed in the running process, a modularized program is arranged in the industrial personal computer of the system, the time interval required when the magnetic blocks at the left end and the right end of two adjacent scrapers provided with the magnetic blocks under the current linear speed respectively pass through the Hall sensor on one side corresponding to the outer surface of the head chain wheel protective shell can be automatically calculated, the time intervals of the left side and the right side are respectively recorded and compared with the theoretical time interval, the running state of the current scraper conveyor is judged, whether the scraper conveyor has hidden trouble or not at present is determined, and whether the scraper conveyor needs to be overhauled or.
As shown in fig. 3, the fatigue life curve of the scraper chain, i.e. the S-N curve, can reflect the relationship between the life of the scraper chain and the load, before point a, the deformation of the scraper chain 5 is elastic deformation, which can be recovered after deformation, and the length of the scraper chain 5 will not be affected, the scraper chain 5 is in the original state, the industrial computer judges the time interval of two adjacent scrapers 1 passing through the nose hall sensor 6 according to the distance between two adjacent scrapers 1 installed with the magnetic block 7 and the current running linear speed of the scraper conveyor, and defines the time interval as the required time for the normal state of the scraper chain of the a-scraper conveyor. When the S-N curve is at the point B, the scraper chain 5 has the maximum deformation, if the deformation continues to increase and the risk of chain breakage exists, the time interval of two adjacent scrapers 1 provided with the magnetic blocks 7 passing through the nose Hall sensor 6 is calculated when the scraper chain 5 is in the stretching limit state in the stress state, and the time interval is defined as the time required by the scraper conveyor chain to pass through in the maximum stretching state. Meanwhile, time intervals inevitably occur between the magnetic blocks 7 on the left side and the right side through the Hall sensors 6, errors are inevitable in the measuring process, the signal transmission process, the sensor installation process, the scraper blade 1 transformation process and the magnetic block 7 installation process, and therefore errors inevitably exist in the time difference recorded by the Hall sensors 6 on the two sides, and the maximum passing time error of the two sides of the scraper blade of the C-scraper conveyor is defined. If the abrasion of the scraper chain 5 on one side is large, the obvious elongation occurs, the abrasion of the scraper chain 5 on the other side is small, the elongation is not obvious, the scraper 1 of the scraper conveyor can obviously deflect, D-time difference of passing through two sides under the maximum deflection state of the scraper conveyor is defined, and if the time difference is exceeded, the phenomenon of chain breakage on one side occurs.
As shown in fig. 4, the specific method of the industrial personal computer determining the current operation state of the blade conveyor is as follows.
When the industrial personal computer calculates that two adjacent scrapers provided with magnetic blocks pass through the Hall sensors on the outer surface of the machine head chain wheel protective shell, the magnetic blocks at the left end and the right end of the two scrapers respectively pass through the time interval required by the Hall sensors on the corresponding sides, and the magnetic block at the left end of the ith scraper passes through the Hall sensors on the outer surface of the machine head chain wheel protective shell and the magnetic block at the left end of the (i + 1) th scraper passes through the machine headThe time interval of the Hall sensor on the outer surface of the chain wheel protective shell is defined as tLeft of iDefining the time interval of the magnetic block at the right end of the ith scraper blade passing through the Hall sensor on the outer surface of the head chain wheel protective shell and the magnetic block at the right end of the (i + 1) th scraper blade passing through the Hall sensor on the outer surface of the head chain wheel protective shell as ti Right sideThe two sides of the time interval tLeft of iAnd ti Right sideIs recorded as Δ ti。
If tLeft of iA and t ≦ Ai Right sideAnd (A), namely the time interval of the magnetic blocks 7 at the left end and the right end of the two adjacent scrapers provided with the magnetic blocks passing through the Hall sensor 6 on the outer surface of the head chain wheel protective shell is not more than the required time A for the normal state of the scraper conveyor chain to pass through, and the current scraper conveyor state is normal.
