WO2017036029A1 - 一种刮板输送机链条断裂检测系统及方法 - Google Patents

一种刮板输送机链条断裂检测系统及方法 Download PDF

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Publication number
WO2017036029A1
WO2017036029A1 PCT/CN2015/099324 CN2015099324W WO2017036029A1 WO 2017036029 A1 WO2017036029 A1 WO 2017036029A1 CN 2015099324 W CN2015099324 W CN 2015099324W WO 2017036029 A1 WO2017036029 A1 WO 2017036029A1
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Prior art keywords
scraper conveyor
speed measuring
speed
scraper
encoder
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PCT/CN2015/099324
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English (en)
French (fr)
Inventor
李伟
张行
朱真才
邱明权
任勇
周公博
彭玉兴
曹国华
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China University of Mining and Technology Beijing CUMTB
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China University of Mining and Technology Beijing CUMTB
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Priority to CA2968708A priority Critical patent/CA2968708C/en
Priority to AU2015407358A priority patent/AU2015407358B2/en
Priority to US15/525,284 priority patent/US10207874B2/en
Publication of WO2017036029A1 publication Critical patent/WO2017036029A1/zh
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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
    • B65G43/06—Control devices, e.g. for safety, warning or fault-correcting interrupting the drive in case of driving element breakage; Braking or stopping loose load-carriers
    • 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
    • B65G23/00—Driving gear for endless conveyors; Belt- or chain-tensioning arrangements
    • B65G23/44—Belt or chain tensioning arrangements
    • 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
    • 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
    • B65G43/04—Control devices, e.g. for safety, warning or fault-correcting detecting slip between driving element and load-carrier, e.g. for interrupting the drive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B66—HOISTING; LIFTING; HAULING
    • B66B—ELEVATORS; ESCALATORS OR MOVING WALKWAYS
    • B66B25/00—Control of escalators or moving walkways
    • B66B25/006—Monitoring for maintenance or repair

