CN115230265A - Sensing layer for intelligent conveying belt and preparation method thereof - Google Patents

Sensing layer for intelligent conveying belt and preparation method thereof Download PDF

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CN115230265A
CN115230265A CN202211082804.1A CN202211082804A CN115230265A CN 115230265 A CN115230265 A CN 115230265A CN 202211082804 A CN202211082804 A CN 202211082804A CN 115230265 A CN115230265 A CN 115230265A
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layer
internal mixer
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sensing
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CN115230265B (en
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袁佳春
陈爱华
王连娇
陈希
高灿宏
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Wuxi Baotong Intelligent Iot Technology Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/04—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/02—Elements
    • C08K3/04—Carbon
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/02—Elements
    • C08K3/04—Carbon
    • C08K3/041—Carbon nanotubes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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    • C08K3/30—Sulfur-, selenium- or tellurium-containing compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/22—Expanded, porous or hollow particles
    • C08K7/24—Expanded, porous or hollow particles inorganic
    • C08K7/26—Silicon- containing compounds
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    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/20—Oxides; Hydroxides
    • C08K3/22—Oxides; Hydroxides of metals
    • C08K2003/2227—Oxides; Hydroxides of metals of aluminium
    • C—CHEMISTRY; METALLURGY
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    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/30—Sulfur-, selenium- or tellurium-containing compounds
    • C08K2003/3045—Sulfates
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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Abstract

The invention belongs to the technical field of conveying belts, and particularly relates to a sensing layer for an intelligent conveying belt and a preparation method thereof. The sensing layer for the intelligent conveying belt has a three-layer structure, the upper surface and the lower surface of the sensing layer are covered with signal isolation layers, the middle of the sensing layer is a signal generation layer, sensing electrodes exist in the signal generation layer, and the sensing electrodes can capture current changes in the signal generation layer. The sensing layer is arranged in the covering rubber of the conveyer belt or the belt core, has the characteristic of high-sensitivity strain sensing in the running strain range of the conveyer belt, has ideal physical and mechanical properties and can be tightly combined with the conveyer belt of a natural butadiene styrene butadiene rubber covering system. The detection technology of the sensing layer combined detection system provided by the invention has the advantages that the detection accuracy and the detection universality are greatly improved, and the conveyor belt can have the self-sensing capability by combining the related technology of the digital conveyor belt.

Description

Sensing layer for intelligent conveying belt and preparation method thereof
Technical Field
The invention belongs to the technical field of conveying belts, and particularly relates to a sensing layer for an intelligent conveying belt and a preparation method thereof.
Background
Conveyor belts are a common piece of equipment used to carry and transport bulk materials. The conveyer belt used by industrial and mining units is generally in a severe application environment, the conveyer belt is easily damaged and destroyed by foreign matters or external mechanical structures, common destruction forms comprise longitudinal tearing of the conveyer belt, damage of a joint of the conveyer belt, transverse breakage of a belt body of the conveyer belt and the like, a plurality of methods for monitoring the defects are available on the market, for example, a stretching switch method, a linear laser method, a material leakage swing plate method and the like can be adopted for monitoring the longitudinal tearing, an X-ray detection method and a magnetic field positioning method can be adopted for monitoring the joint, and a high-speed camera shooting method and a tensioner tension monitoring method and the like can be adopted for monitoring the transverse breakage of the belt body of the conveyer belt. These methods are all detection of specific functions by externally applying various forms of observation. However, the above methods are all external detection, and the damage is generated inside the conveyor belt, the damage characteristics are transformed from inside to outside, the transformation is performed from one characteristic to another characteristic, the fuzzy and fade characteristics with different degrees of characteristics are generated, and finally the external detection distortion is caused, so that the problems of false judgment and false judgment on the damage and the damage of the conveyor belt are caused.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a sensing layer for an intelligent conveying belt and a preparation method thereof, and aims to solve the technical problems that the existing monitoring method for the damage of the conveying belt is external detection, the damage is generated in the conveying belt, the damage characteristics are changed from inside to outside, the fuzziness and desalination of different degrees of characteristics are generated, the external detection distortion is finally caused, and the misjudgment and the missing judgment of the damage and the damage of the conveying belt are further caused.
The invention provides a sensing layer for an intelligent conveying belt, which has the following specific technical scheme:
the sensing layer for the intelligent conveying belt comprises a signal generating layer and signal isolating layers covering the upper surface and the lower surface of the signal generating layer, and sensing electrodes are implanted between the signal generating layer and the signal isolating layers on one side of the signal generating layer;
the signal generation layer comprises the following components in parts by weight: 100 parts of isoprene rubber, 3-6 parts of zinc stearate, 0.8-1.2 parts of accelerator CBBS, 0.1-0.2 part of accelerator TBZTD, 1.2-1.8 parts of insoluble sulfur powder, 8-15 parts of aromatic oil, 0.5-1.0 part of anti-aging agent BLE, 20-30 parts of carbon black N234 and 20-30 parts of signal generator, wherein the signal generator comprises bismuth oxide, multi-walled carbon nanotube EC-MG and carbon black vxc-72;
the signal isolation layer comprises the following components in parts by weight: 100 parts of isoprene rubber, 3-6 parts of zinc stearate, 0.5-0.8 part of accelerator CBBS, 0.1-0.2 part of accelerator TBZTD, 0.8-1.6 parts of insoluble sulfur powder, 8-15 parts of aromatic oil, 0.5-1.0 part of anti-aging agent BLE, 0.5-2.5 parts of adhesive AS-88, 5-15 parts of carbon black N330 and 30-50 parts of signal shielding agent, wherein the signal shielding agent is barium sulfate, fumed silica, aluminum oxide and coupling agent KH-550.