If tLeft of i>A or ti Right side>A, if the time interval on one side is larger than the time A required for the chain of the scraper conveyor to pass through in the normal state and the time interval on the other side is not larger than the time A required for the chain of the scraper conveyor to pass through in the normal state, the absolute value of the difference value of the time intervals on the two sides is judged, and whether delta t is judgediC, if the absolute value of the difference value of the time intervals on the two sides is not larger than the maximum error C of the passing time on the two sides of the scraper conveyor, the scraper conveyor is in a normal state currently, the time interval on the side is larger than the time A required by the normal state of the scraper conveyor chain, namely tLeft of i>A or ti Right side>And A, detecting errors, wherein the scraper conveyor still works normally, if not, namely the absolute value of the difference value of the time intervals at the two sides is larger than the maximum passing time error C at the two sides of the scraper conveyor scraper, then investigating whether the absolute value of the difference value of the time intervals at the two sides is larger than the maximum passing time difference D at the two sides under the maximum deflection state of the scraper conveyor scraper, namely judging whether delta t is delta ti>And D, if so, the current scraper conveyor has a unilateral chain breakage phenomenon, and the side with longer time interval has a chain breakage phenomenon, and if not, the current scraper conveyor has a deflection phenomenon.
If tLeft of i>A and ti Right side>A, namely the magnetic blocks 7 at the left end and the right end of the two adjacent scraping plates provided with the magnetic blocks pass through the Hall sensor on the outer surface of the protective shell of the chain wheel of the machine headThe time intervals of the sensors 6 are all larger than the time A required by the scraper conveyor chain to pass in the normal state, the relation between the current time intervals at the two sides and the time B required by the scraper conveyor chain to pass in the maximum stretching state is considered, and whether t is judgedLeft of i>B and ti Right side>B, if yes, the current scraper conveyor has a double-side chain breakage phenomenon, and if t, the current scraper conveyor has a double-side chain breakage phenomenonLeft of i>B or ti Right side>B, namely, the time interval of one side is larger than the time B required for the scraper conveyor chain to pass in the maximum stretching state, the time interval of the other side is not larger than the time B required for the scraper conveyor chain to pass in the maximum stretching state, the current scraper conveyor is broken at one side, hidden danger exists at the other side, and if t isLeft of iB and t ≦ Bi Right sideB, i.e. the time interval on both sides does not exceed the time B required for passing the scraper conveyor chain in the maximum stretched state, the absolute value of the difference between the time intervals on both sides is considered, whether the absolute value of the difference between the time intervals on both sides is not greater than the maximum error C of the passing time on both sides of the scraper conveyor scraper is judged, i.e. whether Δ t is greater than the maximum error C of the passing time on both sides of the scraper conveyor scraperiC is less than or equal to C, if yes, the potential chain breakage danger exists at two sides of the scraper conveyor at present, if not, the relation between the absolute value of the difference value of the time intervals at two sides and the passing time difference D at two sides under the maximum deflection state of the scraper conveyor scraper needs to be considered, and whether delta t is judgediD, if the value is less than or equal to D, the current scraper conveyor has hidden danger and deflection phenomena, if the value is not less than or equal to D, one side of the current scraper conveyor is broken, the other side of the current scraper conveyor has hidden danger, and one side with longer time interval is broken, this phenomenon often occurs under an impact condition, when the scraper 1 mounted with the magnet block 7 is about to pass through the nose hall sensor 6, an impact occurs, but the magnetic blocks 7 arranged on the scrapers 1 at the two sides can still pass through the Hall sensor 6 within the required time B under the maximum stretching state of the scraper conveyor chain, so that the false phenomenon that the chain is not broken is caused, at the moment, the running state of the current scraper conveyor is judged again by using the absolute value of the difference value of the time intervals of the magnetic blocks 7 at the two sides passing through the Hall sensor 6, the scraper conveyor is overhauled in time, and the scraper conveyor is prevented from continuously running under the state, so that the chain breakage of the scraper conveyor is caused, and the casualties and the property loss are brought.
When the 1 st scraper blade passes through the Hall sensor on the outer surface of the head chain wheel protective shell, the industrial personal computer can judge that the scraper blade passing through the tail part or about to pass through the tail part is the number of the scraper blade according to the distance between the Hall sensor on the outer surface of the head chain wheel protective shell and the Hall sensor on the outer surface of the tail chain wheel protective shell and the distance between two adjacent scraper blades provided with the magnetic blocks.