Definitions

  • the invention relates to a chain break detection system and method, in particular to a scraper conveyor chain break detection system and method.
  • the scraper conveyor is continuously developing in the direction of heavy-duty, automation and intelligence. Due to the complicated working conditions and the backward technical conditions, the safety of transportation is always a key issue to be solved. As one of the main components to realize the operation of the sprocket transmission system, the scraper conveyor chain is affected by factors such as its own materials, human factors and uneven load distribution. It is prone to chain breakage accidents, which causes chain reaction and seriously affects equipment safety production. .
  • the scraper conveyor chain breaking detection technology such as the Hall element detecting method and the pressure sensor detecting method, is susceptible to external interference, and the feasibility is poor; the driving motor current detecting method and the tensioning hydraulic cylinder pressure detecting method cannot realize partial chain break detection.
  • the utility model is not strong; the travel switch and the contact contact detection method are extremely easy to damage and have poor reliability.
  • the present invention overcomes the deficiencies of the existing scraper conveyor chain breakage detection technology, and provides a simple and easy to maintain chain breakage detection system and method.
  • a scraper conveyor chain break detection system including a speed measuring device, a digital display module, an automatic alarm device and a PLC controller; the speed measuring device and the scraper conveyor
  • the sprocket assembly is coaxially mounted, the encoder is mounted on the speed measuring gear of the speed measuring device, and the encoder is an air shaft type photoelectric incremental encoder for measuring the speed of the speed measuring gear; the output of the speed measuring device and the input of the PLC controller
  • the connection of the PLC controller is electrically connected with the automatic alarm device and the digital display module for data processing and program setting, and is used for the start and stop control of the scraper conveyor; the digital display module uses the MAX7219 chip for hardware connection to realize the speed measurement.
  • the speed of the device is displayed by data;
  • the automatic alarm device includes a buzzer and a flashing indicator for early warning of chain breakage;
  • the power supply module is used for power supply of the entire system.
  • the speed measuring device comprises a fixed sleeve cup, a rolling bearing, a positioning ring and a set bolt; a fixed sleeve cup, a positioning ring, a speed measuring gear and a set bolt; a fixed sleeve cup and a positioning are respectively installed between the rolling bearing and the shoulder, the rolling bearing and the rolling bearing
  • the ring and the fixed sleeve are used for positioning of the rolling bearing, the clearance between the rolling bearing and the transmission shaft, the positioning ring is fixed by the set bolt, and is used for the positioning of the speed measuring gear, and the speed measuring gear can rotate around the driving shaft.
  • the speed measuring gear has the same tooth profile as the sprocket, and the gear teeth and the sprocket teeth are arranged in phase.
  • a scraper conveyor chain break detection method includes the following steps:
  • the chain breaking detection system is initialized, and the critical relative rotational speed difference threshold M 0 is set ;
  • encoder speed measurement the scraper conveyor starts, the chain drive system runs, when the scraper runs to the sprocket When the component is extended, the extension part will rotate the speed measuring gear and the scraper conveyor sprocket assembly to rotate synchronously.
  • the counting pulse is continuously generated, and the electrical signal is converted and transmitted to the PLC controller, and the PLC controller is converted.
  • Data processing of the two encoder electrical signals is performed by program setting to obtain two speed measuring gear speed data, and the relative speed difference between the two speed measuring gears is calculated in real time
  • PLC program control PLC controller compares the numerical relationship in real time. If the data value meets
  • the invention has the beneficial effects that the difference between the relative rotational speeds of the two speed measuring gears in contact with the squeegee is used as a standard to judge the breakage of the chain of the squeegee conveyor, and the fault warning of the chain breaking fault and the squeegee conveyor are urgently realized through the setting procedure of the PLC controller. Stop control, in addition, through the digital display module can intuitively determine which speed of the speed measuring gear is abrupt, and then determine which chain breaks, avoiding major safety accidents.
  • the method is simple and easy to operate, has high reliability, and has a high promotion value.
  • FIG. 1 is a schematic flow chart of a chain breakage detecting method of the present invention.
  • FIG. 2 is a schematic view showing the installation of the speed measuring device of the present invention.
  • Figure 2-1 is a structural view of the speed measuring device of the present invention.
  • FIG. 2-2 is a partial enlarged view of FIG. 2-1.
  • Figure 3 is a diagram of the overall detection system of the detection system.
  • drive shaft 2, sprocket, 3, encoder, 4, speed measuring device, 41, fixed cup, 42, rolling bearing, 43, positioning ring, 44, speed measuring gear, 45, tightening bolt.
  • a sprocket 2 and a speed measuring device 4 are connected to the transmission shaft 1, and the encoder 3 is connected to the speed measuring gear 44 of the speed measuring device 4.
  • the scraper conveyor chain breaking detection system of the invention comprises a speed measuring device 4, a digital display module, an automatic alarm device and a PLC controller; the speed measuring device is coaxially mounted with the scraper conveyor sprocket assembly, and the encoder 3 is installed at the speed measuring On the speed measuring gear 44 of the device 4, the encoder 3 is an air shaft type photoelectric incremental encoder for measuring the rotation speed of the speed measuring gear 44; the output end of the speed measuring device 4 is connected to the input end of the PLC controller; The output terminal is electrically connected with the automatic alarm device and the digital display module for data processing and program setting, and is used for the start and stop control of the scraper conveyor; the digital display module selects the MAX7219 chip for hardware connection, and realizes the speed of the speed measuring device to display data; Automatic alarm The device includes a buzzer and a flashing indicator for early warning of chain breakage; the power supply module is used to supply power to the entire system.
  • the speed measuring device comprises a fixing sleeve 41, a rolling bearing 42, a positioning ring 43, a speed measuring gear 44 and a tightening bolt 45, wherein the fixing sleeve cup, the positioning ring, the speed measuring gear and the fixing bolt are used for the speed measuring gear positioning, the bearing and the driving shaft 1 shoulder, bearing and bearing are respectively installed with a fixed sleeve for bearing positioning, the bearing and the drive shaft 1 are matched with each other, the positioning ring is fixed by the set screw 45, and is used for positioning of the speed measuring gear 44, and the speed measuring gear 44 can be wound The drive shaft 1 rotates.
  • the sprocket 2 is welded to the transmission shaft, and the speed measuring gear has the same tooth profile as the sprocket, and the gear teeth and the sprocket teeth are arranged in phase.
  • a scraper conveyor chain breakage detecting method includes the following steps:
  • the chain breaking detection system is initialized, and the critical relative rotational speed difference threshold M 0 is set ;
  • the scraper conveyor starts, during the operation of the chain drive system, when the scraper is running to the sprocket assembly, the protruding part will rotate the speed measuring gear and the scraper conveyor sprocket assembly to rotate synchronously.
  • the counting pulse is continuously generated and converted to form an electrical signal feedback transmission to the PLC controller.
  • the PLC controller separately performs data processing on the two encoder electrical signals by program setting to obtain two speed measuring gear speed data, and real-time. Calculate the relative speed difference between the two speed measuring gears
  • PLC program control PLC controller compares the numerical relationship in real time. If the data value meets