In certain embodiments, the ratio of the bismuth oxide, the multi-walled carbon nanotubes EC-MG, and the carbon black vxc-72 is 1.
In certain embodiments, the ratio of said barium sulfate, said fumed silica, said alumina, and said coupling agent KH-550 is 5.
The invention also provides a preparation method of the sensing layer for the intelligent conveying belt, which is used for the sensing layer and comprises the following steps:
s1, mixing and uniformly molding 100 parts of isoprene rubber, 3-6 parts of zinc stearate, 0.8-1.2 parts of accelerator CBBS, 0.1-0.2 part of accelerator TBZTD, 1.2-1.8 parts of insoluble sulfur powder, 8-15 parts of aromatic oil, 0.5-1.0 part of anti-aging agent BLE-65, 20-30 parts of carbon black N234 and 20-30 parts of signal generator to obtain a signal generation layer;
s2, mixing and uniformly mixing 100 parts of isoprene rubber, 3-6 parts of zinc stearate, 0.5-0.8 part of accelerator CBBS, 0.1-0.2 part of accelerator TBZTD, 0.8-1.6 parts of insoluble sulfur powder, 8-15 parts of aromatic oil, 0.5-1.0 part of anti-aging agent BLE-65, 0.5-2.5 parts of adhesive AS-88, 5-15 parts of carbon black N330 and 30-50 parts of signal shielding agent to form a signal isolation layer;
and S3, placing the signal generation layer in the step S1 between two isolation layers, placing the sensing electrode between the generation layer and the isolation layers, and compacting to obtain the sensing layer for the intelligent conveying belt.
In certain embodiments, step S1 comprises the steps of:
s11, weighing bismuth oxide, a multi-walled carbon nanotube EC-MG and carbon black vxc-72 according to the weight ratio of 1;
s12, weighing 100 parts of isoprene rubber, adding the isoprene rubber into an internal mixer, wherein the rotating speed of a rotor of the internal mixer is 22-24 r/min, and stirring for 20-30 seconds; then 20-30 parts of the signal generating agent in the step S11 is added into an internal mixer, the rotating speed of a rotor of the internal mixer is controlled at 22-24 r/min, the mixture is stirred for 40-50 seconds, then the mixture is discharged, and the mixture is cooled at room temperature and is parked for more than 4 hours to obtain a section of mixture;
s13, adding the rubber material obtained in the step S12 into an internal mixer, controlling the rotating speed of a rotor of the internal mixer to be 22-24 r/min, and stirring for 20-30 seconds; then adding 3-6 parts of stearic acid, 0.8-1.2 parts of accelerator CBBS, 3-6 parts of zinc stearate, 0.8-1.2 parts of accelerator CBBS, 8-15 parts of aromatic oil, 0.5-1.0 part of anti-aging agent BLE-65 and 20-30 parts of carbon black N into an internal mixer, continuously stirring for 40-50 seconds; then adding 0.1-0.2 part of accelerator TBZTD and 1.2-1.8 parts of insoluble sulfur powder, stirring for 50-60 seconds, discharging the sizing material, cooling at room temperature, standing for more than 4 hours, and obtaining a second-stage sizing material;
and S14, feeding the two-stage rubber material obtained in the step S13 into an open mill, turning over for 8-12 times, discharging, adjusting the thickness of the discharged sheet to 1-1.5 mm, and cooling to room temperature after discharging to obtain a signal generation layer.
In certain embodiments, step S2 comprises the steps of:
s21, weighing barium sulfate, fumed silica, aluminum oxide and a coupling agent KH-550 according to a weight ratio of 5;
s22, weighing 100 parts of isoprene rubber, adding the isoprene rubber into an internal mixer, controlling the rotating speed of a rotor of the internal mixer to be 22-24 r/min, and stirring for 20-30 seconds; then 30-50 parts of signal separant is added into the internal mixer, the rotor speed of the internal mixer is 24-26 r/min, and the mixture is stirred for 50-60 seconds; discharging the sizing material, cooling at room temperature and standing for more than 4 hours to obtain a first sizing material;
s23, adding the rubber material obtained in the step S22 into an internal mixer, wherein the rotating speed of a rotor of the internal mixer is 22-24 r/min; stirring for 20-30 seconds, opening a top plug, adding 3-6 parts of zinc stearate, 0.5-0.8 part of accelerator CBBS, 0.1-0.2 part of accelerator TBZTD, 0.8-1.6 parts of insoluble sulfur powder, 8-15 parts of aromatic oil, 0.5-1.0 part of antioxidant BLE-65, 0.5-2.5 parts of adhesive AS-88 and 5-15 parts of carbon black N330 into an internal mixer, continuously stirring for 40-50 seconds; then adding 0.1-0.2 part of accelerator TBZTD and 1.2-1.8 parts of insoluble sulfur powder, stirring for 50-60 seconds, discharging the sizing material, cooling at room temperature, standing for more than 4 hours to obtain a second-stage sizing material
And S24, feeding the two-stage rubber material obtained in the step S23 into an open mill, turning over for 8-12 times, discharging, adjusting the thickness of the discharged sheet to 1-1.5 mm, and cooling to room temperature after discharging to obtain the signal isolation layer.