The current running linear speed of scraper conveyor operation, motor power and rotational speed, real-time load are transmitted to the industrial computer by scraper conveyor self module, and the industrial computer can master the above parameter of scraper conveyor in real time to the running state according to the current scraper conveyor of judging sends control signal, by signal transceiver feedback to scraper conveyor, controls scraper conveyor's operation. If the load change of the scraper conveyor is obvious, the speed change inevitably occurs, at the moment, the required time A for the scraper conveyor chain to pass in a normal state, the required time B for the scraper conveyor chain to pass in a maximum stretching state, the maximum error C of the passing time of the two sides of the scraper conveyor scraper and the passing time difference D of the two sides of the scraper conveyor scraper in a maximum deflection state all change, at the moment, the industrial personal computer calculates the time interval of two adjacent scrapers 1 provided with the magnetic blocks 7 passing through the Hall sensor 6 on the outer surface of the head chain wheel protective shell under a new speed condition, if the Hall sensor 6 is arranged between two adjacent scrapers 1 provided with the magnetic blocks 7, the next scraper 1 provided with the magnetic block 7 starts to use new time monitoring through the Hall sensor 6, the current monitoring result is abandoned, and the time is recorded from the next time when the magnetic block, and judging the running state of the scraper conveyor.
The method for predicting the service life of the scraper conveyor chain and judging the chain breakage position is applied as follows:
firstly, when a scraper 1 provided with two magnetic blocks 7 passes through the head of a scraper conveyor, an industrial personal computer records and defines the scraper as a 1 st scraper; and then, the control system works, and after the judgment of the judgment method, if the abnormality between the ith scraper blade and the (i + 1) th scraper blade is judged, the ith scraper blade passes through a Hall sensor on the outer surface of the head chain wheel protective shell and the 1 st scraper blade passes through the head chain wheel for protection according to the current running linear speed v of the scraper conveyorTime interval T between Hall sensors on outer surface of shelliTime interval T between hall sensor of the (i + 1) th scraper passing through outer surface of machine head chain wheel protective shell and hall sensor of the (1) th scraper passing through outer surface of machine head chain wheel protective shelli+1Using displacement equal to velocity times time, i.e. si＝vTiAnd si+1＝vTi+1Pushing out s on the scraper chainiTo si+1And the scraper conveyor is abnormal, and the output informs workers, and the scraper conveyor is overhauled in time according to the position judged by the industrial personal computer and the fault type predicted by the control system of the industrial personal computer, so that the scraper conveyor is prevented from running under the fault condition and potential safety hazards are avoided.
Finally, it should be noted that: the above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; such modifications and substitutions do not depart from the spirit of the corresponding technical solutions and scope of the present invention as defined in the appended claims.
Claims (6)
1. A method for predicting the service life of a scraper conveyor chain and judging the chain breakage position is characterized by comprising the following steps: installing magnetic blocks on a scraper of a scraper conveyor, arranging Hall sensors on the left side and the right side of the outer surfaces of a head and a tail chain wheel protective shell of the scraper conveyor, and detecting chain breakage of the scraper conveyor by using the time interval of the Hall sensors of adjacent scrapers provided with the magnetic blocks;
two Hall sensors are arranged on each side of the outer surface of the machine head chain wheel protection shell along the movement direction of the scraper conveyor, one Hall sensor is arranged on each side of the outer surface of the machine tail chain wheel protection shell, and the positions of the Hall sensors arranged on the left side and the right side are completely symmetrical relative to the scraper central line parallel to the short edge of the scraper;
the magnetic blocks arranged on the scraper are symmetrically arranged in the middle of the left end and the right end of the scraper; the distances between every two of the scraping plates provided with the magnetic blocks are completely the same; two magnetic blocks are respectively arranged at the left end and the right end of one scraper in the scrapers provided with the magnetic blocks, and the scraper is defined as the No. 1 scraper; the left end and the right end of each of the other scraping plates provided with the magnetic block are respectively provided with one magnetic block, and the two magnetic blocks are sequentially defined as a 2 nd scraping plate, a 3 rd scraping plate, an i th scraping plate, an n th scraping plate according to the direction from the machine head to the machine tail of the scraper conveyor;
