RU2702490C1 - Method of monitoring condition of rock cutting tools - Google Patents

Abstract

FIELD: mining.

SUBSTANCE: invention relates to mechanical driving of mine workings, in particular, to methods of monitoring condition of rock cutting tools. Proposed method comprises identification of cutting units arranged on rotating working tool and consisting of, at least, one rock-breaking tool, case and elements of rock-destructing tools attachment to the body. Measurement of preset parameters characterizing state of rock-destructing tools during operation of working element by means of at least one instrument cluster. Comparison of values of measured values of specified parameters with critical values, wherein unit of instruments is stationary placed in an external manner relative to working member, so that the range of action of devices covers the trajectory of movement of at least one cutting unit, and identification of cutting units is carried out by measuring the angle of rotation of the working member relative to the initial position and comparing the measured value of the angle of rotation with the initial position of the cutting unit on the working member.

EFFECT: technical result consists in improvement of reliability during monitoring of condition of rock cutting tools without complication and rise in price of design of cutting blocks, applicable in any operating conditions.

10 cl, 3 dwg, 4 ex

Description

The invention relates to the field of mechanical mining of mine workings, in particular, to methods for monitoring the condition of rock cutting tools.

Known high-precision sensors for determining the mechanical load of rock cutting tools of a tunneling mechanized complex [Description of the invention to Canadian patent No. 2944967 of 04/08/2014, IPC E21D 9/00, E21D 9/10, publ. 10/05/2016], made in the form of a sleeve installed at least partially in a device for mounting a roller or on a roller, the sensor device comprising at least one load-sensitive element, as well as including a device for analyzing sensor signals from sensitive to the load of the elements.

The disadvantages of this technical solution include the control of only one indicator characterizing the state of a particular rock cutting tool, namely the load on the tool. This is insufficient for reliable monitoring of the state of rock cutting tools, since the current load is important from the point of view of reliability of the drive transmission of the executive body, but not indicative in the context of the state of the tools themselves. In addition, the data determined by measurements by the indicated sensors is transmitted via wires, the risk of damage to which is very high in mountain conditions.

A device for determining the state of rock cutting tools for a tunneling mechanized complex [Description of the invention to US patent No. 7014271 of 07/28/2004, IPC E21C 37/26, publ. 03/21/2006], containing at least one generator unit that generates electrical energy when the corresponding rock cutting tool made in the form of a disk cutter rotates, a signal conditioning unit connected to the generator unit, and an antenna unit connected to the signal generating unit the antenna of which is located on at least one outer peripheral part of the corresponding rock cutting tool and is equipped for wireless transmission of transmission signals to the receiving unit, equipment assigned to receive signals and interpret them for each corresponding rock cutting tool.

The disadvantage of this technical solution is to evaluate only the fact of the operability of the tools, and the registration of the failure of the tools is carried out after the fact, that is, this technical solution does not allow to monitor the dynamics of the deterioration of the state of the tools and take early steps to minimize the negative consequences of this process.

The closest technical solution (prototype) is a method for monitoring the effectiveness of tunneling and a device for its implementation [Description of the invention to the patent of the Russian Federation No. 2455490 dated 05/29/2009, IPC E21D 9/06, E21D 9/093, publ. 07/10/2012, Bull. No. 19]. The device is a plurality of instrument units consisting of a number of sensors, including an accelerometer, a magnetometer, and a temperature sensor connected to a rotating cutting head, and each instrument unit contains a distal end in contact with the corresponding cutting unit and is intended for monitoring it. In this case, the sensors are installed at the far end of the instrument blocks and are tightened to contact the cutting unit. The instrument units include a wireless transceiver and are connected to each other in a data network or a peer-to-peer network, and a power supply source is provided for each instrument unit. Monitoring the status of cutting units is the collection and processing of data from all units of devices in a remote receiver-dispatcher.

The disadvantages of this prototype include the fundamental lack of visual monitoring of the condition of rock cutting tools, the placement of sensors directly in the cutting unit, which is why their failure is highly probable, the need to equip all rock cutting tools with sensors, which also complicates and increases the cost of the design of cutting blocks, and also does not allow to perform them in explosion-proof execution, which leads to the impossibility of their use in explosive conditions ditions.

The objective of the invention is the provision of reliable monitoring of the condition of rock cutting tools without complicating and increasing the cost of the design of the cutting blocks, applicable in any operating conditions. The technical result achieved is to reduce the cost of ensuring the normal operation of rock cutting tools.

Failure of rock cutting tools occurs for various reasons, the main of which are:

- tool wear due to contact with the massif, expressed in loss of shape of the cutting part of the rock cutting tool, namely, in a decrease in its size;

- overheating of the instrument;

- fatigue deformations of the material from which the rock cutting tools are made, which are expressed in the first occurrence of microdefects in the material, which then develop into macrodefects, such as cracks, etc.