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Control Of Conveyors (AREA)
  • Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)

Abstract

一种刮板输送机链条断裂检测系统及方法，其中检测系统的测速装置（4）与刮板输送机链轮组件同轴安装，编码器（3）安装在测速装置（4）的测速齿轮（44）上，编码器（3）为空轴式光电增量式编码器，用于测量测速齿轮（44）的转速；测速装置（4）的输出端与PLC控制器的输入端连接，PLC控制器的输出端与自动报警装置和数显模块电气连接，供电模块用于整个系统供电。链条断裂检测方法以与刮板接触的两测速齿轮（44）之间的相对转速差值为标准，判断刮板输送机链条断裂故障，通过PLC控制器设置程序实现断链故障预警和刮板输送机急停控制。通过数显模块直观判断测速齿轮（44）速度发生突变，进而判断哪一条链条发生断裂，避免了重大安全事故发生。

Description

一种刮板输送机链条断裂检测系统及方法 技术领域
本发明涉及一种链条断裂检测系统及方法，特别是一种刮板输送机链条断裂检测系统及方法。
背景技术
目前刮板输送机不断向重型化、自动化和智能化方向发展，由于工况条件复杂、检测技术条件落后等限制，运输安全性始终是亟于解决的关键问题。刮板输送机链条作为实现链轮传动系统运作的主要部件之一，受到自身材料、人为因素和载荷分布不均等因素的影响，极易发生断链事故，进而引起连锁反应，严重影响设备安全生产。
已有刮板输送机断链检测技术，如霍尔元件检测法和压力传感器检测法易受到外界干扰，可行性差；驱动电机电流检测法和张紧液压缸压力检测法，无法实现部分链条断裂检测，实用性不强；行程开关和接触触头检测法，极易损坏，可靠性差。
发明内容
发明目的：本发明克服了现有刮板输送机链条断裂检测技术的不足，提供了一种简单易行、易于维护的链断裂检测系统及方法。
为了实现上述目的，本发明采用了如下的技术方案：一种刮板输送机链条断裂检测系统，包括测速装置、数显模块、自动报警装置和PLC控制器；所述测速装置与刮板输送机链轮组件同轴安装，编码器安装在测速装置的测速齿轮上，编码器为空轴式光电增量式编码器，用于测量测速齿轮的转速；测速装置的输出端与PLC控制器的输入端连接；PLC控制器的输出端与自动报警装置和数显模块电气连接，用于数据处理和程序设置，并用于刮板输送机启停控制；数显模块选用MAX7219芯片进行硬件连接，实现测速装置的转速以数据显示；自动报警装置包括蜂鸣器和闪烁指示灯，用于断链故障预警；供电模块用于整个系统供电。
所述测速装置包括固定套杯、滚动轴承、定位环和紧定螺栓；固定套杯、定位环、测速齿轮和紧定螺栓，滚动轴承与轴肩、滚动轴承与滚动轴承之间分别安装有固定套杯和定位环，固定套杯用于滚动轴承定位，滚动轴承和传动轴之间间隙配合，定位环通过紧定螺栓固定，用于测速齿轮定位，测速齿轮可绕传动轴旋转。
所述的编码器有两个，两个编码器中心轴线处于同一水平线上，并对称安装于两个测速齿轮外侧。
所述的测速齿轮与链轮具有相同的齿形轮廓，且齿轮轮齿和链轮轮齿同相位布置。
一种刮板输送机链条断裂检测方法，包括以下步骤：
a)、断链检测系统初始化，设置临界相对转速差阈值M0；
b)、编码器测速：刮板输送机启动，链传动系统运行过程中，当刮板运行至链轮 组件时，其伸出部分会拨动测速齿轮与刮板输送机链轮组件同步旋转，编码器随动过程中，不断产生计数脉冲，并转换形成电信号反馈传输至PLC控制器，PLC控制器通过程序设置分别对两编码器电信号进行数据处理得出两测速齿轮转速数据，并实时计算得出两测速齿轮相对转速差|N|；