when the next scraper blade provided with the magnetic block passes through the Hall sensor on the outer surface of the head chain wheel protective shell, the Hall sensors on the left side and the right side can sense the magnetic block again to send out pulses, and the pulses are fed back to the industrial personal computer through the A/D converter and the signal transceiver; the scraper conveyor runs at a constant speed in the running process, a modularized program is arranged in an industrial personal computer of the system, the time interval required when the magnetic blocks at the left end and the right end of two adjacent scrapers provided with the magnetic blocks pass through the Hall sensors on the corresponding side of the outer surface of the head chain wheel protective shell respectively under the current linear speed can be automatically calculated, the time intervals at the left side and the right side are respectively recorded and compared with the theoretical time interval, the running state of the current scraper conveyor is judged, and whether the scraper conveyor has the potential fault hazard currently or not and needs to be overhauled or not is determined;
the current running linear speed of scraper conveyor operation, motor power and rotational speed, real-time load are transmitted to the industrial computer by scraper conveyor self module, and the industrial computer can master the above parameter of scraper conveyor in real time to the running state according to the current scraper conveyor of judging sends control signal, by signal transceiver feedback to scraper conveyor, controls scraper conveyor's operation.
2. The scraper conveyor chain life prediction and chain breakage position determination method according to claim 1, characterized in that: the transverse distance between the two magnetic blocks arranged at each end of the 1 st scraper blade is the same as the transverse distance between the two Hall sensors arranged on each side of the outer surface of the head chain wheel protective shell; when two hall sensor of the homonymy of aircraft nose sprocket protective housing surface detected pulse signal simultaneously, record as 1 st scraper blade and pass through, later install the scraper blade of magnetic path at every turn and when passing through the hall sensor of aircraft nose sprocket protective housing surface, the hall sensor who senses the magnetic path earlier can respond to the magnetic path and send pulse signal, and the inside procedure of industrial computer is from adding to the scraper blade serial number.
3. The scraper conveyor chain life prediction and chain breakage position determination method according to claim 2, characterized in that: when the 1 st scraper blade passes through the hall sensor of aircraft nose sprocket protective housing surface, the industrial computer can be according to aircraft nose sprocket protective housing surface and the hall sensor's of tail sprocket protective housing surface distance and two adjacent scraper blades of installing the magnetic path between the distance, and the scraper blade that judges to have passed through the afterbody or be about to pass through the afterbody is several scraper blades.
4. The scraper conveyor chain life prediction and chain breakage position determination method according to claim 3, characterized in that: the specific method for judging the current running state of the scraper conveyor by the industrial personal computer comprises the following steps:
when the scraper chain is in the original length state, defining the time interval of two adjacent scrapers provided with magnetic blocks passing through a Hall sensor on the outer surface of the head chain wheel protective shell as the time A required by the scraper conveyor chain to pass in the normal state; when the scraper chain is subjected to maximum deformation and is in a stretching limit state, defining the time interval of two adjacent scrapers provided with magnetic blocks passing through a Hall sensor on the outer surface of a head chain wheel protective shell as the time B required by the scraper conveyor chain to pass in the maximum stretching state; errors exist in the measuring process, the signal transmission process, the installation of the Hall sensors, the scraper modification process and the magnetic block installation process, so that errors inevitably exist in time intervals obtained after the Hall sensors on the left side and the right side sense pulses and the industrial personal computer record time, and the difference value of the time intervals sensed by the Hall sensors on the left side and the right side of two adjacent scrapers provided with the magnetic blocks under the state of the maximum error is defined as the maximum passing time error C on the two sides of the scraper conveyor; if the abrasion of the scraper chain on one side is large, the scraper chain on the other side is obviously elongated, the abrasion of the scraper chain on the other side is small, the elongation is not obvious, the scraper of the scraper conveyor can obviously deflect, and the difference value of the time intervals sensed by the Hall sensors on the left side and the right side of the adjacent two scrapers provided with the magnetic blocks under the condition is defined as the passing time difference D of the two sides of the scraper conveyor in the maximum deflection state of the scraper;