The invention has the following beneficial effects: the invention provides a sensing layer for an intelligent conveying belt, which is an elastomer material for the function of a conveying belt body, the material can be combined with a conveying belt rubber layer into a whole, a foreign body structure cannot be formed, the material can provide physical properties similar to those of the conveying belt rubber layer and has strain sensing capacity, an external data receiver can receive real-time data of synchronous strain of the conveying belt sensing layer and the rubber layer in real time by implanting a sensing electrode and a processing unit in the conveying belt, and the data can accurately represent the current running strain state of the conveying belt so as to represent whether longitudinal tearing, joint damage, transverse breakage and other characteristics of the corresponding conveying belt occur. The functional elastomer and the sensing layer structure formed by the functional elastomer have the characteristic of high-sensitivity strain induction in the running strain range of the conveyor belt, have ideal physical and mechanical properties and can be tightly combined with the conveyor belt of a natural butadiene styrene butadiene rubber covered system. The technology for detecting the strain of the conveyer belt by using the sensing layer, the structure of the sensing layer and the preparation method provided by the invention can enable the conveyer belt body to have self-sensing capability, the capability can derive various monitoring capabilities such as tearing, breakage, joint stretching and the like of the conveyer belt, the detection technology combined with a detection system is greatly improved in detection accuracy and universality compared with the traditional technology, and the conveyer belt can have the self-sensing capability by combining with the related technology of a digital conveyer belt.
Drawings
Fig. 1 is a graph showing the results of strain resistance tests of the sensor layer of the present invention and the rubber material of the comparative example.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings 1 in conjunction with specific embodiments.
Example 1
The sensing layer for intelligent conveyer belt that this embodiment provided, concrete technical scheme is as follows:
the sensing layer for the intelligent conveying belt comprises a signal generation layer and signal isolation layers covering the upper surface and the lower surface of the signal generation layer, wherein sensing electrodes are implanted in the signal generation layer;
the signal generation layer comprises the following components in parts by weight: 100 parts of isoprene rubber, 3 parts of zinc stearate, 0.8 part of accelerator CBBS, 0.1 part of accelerator TBZTD, 1.2 parts of insoluble sulfur powder, 8 parts of aromatic oil, 0.5 part of anti-aging agent BLE-65, 20 parts of carbon black N234 and 20 parts of signal generator, wherein the signal generator comprises bismuth oxide, a multi-wall carbon nanotube EC-MG and carbon black vxc-72, and the ratio of the three raw materials is 1;
the signal isolation layer comprises the following components in parts by weight: 100 parts of isoprene rubber, 3 parts of zinc stearate, 0.5 part of accelerator CBBS, 0.1 part of accelerator TBZTD, 0.8 part of insoluble sulfur powder, 8 parts of aromatic oil, 0.5 part of anti-aging agent BLE-65, 0.5 part of adhesive AS-88, 5 parts of carbon black N330 and 30 parts of signal shielding agent, wherein the signal shielding agent comprises barium sulfate, gas phase method silicon dioxide, aluminum oxide and coupling agent KH-550, and the ratio of the four raw materials is 5.
The preparation method of the sensing layer for the intelligent conveying belt comprises the following steps:
1) Signal generation layer
(1) Signal generating agent: weighing bismuth oxide, a multi-walled carbon nanotube EC-MG and carbon black vxc-72 according to the weight ratio of 1;
(2) Mixing: weighing 100 parts by weight of isoprene rubber, adding the isoprene rubber into an internal mixer, pressing a top bolt, and controlling the rotating speed of a rotor of the internal mixer at 24 revolutions per minute; after stirring for 20 seconds, opening a top bolt, and adding 20 parts of signal generating agent into an internal mixer; pressing a top bolt, and controlling the rotating speed of a rotor of the internal mixer to be 24 r/min; stirring for 40 seconds, discharging the sizing material, cooling at room temperature and standing for more than 4 hours to prepare a first-stage sizing material;
taking a section of rubber material, adding the rubber material into an internal mixer, pressing a top bolt on the internal mixer, and controlling the rotating speed of a rotor of the internal mixer to be 24 r/min; stirring for 20 seconds, opening a top bolt, adding 3 parts by weight of zinc stearate, 0.8 part by weight of accelerator CBBS, 8 parts by weight of aromatic oil, 0.5 part by weight of anti-aging agent BLE-65 and 20 parts by weight of carbon black N234 into an internal mixer, pressing the top bolt, and continuing stirring; stirring for 40 seconds, opening a top plug, adding 0.1 weight part of accelerator TBZTD and 1.2 weight parts of insoluble sulfur powder, stirring for 50 seconds, discharging the rubber material, cooling at room temperature, standing for more than 4 hours, and preparing a second-stage rubber material;
(3) And (3) uniformly refining and forming: and (3) feeding the two-stage rubber material into an open mill, turning over for 8 times, discharging, adjusting the thickness of the discharged sheet to 1mm, and cooling to room temperature after discharging to obtain the signal isolation layer.