To ensure reliable operation of rock cutting tools, it is necessary to simultaneously monitor their condition from the point of view of the absence of failure conditions for all these reasons. In the present invention, this is achieved through the use of several devices in the instrument cluster. Tracking the shape loss of rock cutting tools due to wear is carried out using a distance measuring device, such as a laser; instrument overheating is monitored by a temperature sensor; macrodefects are tracked using a visual observation device, such as a video camera. In this case, the instrument cluster is located stationary and externally with respect to the working body, so that the range of the instruments covers part of the trajectory of at least one cutting unit. Since these devices are not built into the cutting blocks with rock cutting tools, the complexity of the design of the cutting blocks and their cost does not occur. The instrument cluster itself has less geometric restrictions, due to which it can be executed in an explosion-proof enclosure.

Given that the instrument cluster is not tied to specific rock cutting tools, there is a need for their identification. The solution to this problem in this invention is as follows. Before starting work, each cutting unit with a rock cutting tool is assigned a symbol, the position of the cutting unit on the working body relative to each other is fixed, the position of the working body in relation to the instrument block is fixed taking into account the fixed position of the cutting blocks on the working body relative to each other, which also means known position of the cutting units relative to the instrument cluster. At the same time, it is convenient to set the working body in such a way that one of the cutting blocks is in the area of the range of the instrument block. Then, in the process of operation, as the working body rotates itself around its axis, knowing the number and phase of the working body revolutions, it is possible to determine the exact position of each cutting block relative to the instrument cluster, including determining which of the cutting blocks is in the range of the instrument cluster. To this end, measuring the angle of rotation of the working body around its axis relative to the position at the time of the start of work. At the moment of passage of a specific cutting unit through the scope of the instrument block, the symbol of this cutting unit is fixed, the set parameters are measured that characterize the state of rock cutting tools during the operation of the working body, the values of the measured values are compared with the specified critical values. In case of non-compliance (for example, excess) of the measured values with the critical values, the cutting unit is recognized as being subject to replacement. Moreover, since there are structural gaps between the cutting blocks, only values corresponding to the moments of passage of the cutting blocks through the range of the instrument block are subjected to analysis. For this, taking into account the popularity of the relative position of the cutting units on the working body, as well as the current position of the working body, the data is analyzed with a certain periodicity corresponding to the moments of passage of the cutting blocks through the scope of the instrument block. It should be noted that sometimes a rock cutting tool can operate in emergency mode, while formally not going beyond the established critical values. This is possible, for example, when punching cutting blocks that impede or preclude the rotation of rock cutting tools around its axis. In this case, there is increased wear on one side of the rock cutting tool, which directly interacts with the massif. In order to identify such operating modes of the rock cutting tool, the measured values of the specified parameters are recorded, for example, in the electronic memory of the control system of the instrument unit each time after measurement. As the data accumulate, the new measured values of the specified parameters are compared not only with critical values, but also with previous values on the current rock cutting tool and with values on other rock cutting tools, which allows you to monitor the nature of wear accumulation on each rock cutting tool, as well as build typical change models the state of rock cutting tools during operation, that is, to carry out a dynamic analysis of the state of rock cutting tools at. A significant difference in the nature of the change in state of a specific rock cutting tool from the standard model is the basis for recognizing such a rock cutting tool working in emergency mode.

The invention is illustrated by three drawings:

FIG. 1 is a fragment of a general view of the planetary type executive body equipped with a rock-cutting instrument monitoring system.

FIG. 2 is a fragment of a general view of a rotary type actuator equipped with a rock cutting tool monitoring system with several instrument units.

FIG. 3 is a schematic block diagram of the operation of a unit of devices with data processing.

The planetary type executive body is equipped with at least one rock-destroying body 1, which rotates around its own axis, as well as a portable movement. The drive of rotation of the executive body is conventionally not shown. At the periphery of the actuator, cutting units with rock cutting tools are installed 2. On any part of the actuator performing portable rotation with it, for example, on housing 3, at least one instrument unit 4 is installed per working organ 1. Instrument range in the instrument block 4 it is directed to rock cutting tools 2 installed on the periphery of the working body 1. In this case, the areas of action of individual instruments and sensors can vary and have a different character. For example, the distance measurement is carried out pointwise by means of beam 5 — a dashed line directed strictly in one position; the scope of the temperature sensor 6, it is advisable to extend to the entire cutting unit for measuring the temperature of not only the rock cutting tool itself, but also the attachment points - the area between two thin solid lines; the scope of the visual observation device 7 is limited by its viewing parameters (viewing angle, focal length, geometric dimensions of the lens, etc.) - the area between two dashed-dotted lines.