when the industrial personal computer calculates that two adjacent scrapers provided with magnetic blocks pass through the Hall sensors on the outer surface of the machine head chain wheel protective shell, the magnetic blocks at the left end and the right end of the two scrapers respectively pass through the time interval required by the Hall sensors on the corresponding sides, and the time interval between the magnetic block at the left end of the ith scraper passing through the Hall sensors on the outer surface of the machine head chain wheel protective shell and the magnetic block at the left end of the (i + 1) th scraper passing through the Hall sensors on the outer surface of the machine head chainLeft of iDefining the time interval of the magnet at the right end of the ith scraper blade passing through the Hall sensor on the outer surface of the head chain wheel protective shell and the magnet at the right end of the (i + 1) th scraper blade passing through the Hall sensor on the outer surface of the head chain wheel protective shell as ti Right sideWill separate the time tLeft of iAnd ti Right sideIs recorded as Δ ti；
If tLeft of iA and t ≦ Ai Right sideWhen A is less than or equal to A, the current scraper conveyor state is normal;
if tLeft of i>A or ti Right side>A, judging whether to judge delta tiC is less than or equal to C, if yes, the current scraper conveyor is in a normal state, and t is appearedLeft of i>A or ti Right side>A is the detection error, the scraper conveyor still works normally, if not, whether the delta t is judgedi>D, if so, the current scraper conveyor has a unilateral chain breakage phenomenon, and one side with longer time interval has a chain breakage phenomenon, otherwise, the current scraper conveyor has a deflection phenomenon;
if tLeft of i>A and ti Right side>A, then judge whether t isLeft of i>B and ti Right side>B, if yes, the current scraper conveyor has a double-side chain breakage phenomenon, and if t, the current scraper conveyor has a double-side chain breakage phenomenonLeft of i>B or ti Right side>B, then the current scraper conveyerOne side is broken and the other side has hidden trouble if tLeft of iB and t ≦ Bi Right sideB ≦ B, determine if Δ tiC is less than or equal to C, if yes, the potential chain breakage hazards exist on two sides of the current scraper conveyor, and if not, whether delta t is judgediD, if yes, hidden danger and deflection phenomena exist in the current scraper conveyor, if not, the chain is broken at one side of the current scraper conveyor, hidden danger exists at the other side of the current scraper conveyor, and the chain is broken at one side with longer time interval.
5. The scraper conveyor chain life prediction and chain breakage position determination method according to claim 4, characterized in that: through the judgment of the industrial personal computer, if the abnormality occurs between the ith scraper blade and the (i + 1) th scraper blade, the time interval T between the situation that the ith scraper blade passes through the Hall sensor on the outer surface of the head chain wheel protective shell and the situation that the 1 st scraper blade passes through the Hall sensor on the outer surface of the head chain wheel protective shell is determined according to the current running linear speed v of the scraper conveyoriTime interval T between hall sensor of the (i + 1) th scraper passing through outer surface of machine head chain wheel protective shell and hall sensor of the (1) th scraper passing through outer surface of machine head chain wheel protective shelli+1Using displacement equal to velocity times time, i.e. si＝vTiAnd si+1＝vTi+1Pushing out s on the scraper chainiTo si+1The scraper conveyor is abnormal.
6. The scraper conveyor chain life prediction and chain breakage position determination method according to claim 4 or 5, characterized in that: if the load change of the scraper conveyor is obvious, the speed change inevitably occurs, the required time A for the chain of the scraper conveyor to pass through in a normal state, the required time B for the chain of the scraper conveyor to pass through in a maximum stretching state, the maximum error C of the passing time of the two sides of the scraper conveyor scraper and the time difference D of the passing time of the two sides of the scraper conveyor in a maximum deflection state all change, at the moment, the industrial personal computer calculates the time interval for the two adjacent scrapers provided with the magnetic blocks to pass through the Hall sensor on the outer surface of the chain wheel protective shell of the machine head under a new speed condition, if the Hall sensor is arranged between the two adjacent scrapers provided with the magnetic blocks, the next scraper provided with the magnetic block starts to use new time monitoring through the Hall sensor, the current monitoring result is abandoned, the time is recorded from the.
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