2) Signal isolation layer
(1) Signal shielding agent: weighing barium sulfate, fumed silica, aluminum oxide and a coupling agent KH-550 according to a weight ratio of 5;
(2) Mixing: weighing 100 parts by weight of isoprene rubber, adding the isoprene rubber into an internal mixer, pressing a top bolt, and controlling the rotating speed of a rotor of the internal mixer at 24 revolutions per minute; stirring for 20 seconds, opening a top bolt, and adding 30 parts of signal isolating agent into an internal mixer; pressing a top bolt, and controlling the rotating speed of a rotor of the internal mixer to be 26 r/min; stirring for 50 seconds, discharging the sizing material, cooling at room temperature, standing for more than 4 hours, and preparing a first-stage sizing material;
taking a section of rubber material, adding the rubber material into an internal mixer, pressing a top bolt on the internal mixer, and controlling the rotating speed of a rotor of the internal mixer to be 24 r/min; after stirring for 20 seconds, opening a top bolt, adding 3 parts by weight of zinc stearate, 0.5 part by weight of accelerator CBBS, 0.1 part by weight of accelerator TBZTD, 0.8 part by weight of insoluble sulfur powder, 8 parts by weight of aromatic oil, 0.5 part by weight of antioxidant BLE-65, 0.5 part by weight of adhesive AS-88 and 5 parts by weight of carbon black N330 into an internal mixer, and pressing the top bolt to continue stirring; stirring for 40 seconds, opening a top plug, adding 0.1 weight part of accelerator TBZTD and 1.2 weight parts of insoluble sulfur powder, stirring for 50 seconds, discharging the sizing material, cooling at room temperature, standing for more than 4 hours, and preparing a second-stage sizing material;
(3) Mixing and forming: and (3) feeding the two-stage rubber material into an open mill, turning over the rubber material for 8 times, then discharging the rubber material, adjusting the thickness of the discharged rubber material to be 1mm, and cooling the rubber material to room temperature after discharging to obtain the signal isolation layer.
3) Making a sensing layer
One piece of signal generation layer film, two pieces of signal isolation layer film and one set of sensing electrode are taken, the sizes of the films are ensured to be consistent, the signal generation layer is arranged between the two isolation layers, and the sensing electrode is arranged between the generation layer and the isolation layers and is compressed and compacted, so that the sensing layer for the intelligent conveying belt is formed. When the conveyer belt is manufactured, the sensing layer is used for replacing a covering glue layer close to the belt core.
Example 2
The sensing layer for intelligent conveyer belt that this embodiment provided, concrete technical scheme is as follows:
the sensing layer for the intelligent conveying belt comprises a signal generating layer and signal isolating layers covering the upper surface and the lower surface of the signal generating layer, and sensing electrodes are implanted in the signal generating layer;
the signal generation layer comprises the following components in parts by weight: 100 parts of isoprene rubber, 6 parts of zinc stearate, 1.2 parts of accelerator CBBS, 0.2 part of accelerator TBZTD, 1.8 parts of insoluble sulfur powder, 15 parts of aromatic oil, 1.0 part of anti-aging agent BLE-65, 30 parts of carbon black N234 and 30 parts of signal generator, wherein the signal generator comprises bismuth oxide, a multi-walled carbon nanotube EC-MG and carbon black vxc-72, and the proportion of the three raw materials is 1;
the signal isolation layer comprises the following components in parts by weight: 100 parts of isoprene rubber, 6 parts of zinc stearate, 0.8 part of a promoter CBBS, 0.2 part of a promoter TBZTD, 1.6 parts of insoluble sulfur powder, 15 parts of aromatic oil, 1.0 part of an anti-aging agent BLE-65, 2.5 parts of an adhesive AS-88, 15 parts of carbon black N330 and 50 parts of a signal shielding agent, wherein the signal shielding agent comprises barium sulfate, fumed silica, aluminum oxide and a coupling agent KH-550, and the ratio of the four raw materials is 5.