c)、PLC程序控制：PLC控制器实时对比数值关系，若每5s内任意时刻数据值满足|N|＜M0，刮板输送机链条正常工作；若每5s内任意时刻出现|N|＞M0，表明刮板不能正常拨动测速齿轮与刮板输送机链轮组件同步旋转，此时可判定刮板输送机出现断链故障，PLC控制自动报警装置发出声光信号并对刮板输送机停机检查，进一步地，可通过数显模块判断具体是哪一根链条发生断裂故障，由此完成一次刮板输送机链条断裂检测；
d)、重复步骤b)至c)，实时检测刮板输送机链条断裂情况。
有益效果：本发明以与刮板接触的两测速齿轮之间的相对转速差值为标准，判断刮板输送机链条断裂故障，通过PLC控制器设置程序实现断链故障预警和刮板输送机急停控制，此外，通过数显模块可直观判断具体是哪个测速齿轮速度发生突变，进而判断哪一条链条发生断裂，避免了重大安全事故发生。该方法简单易行，可靠性强，具有极高的推广价值。
附图说明
图1为本发明的链条断裂检测方法的流程示意图。
图2为本发明的测速装置安装示意图。
图2-1为本发明的测速装置结构图。
图2-2为图2-1的局部放大图。
图3为检测系统的整体检测系统图。
图中：1、传动轴，2、链轮，3、编码器，4、测速装置，41、固定套杯，42、滚动轴承，43、定位环，44、测速齿轮，45、紧定螺栓。
具体实施方式：
下面结合附图对本发明做更进一步的解释。
如图2所示，在传动轴1上连接有链轮2和测速装置4，编码器3连接在测速装置4的测速齿轮44上。
本发明的刮板输送机链条断裂检测系统包括测速装置4、数显模块、自动报警装置和PLC控制器；所述测速装置与刮板输送机链轮组件同轴安装，编码器3安装在测速装置4的测速齿轮44上，编码器3为空轴式光电增量式编码器，用于测量测速齿轮44的转速；测速装置4的输出端与PLC控制器的输入端连接；PLC控制器的输出端与自动报警装置和数显模块电气连接，用于数据处理和程序设置，并用于刮板输送机启停控制；数显模块选用MAX7219芯片进行硬件连接，实现测速装置的转速以数据显示；自动报警 装置包括蜂鸣器和闪烁指示灯，用于断链故障预警；供电模块用于整个系统供电。
所述测速装置包括固定套杯41、滚动轴承42、定位环43、测速齿轮44和紧定螺栓45，其中固定套杯、定位环、测速齿轮和紧定螺栓用于测速齿轮定位，轴承与传动轴1肩、轴承与轴承之间分别安装有固定套杯用于轴承定位，轴承和传动轴1之间间隙配合，定位环通过紧定螺栓45固定，用于测速齿轮44定位，测速齿轮44可绕传动轴1旋转。
所述的编码器有两个，两个编码器中心轴线处于同一水平线上，并对称安装于两个测速齿轮外侧。
所述链轮2焊接于传动轴上，测速齿轮与链轮具有相同的齿形轮廓，且齿轮轮齿和链轮轮齿同相位布置。
如图1、2、3，一种刮板输送机链条断裂检测方法，包括以下步骤：
a)、断链检测系统初始化，设置临界相对转速差阈值M0；
b)、编码器测速：刮板输送机启动，链传动系统运行过程中，当刮板运行至链轮组件时，其伸出部分会拨动测速齿轮与刮板输送机链轮组件同步旋转，编码器随动过程中，不断产生计数脉冲，并转换形成电信号反馈传输至PLC控制器，PLC控制器通过程序设置分别对两编码器电信号进行数据处理得出两测速齿轮转速数据，并实时计算得出两测速齿轮相对转速差|N|；
c)、PLC程序控制：PLC控制器实时对比数值关系，若每5s内任意时刻数据值满足|N|＜M0，刮板输送机链条正常工作；若每5s内任意时刻出现|N|＞M0，表明刮板不能正常拨动测速齿轮与刮板输送机链轮组件同步旋转，此时可判定刮板输送机出现断链故障，PLC控制自动报警装置发出声光信号并对刮板输送机停机检查，进一步地，可通过数显模块判断具体是哪一根链条发生断裂故障，由此完成一次刮板输送机链条断裂检测；
d)、重复步骤b)至c)，实时检测刮板输送机链条断裂情况。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。