The rotary-type actuator performs rotation only relative to its own axis during operation. The drive of rotation of the executive body is conventionally not shown. Rock-cutting tools 2 are installed on the front part of the rotor body. On the fixed (not rotating) body 3 of the rotor actuator, the required number of instrument blocks 4 is fixed, but not less than one. In FIG. 2 shows three instrument units 4: two units that monitor the status of instruments in the central part, and one in the cut-out part of the rotary actuator. At the same time, it is also shown that for each of the device blocks, the settings for the range of individual sensors and devices may vary. At the upper instrument cluster, the scope is limited only by shear rock cutting tools made paired in one housing 8. The geometric dimensions of the rock cutting tools 2 are measured by two beams 5 emanating from the instrument block 4, and the scope of the temperature sensor 6 covers one pair of rock cutting tools 2 in one case 8. The middle instrument cluster covers three pairs of rock cutting tools 2, respectively, in three cases 8. However, using beams 5, g the geometric dimensions of not six rock cutting tools 2, but five. The geometric dimensions of the “sixth” rock cutting tool are monitored using the lower instrument cluster 4. The scope of the temperature sensors 6 of the lower instrument cluster 4 does not extend to the “sixth” rock cutting tool, which is located in the range of the temperature sensor of the middle instrument cluster. Thus, figure 2 shows the case when monitoring various aspects of the state (wear, overheating, deformation) of rock cutting tools 2 is carried out using instruments and sensors of various instrument blocks 4. In addition, the settings of the action of instrument blocks 4 can be performed in this way so that their areas of effect duplicate each other. For example, the scope of the visual observation devices, which are conventionally not shown in FIG. 2, obviously intersect.

Regardless of the type of actuator, the measurement results obtained by the instrument cluster 4 go through stages according to the flowchart shown in FIG. 3. Under the data processing is understood the primary interpretation of the measurement results, that is, for example, the correlation of specific values with the instruments with which they were obtained, which allows you to set the type of data (for example, the temperature of rock cutting tools 2 or video recording). The identification of tools 2 is carried out by measuring the current angle of rotation of the executive body relative to the initial position and further comparing the measured value of the current angle of rotation of the executive body relative to the initial position with the initial position of each cutting unit. After identifying the cutting unit, it is "assigned" the measurement results obtained by the instrument unit 4. Next, the data is analyzed.

In the simplest case, data analysis involves an express assessment of the current state of rock cutting tools 2 in the identified cutting unit by comparing the measured values with the specified critical values. Depending on the comparison results, three options for further work are possible:

1) if the analysis did not reveal deviations from the set norm, then the work continues in normal mode;

2) if the analysis showed that a deviation from the norm was not detected, but the situation is close to this, then the work can continue in a special mode;

3) if the analysis showed a deviation from the norm, it is recommended to replace the tool.

More complex forms of analysis are also possible, for example, by comparing the measurement results not only with critical values, but also with the values of previous measurements and / or measurements obtained for other cutting units.

The invention is illustrated by the following examples.

Example 1

First, we describe an example of the general principle of the monitoring system for the condition of rock-cutting tools. Before starting operation, the working body 1 is set so that one of the cutting blocks with a rock cutting tool 4 is in the area of action of the instrument block 6. Let eighteen cutting blocks with rock cutting tools 4 are uniformly and symmetrically located on the working body 1, and their number is twenty. Then the angular distance between the cutting blocks 4 is 360/18 = 20 °, that is, the measurement of the specified parameters using the instrument block 6 should be carried out when the working body 1 is rotated around its axis for every 20 °. Let us give the cutting unit, which is at the time of the start of operation in the field of operation of the instrument block, the legend No. 1, and the following cutting blocks - the legend No. i, where i is the serial number of the cutting block. As a rock cutting tool, frontal disk cones are used.

For frontal disk cones, a measure of tool wear due to contact with the massif, which is reflected in the loss of shape of the cutting part of the rock cutting tool, is a decrease in radius. That is, to assess the wear of the rock cutting tool 4, expressed in the loss of shape of the cutting part and measured using the instrument block 6, as well as to decide on the compliance of the rock cutting tool 4 with the performance criteria, the measured distances for each of the cutting blocks with rock cutting tools 4 are compared with the value equal to the sum of the initial distance from the instrument block (more precisely, from the distance measuring device) to the cutting unit with the rock cutting tool 4 before operation and Permissible wear cutter tool, which for modern head-disk bits is typically 25 mm. During the measurements it was found that all rock cutting tools 4 for each revolution of the working body 1 uniformly decrease in the radial direction by 0.001 mm Thus, after 10,000 revolutions of the working body 1, the wear of all rock-cutting bodies 4 was 10 mm, which is less than the critical value of 25 mm. With the continued pace of wear for the failure of rock cutting tools 4, it is necessary that the working body 1 has made 25,000 full revolutions.