The preparation method of the sensing layer for the intelligent conveying belt comprises the following steps:
1) Signal generation layer
(1) Signal generating agent: weighing bismuth oxide, a multi-walled carbon nanotube EC-MG and carbon black vxc-72 according to the weight ratio of 1;
(2) Mixing: weighing 100 parts by weight of isoprene rubber, adding the isoprene rubber into an internal mixer, pressing a top bolt, and controlling the rotating speed of a rotor of the internal mixer at 22 revolutions per minute; stirring for 30 seconds, opening a top bolt, and adding 30 parts of signal generating agent into an internal mixer; pressing a top bolt, and controlling the rotating speed of a rotor of the internal mixer to be 22 rpm; stirring for 50 seconds, discharging the sizing material, cooling at room temperature and standing for more than 4 hours to prepare a first-stage sizing material;
taking a section of rubber material, adding the rubber material into an internal mixer, pressing a top bolt on the internal mixer, and controlling the rotating speed of a rotor of the internal mixer to be 22 revolutions per minute; stirring for 30 seconds, opening a top bolt, adding 6 parts by weight of zinc stearate, 1.2 parts by weight of accelerator CBBS, 15 parts by weight of aromatic oil, 1.0 part by weight of anti-aging agent BLE-65 and 30 parts by weight of carbon black N234 into an internal mixer, pressing the top bolt, and continuing stirring; stirring for 50 seconds, opening a top plug, adding 0.2 weight part of accelerator TBZTD and 1.8 weight parts of insoluble sulfur powder, stirring for 60 seconds, discharging the rubber material, cooling at room temperature, standing for more than 4 hours, and preparing a second-stage rubber material;
(3) Mixing and forming: and (3) feeding the two-stage rubber material into an open mill, turning over for 12 times, discharging, adjusting the thickness of the discharged sheet to 1.5mm, and cooling to room temperature after discharging to obtain the signal isolation layer.
2) Signal isolation layer
(1) Signal shielding agent: weighing barium sulfate, fumed silica, aluminum oxide and a coupling agent KH-550 according to a weight ratio of 5;
(2) Mixing: weighing 100 parts by weight of isoprene rubber, adding the isoprene rubber into an internal mixer, pressing a top bolt, and controlling the rotating speed of a rotor of the internal mixer at 22 revolutions per minute; stirring for 30 seconds, opening a top bolt, and adding 50 parts of signal separant into an internal mixer; pressing a top bolt, and controlling the rotating speed of a rotor of an internal mixer to be 24 revolutions per minute; stirring for 60 seconds, discharging the sizing material, cooling at room temperature, standing for more than 4 hours, and preparing a first-stage sizing material;
taking a section of rubber material, adding the rubber material into an internal mixer, pressing a top bolt on the internal mixer, and controlling the rotating speed of a rotor of the internal mixer to be 22 revolutions per minute; after stirring for 30 seconds, opening the top plug, adding 6 parts by weight of zinc stearate, 0.8 part by weight of accelerator CBBS, 0.2 part by weight of accelerator TBZTD, 1.6 parts by weight of insoluble sulfur powder, 15 parts by weight of aromatic oil, 1.0 part by weight of anti-aging agent BLE, 2.5 parts by weight of adhesive AS-88 and 15 parts by weight of carbon black N330 into an internal mixer, pressing the top plug and continuously stirring; stirring for 40 seconds, opening a top plug, adding 0.2 weight part of accelerator TBZTD and 1.2-1.8 weight parts of insoluble sulfur powder, stirring for 50 seconds, discharging the rubber material, cooling at room temperature, standing for more than 4 hours, and preparing a second-stage rubber material;
(3) And (3) uniformly refining and forming: and (3) feeding the two-stage rubber material into an open mill, turning over for 8-12 times, discharging the rubber material, adjusting the thickness of the discharged rubber material to 1-1.5 mm, and cooling to room temperature after discharging to obtain the signal isolation layer.
3) Making a sensing layer
One piece of signal generation layer film, two pieces of signal isolation layer film and one set of sensing electrode are taken, the sizes of the films are ensured to be consistent, the signal generation layer is arranged between the two isolation layers, and the sensing electrode is arranged between the generation layer and the isolation layers and is compressed and compacted, so that the sensing layer for the intelligent conveying belt is formed. When the conveyer belt is manufactured, the sensing layer is used for replacing a covering glue layer close to the belt core.
Example 3
The sensing layer for intelligent conveyer belt that this embodiment provided, concrete technical scheme is as follows:
the sensing layer for the intelligent conveying belt comprises a signal generation layer and signal isolation layers covering the upper surface and the lower surface of the signal generation layer, wherein sensing electrodes are implanted in the signal generation layer;
the signal generation layer comprises the following components in parts by weight: 100 parts of isoprene rubber, 5 parts of zinc stearate, 1 part of accelerator CBBS, 0.15 part of accelerator TBZTD, 1.5 parts of insoluble sulfur powder, 10 parts of aromatic oil, 0.8 part of anti-aging agent BLE-65, 25 parts of carbon black N234 and 25 parts of signal generator, wherein the signal generator comprises bismuth oxide, a multi-wall carbon nanotube EC-MG and carbon black vxc-72, and the proportion of the three raw materials is 1;
the signal isolation layer comprises the following components in parts by weight: 100 parts of isoprene rubber, 4 parts of zinc stearate, 0.6 part of accelerator CBBS, 0.15 part of accelerator TBZTD, 1 part of insoluble sulfur powder, 10 parts of aromatic oil, 0.8 part of anti-aging agent BLE-65, 1.5 parts of adhesive AS-88, 10 parts of carbon black N330 and 40 parts of signal shielding agent, wherein the signal shielding agent is barium sulfate, fumed silica, aluminum oxide and coupling agent KH-550, and the ratio of the four raw materials is 5.
The preparation method of the sensing layer for the intelligent conveying belt comprises the following steps:
1) Signal generation layer
(1) Signal generating agent: weighing bismuth oxide, a multi-walled carbon nanotube EC-MG and carbon black vxc-72 according to the weight ratio of 1;
(2) Mixing: weighing 100 parts by weight of isoprene rubber, adding the isoprene rubber into an internal mixer, pressing a top bolt, and controlling the rotating speed of a rotor of the internal mixer at 23 r/min; after stirring for 25 seconds, opening a top bolt, and adding 25 parts of signal generating agent into an internal mixer; pressing a top bolt, and controlling the rotating speed of a rotor of the internal mixer to be 23 revolutions per minute; stirring for 45 seconds, discharging the sizing material, cooling at room temperature, standing for more than 4 hours, and preparing a section of sizing material;
taking a section of rubber material, adding the rubber material into an internal mixer, pressing a top bolt on the internal mixer, and controlling the rotating speed of a rotor of the internal mixer to be 23 revolutions per minute; after stirring for 25 seconds, opening the top plug, adding 5 parts by weight of zinc stearate, 1 part by weight of accelerator CBBS, 10 parts by weight of aromatic oil, 0.8 part by weight of anti-aging agent BLE-65 and 25 parts by weight of carbon black N into an internal mixer, pressing the top plug, and continuing stirring; stirring for 45 seconds, opening a top plug, adding 0.15 weight part of accelerator TBZTD and 1.5 weight parts of insoluble sulfur powder, stirring for 55 seconds, discharging the rubber material, cooling at room temperature, standing for more than 4 hours, and preparing a second-stage rubber material;
(3) Mixing and forming: and (3) feeding the two-stage rubber material into an open mill, turning over for 10 times, discharging, adjusting the thickness of the discharged sheet to 1.2mm, and cooling to room temperature after discharging to obtain the signal isolation layer.
2) Signal isolation layer
(1) Signal shielding agent: weighing barium sulfate, fumed silica, aluminum oxide and a coupling agent KH-550 according to the weight ratio of 5;
(2) Mixing: weighing 100 parts by weight of isoprene rubber, adding the isoprene rubber into an internal mixer, pressing a top bolt, and controlling the rotating speed of a rotor of the internal mixer at 23 r/min; stirring for 25 seconds, opening a top bolt, and adding 40 parts of signal isolating agent into an internal mixer; pressing a top bolt, and controlling the rotating speed of a rotor of the internal mixer to be 25 rpm; stirring for 55 seconds, discharging the sizing material, cooling at room temperature, standing for more than 4 hours, and preparing a section of sizing material;
taking a section of rubber material, adding the rubber material into an internal mixer, pressing a top bolt, and controlling the rotating speed of a rotor of the internal mixer to be 23 r/min; stirring for 25 seconds, opening a top plug, adding 4 parts by weight of zinc stearate, 0.6 part by weight of accelerator CBBS, 0.15 part by weight of accelerator TBZTD, 1 part by weight of insoluble sulfur powder, 10 parts by weight of aromatic oil, 0.8 part by weight of anti-aging agent BLE-65, 1.5 parts by weight of adhesive AS-88 and 10 parts by weight of carbon black N330, pressing the top plug and continuously stirring; stirring for 45 seconds, opening a top plug, adding 0.15 weight part of accelerator TBZTD and 1.5 weight parts of insoluble sulfur powder, stirring for 55 seconds, discharging the rubber material, cooling at room temperature, standing for more than 4 hours, and preparing a second-stage rubber material;
(3) And (3) uniformly refining and forming: and (3) feeding the two-stage rubber material into an open mill, turning over for 10 times, discharging, adjusting the thickness of the discharged sheet to 1.2mm, and cooling to room temperature after discharging to obtain the signal isolation layer.
3) Making a sensing layer
One piece of signal generation layer film, two pieces of signal isolation layer film and one set of sensing electrode are taken, the sizes of the films are ensured to be consistent, the signal generation layer is arranged between the two isolation layers, and the sensing electrode is arranged between the generation layer and the isolation layers and is compressed and compacted, so that the sensing layer for the intelligent conveying belt is formed. When the conveyer belt is manufactured, the sensing layer is used for replacing a covering glue layer close to the belt core.
Comparative example 1
Formula of common conductive rubber 1: 100 parts of natural rubber, 3 parts of nano zinc oxide, 1.5 parts of stearic acid, 234 parts of carbon black N, 1 part of accelerator CBS, 0 part of anti-aging agent 4022, 5 parts of coumarone resin, 10 parts of aromatic oil, 1.5 parts of sulfur powder and 2 parts of microcrystalline wax.
Comparative example 2
The formula of the common conductive rubber 2 is as follows: 100 parts of natural rubber, 3 parts of nano zinc oxide, 1.5 parts of stearic acid, 45 parts of acetylene black, 1 part of accelerator CBS, 0 part of anti-aging agent 4022, 5 parts of coumarone resin, 10 parts of aromatic oil, 1.5 parts of sulfur powder and 2 parts of microcrystalline wax.