Example 2

The general principle of the monitoring system for the state of rock cutting tools is the same as in example 1.

For rock cutting tools 4, the maximum allowable heating temperature is set at 80 ° C. During operation, rock cutting tools 4 heated to a temperature of 76 ° C, which is less than the critical value, but very close to it - 95%. This means that replacement of rock cutting tools 4 is not required, however, a number of measures should be considered to reduce the heating temperature of rock cutting tools 4, for example, turning on irrigation or reducing the cutting speed.

Example 3

The general principle of the monitoring system for the state of rock cutting tools is the same as in example 1.

During visual observation of the state of rock-cutting tools, for example, using a video camera installed in the device block 6, the machine operator (or other responsible person) noticed a line resembling a crack on one of the rock-cutting tools 4. Using instrument block 6, he found that this line refers to a rock cutting tool in cutting unit No. 13, since 238 full revolutions and one incomplete revolution of 260 ° (260 ° / 20 ° = 13) were completed during operation. Being a superstitious person, and also in order to eliminate the likelihood of failure of the rock cutting tool in the cutting block, the operator (or other responsible person) decided to suspend work and inspect the rock cutting tool in cutting block No. 13 for defects, if any replace the rock cutting tool in the cutting block No. 13.

Example 4

The general principle of the monitoring system for the state of rock cutting tools is the same as in example 1.

During measurements of the distance from the instrument block 6 to the cutting blocks with rock cutting tools 4, it was found that most rock cutting tools 4 for each revolution of the working body 1 uniformly decrease in the radial direction by 0.001 mm. After 1000 revolutions of the working body 1, a typical decrease in rock cutting tools 4 in the radial direction was 1 mm. However, according to the measurements made using the instrument block 6, the rock cutting tool in the cutting block No. 8 (the working body made 562 full turns and one incomplete by 160 °) for this decreased in the radial direction by 3 mm. In addition, a temperature of 15% higher was recorded for the rock cutting tool in this cutting block than in the typical case according to the measurement results. The machine operator (or other responsible person) tracked the cutting unit No. 8 with the aid of the visual observation device unit 6 and determined that there was probably a mash in this cutting unit. He decided to stop the work and inspect the cutting unit number 8 in detail with a view to making further decisions. It should be noted that in this case, taking into account a small wear relative to the critical value of 25 mm, it may be sufficient to clean the cutting block No. 8 from the rod without replacing the rock cutting tool.

As a result of the use of the invention, the costs of monitoring the condition of rock cutting tools on planetary actuators have been reduced without compromising operational reliability.

Claims (10)

1. A method for monitoring the state of rock cutting tools, including identification of cutting blocks placed on a rotating working body and consisting of at least one rock cutting tool, a housing and fastening elements of rock cutting tools to the housing, measuring predetermined parameters characterizing the condition of the rock cutting tools during operation working body, using at least one instrument cluster, comparing the values of the measured values of the given parameters with crit different values, characterized in that the instrument block is stationary stationary externally with respect to the working body, so that the range of the devices covers part of the motion path of at least one cutting block, and the identification of the cutting blocks is carried out by measuring the angle of rotation of the working body relative to the original position and comparison of the measured value of the angle of rotation with the initial position of the cutting unit on the working body. 2. The method according to p. 1, characterized in that the width of the working area of the instrument block covers the width of at least one cutting block. 3. The method according to PP. 1 and 2, characterized in that as a given parameter, measure the distance from the instrument block to at least one characteristic point of the cutting block. 4. The method according to p. 3, characterized in that the measurement of the distance from the unit to a characteristic point is made with a set frequency. 5. The method according to p. 4, characterized in that the working body is pre-set in such a position that the characteristic point is exactly in the range of the device for measuring distance. 6. The method according to any one of paragraphs. 1-5, characterized in that as a predetermined parameter measure the heating temperature of the rock cutting tool 7. The method according to any one of paragraphs. 1-6, characterized in that, along with measurements of characteristic parameters, visual observation is performed, for example, using a video camera or periodic photography. 8. The method according to any one of paragraphs. 1-7, characterized in that the tracking of the spatial position is carried out by measuring the angle of rotation of the working body around its axis relative to the position at the time of the start of work. 9. The method according to any one of paragraphs. 1-8, characterized in that the values of the measured values are recorded. 10. The method according to p. 9, characterized in that according to the measurement results build a dynamic picture of the change in the state of rock cutting tools.

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