Comparative example 3
The general rubber conveyer belt covering rubber formula comprises the following components: 100 parts of natural rubber, 3 parts of nano zinc oxide, 1.5 parts of stearic acid, 50 parts of carbon black N330, 1 part of accelerator CBS, 0 part of anti-aging agent 4022, 5 parts of coumarone resin, 10 parts of aromatic oil, 1.5 parts of sulfur powder and 2 parts of microcrystalline wax.
The sensor layers of the present invention and the rubbers of comparative examples 1-3 were tested for performance, and the results were as follows:
TABLE 1 conventional Property testing
Figure BDA0003834091120000081
TABLE 2 Strain resistance test
Strain sensitive sensitivity index (Σ δ Rn/R0, n =10% -100%)
Inventive sensing layer 72.4
Ordinary conductive rubber 1 3.7
Ordinary conductive rubber 2 6.4
Universal covering glue 13.2
As shown in FIG. 1 and tables 1-2, the sensing layer prepared by the invention has high sensitive strain sensing capability under the deformation (0-100% tensile deformation) of the conveyer belt during operation. The sensing layer mode is embedded in the conveying belt, so that the conveying belt is damaged (torn, broken, impacted and the like), the inner part of the conveying belt can firstly sense the damage and then diffuse to the outside, external characteristics (such as temperature rise, surface traces and the like) are formed, the monitoring by an external means can be subjected to one more characteristic conversion, the conversion process can cause distortion, and high misjudgment and misjudgment exist in the appearance through external detection. The sensing layer is directly planted in the conveying belt and integrated with the conveying belt, the damage of the conveying belt can synchronously cause the strain of the sensing layer, and the deformation process does not exist, so the detection is more accurate and faster. According to the invention, the strain induction sensitivity index is greatly improved through special formula components, and the sensing layer is obviously different from other contrast glue, so that the strain self-induction detection of the conveyer belt is feasible. The higher the strain sensing sensitivity, the easier the resistance change detection thereof, and the stronger the applicability thereof.
In summary, the sensing layer for the intelligent conveyor belt provided by the invention is an elastomer material for the conveyor belt body function, the material can be integrated with the conveyor belt rubber layer, a foreign body structure cannot be formed, the material can provide physical properties similar to those of the conveyor belt rubber layer and has strain sensing capability, the strain sensing capability refers to that some electrical properties of the material are synchronously changed when the material is subjected to physical changes, the synchronization refers to that the material conforms to a linear or more complex functional relationship, and the electrical properties have measurable properties. We can reverse their strain by measuring changes in their electrical properties. The sensing electrode and the processing unit are implanted in the conveying belt, the processing unit of the electrode is a part which is embedded in the conveying belt and connected with the tail end of the electrode, the processing unit is responsible for acquiring signals and wirelessly transmitting the signals to the outside of the conveying belt, the external data receiver can receive real-time data of synchronous strain of the sensing layer and the rubber layer of the conveying belt in real time, and the data can accurately represent the current operation strain state of the conveying belt and represent whether the corresponding conveying belt generates longitudinal tearing, joint damage, transverse fracture and other characteristics. Compared with the traditional technology, the detection technology of the sensing layer combined detection system provided by the invention has the advantages that the detection accuracy and the detection universality are greatly improved, and the conveyor belt can have the self-sensing capability by combining the related technology of the digital conveyor belt.
The above description is only a preferred and practical embodiment of the present invention, and is not intended to limit the present invention, and the present invention is not limited to the above examples, and those skilled in the art should also make changes, modifications, additions or substitutions within the spirit and scope of the present invention.

Claims (6)

1. The sensing layer for the intelligent conveying belt is characterized by comprising a signal generating layer and signal isolating layers covering the upper surface and the lower surface of the signal generating layer, wherein sensing electrodes are implanted between the signal generating layer and the signal isolating layers on one side of the signal generating layer;
the signal generation layer comprises the following components in parts by weight: 100 parts of isoprene rubber, 3-6 parts of zinc stearate, 0.8-1.2 parts of accelerator CBBS, 0.1-0.2 part of accelerator TBZTD, 1.2-1.8 parts of insoluble sulfur powder, 8-15 parts of aromatic oil, 20-30 parts of anti-aging agent BLE 650.5, 20-30 parts of carbon black N234 and 20-30 parts of signal generator, wherein the signal generator comprises bismuth oxide, a multi-wall carbon nanotube EC-MG and carbon black vxc-72;
the signal isolation layer comprises the following components in parts by weight: 100 parts of isoprene rubber, 3-6 parts of zinc stearate, 0.5-0.8 part of accelerator CBBS, 0.1-0.2 part of accelerator TBZTD, 0.8-1.6 parts of insoluble sulfur powder, 8-15 parts of aromatic oil, 0.5-1.0 part of anti-aging agent BLE, 0.5-2.5 parts of adhesive AS-88, 5-15 parts of carbon black N330 and 30-50 parts of signal shielding agent, wherein the signal shielding agent is barium sulfate, fumed silica, aluminum oxide and coupling agent KH-550.
2. The sensing layer for a smart belt of claim 1, wherein the ratio of the bismuth oxide, the multi-walled carbon nanotubes EC-MG, and the carbon black vxc-72 is 1.
3. The sensing layer for the intelligent conveying belt according to claim 1, wherein the ratio of the barium sulfate, the fumed silica, the aluminum oxide and the coupling agent KH-550 is 5.
4. A method for producing a sensor layer for a smart belt, for producing the sensor layer according to any one of claims 1 to 3, comprising the steps of:
s1, mixing and uniformly mixing 100 parts of isoprene rubber, 3-6 parts of zinc stearate, 0.8-1.2 parts of accelerator CBBS, 0.1-0.2 part of accelerator TBZTD, 1.2-1.8 parts of insoluble sulfur powder, 8-15 parts of aromatic oil, 0.5-1.0 part of anti-aging agent BLE-65, 20-30 parts of carbon black N234 and 20-30 parts of signal generator to form a signal generating layer;
s2, mixing and uniformly molding 100 parts of isoprene rubber, 3-6 parts of zinc stearate, 0.5-0.8 part of accelerator CBBS, 0.1-0.2 part of accelerator TBZTD, 0.8-1.6 parts of insoluble sulfur powder, 8-15 parts of aromatic oil, 42-1.0 part of age inhibitor BLE-650.5, 0.5-2.5 parts of adhesive AS-88, 5-15 parts of carbon black N330 and 30-50 parts of signal shielding agent to obtain a signal isolation layer;
and S3, placing the signal generation layer in the step S1 between two isolation layers, placing the sensing electrode between the generation layer and the isolation layers, and compacting to obtain the sensing layer for the intelligent conveying belt.
5. The method for preparing the sensing layer for the intelligent conveyor belt according to claim 4, wherein the step S1 comprises the following steps:
s11, weighing bismuth oxide, a multi-walled carbon nanotube EC-MG and carbon black vxc-72 according to the weight ratio of 1;
s12, weighing 100 parts of isoprene rubber, adding the isoprene rubber into an internal mixer, wherein the rotating speed of a rotor of the internal mixer is 22-24 r/min, and stirring for 20-30 seconds; then 20-30 parts of the signal generating agent in the step S11 is added into an internal mixer, the rotating speed of a rotor of the internal mixer is controlled at 22-24 r/min, the mixture is stirred for 40-50 seconds, then the mixture is discharged, and the mixture is cooled at room temperature and is parked for more than 4 hours to obtain a section of mixture;
s13, adding the rubber material obtained in the step S12 into an internal mixer, controlling the rotating speed of a rotor of the internal mixer to be 22-24 r/min, and stirring for 20-30 seconds; then adding 3-6 parts of stearic acid, 0.8-1.2 parts of accelerator CBBS, 3-6 parts of zinc stearate, 0.8-1.2 parts of accelerator CBBS, 8-15 parts of aromatic oil, 0.5-1.0 part of anti-aging agent BLE-65 and 20-30 parts of carbon black N into an internal mixer, continuously stirring for 40-50 seconds; then adding 0.1-0.2 part of accelerator TBZTD and 1.2-1.8 parts of insoluble sulfur powder, stirring for 50-60 seconds, discharging the sizing material, cooling at room temperature, standing for more than 4 hours, and obtaining a second-stage sizing material;
and S14, feeding the two-stage rubber material obtained in the step S13 into an open mill, turning over for 8-12 times, discharging, adjusting the thickness of the discharged sheet to 1-1.5 mm, and cooling to room temperature after discharging to obtain a signal generation layer.
6. The method for preparing the sensing layer for the intelligent conveyor belt according to claim 4, wherein the step S2 comprises the following steps:
s21, weighing barium sulfate, fumed silica, aluminum oxide and a coupling agent KH-550 according to a weight ratio of 5;
s22, weighing 100 parts of isoprene rubber, adding the isoprene rubber into an internal mixer, controlling the rotating speed of a rotor of the internal mixer to be 22-24 r/min, and stirring for 20-30 seconds; then 30-50 parts of signal isolating agent is added into the internal mixer, the rotating speed of a rotor of the internal mixer is 24-26 r/min, and the mixture is stirred for 50-60 seconds; discharging the sizing material, cooling at room temperature and standing for more than 4 hours to obtain a section of sizing material;
s23, adding the rubber material obtained in the step S22 into an internal mixer, wherein the rotating speed of a rotor of the internal mixer is 22-24 r/min; stirring for 20-30 seconds, opening a top plug, adding 3-6 parts of zinc stearate, 0.5-0.8 part of accelerator CBBS, 0.1-0.2 part of accelerator TBZTD, 0.8-1.6 parts of insoluble sulfur powder, 8-15 parts of aromatic oil, 0.5-1.0 part of antioxidant BLE-65, 0.5-2.5 parts of adhesive AS-88 and 5-15 parts of carbon black N330 into an internal mixer, continuously stirring for 40-50 seconds; then adding 0.1-0.2 part of accelerator TBZTD and 1.2-1.8 parts of insoluble sulfur powder, stirring for 50-60 seconds, discharging the sizing material, cooling at room temperature, standing for more than 4 hours to obtain a second-stage sizing material
And S24, feeding the two-stage rubber material obtained in the step S23 into an open mill, turning over for 8-12 times, discharging, adjusting the thickness of the discharged sheet to 1-1.5 mm, and cooling to room temperature after discharging to obtain the signal isolation layer.
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