Claims (5)

  1. 一种刮板输送机链条断裂检测系统，其特征在于：该检测系统，包括测速装置、数显模块、自动报警装置和PLC控制器；所述测速装置与刮板输送机链轮组件同轴安装，编码器安装在测速装置的测速齿轮上，编码器为空轴式光电增量式编码器，用于测量测速齿轮的转速；测速装置的输出端与PLC控制器的输入端连接；PLC控制器的输出端与自动报警装置和数显模块电气连接，用于数据处理和程序设置，并用于刮板输送机启停控制；数显模块选用MAX7219芯片进行硬件连接，实现测速装置的转速以数据显示；自动报警装置包括蜂鸣器和闪烁指示灯，用于断链故障预警；供电模块用于整个系统供电。
  2. 根据权利要求1所述的一种刮板输送机链条断裂检测系统，其特征在于：所述测速装置包括固定套杯、滚动轴承、定位环和紧定螺栓；固定套杯、定位环、测速齿轮和紧定螺栓，滚动轴承与轴肩、滚动轴承与滚动轴承之间分别安装有固定套杯和定位环，固定套杯用于滚动轴承定位，滚动轴承和传动轴之间间隙配合，定位环通过紧定螺栓固定，用于测速齿轮定位，测速齿轮可绕传动轴旋转。
  3. 根据权利要求1所述的一种刮板输送机链条断裂检测系统，其特征在于：所述的编码器有两个，两个编码器中心轴线处于同一水平线上，并对称安装于两个测速齿轮外侧。
  4. 根据权利要求1所述的一种刮板输送机链条断裂检测系统，其特征在于：所述的测速齿轮与链轮具有相同的齿形轮廓，且齿轮轮齿和链轮轮齿同相位布置。
  5. 权利要求所述的刮板输送机链条断裂检测系统的方法，其特征在于：检测方法，包括以下步骤：
    a)、断链检测系统初始化，设置临界相对转速差阈值M0；
    b)、编码器测速：刮板输送机启动，链传动系统运行过程中，当刮板运行至链轮组件时，其伸出部分会拨动测速齿轮与刮板输送机链轮组件同步旋转，编码器随动过程中，不断产生计数脉冲，并转换形成电信号反馈传输至PLC控制器，PLC控制器通过程序设置分别对两编码器电信号进行数据处理得出两测速齿轮转速数据，并实时计算得出两测速齿轮相对转速差|N|；
    c)、PLC程序控制：PLC控制器实时对比数值关系，若每5s内任意时刻数据值满足|N|＜M0，刮板输送机链条正常工作；若每5s内任意时刻出现|N|＞M0，表明刮板不能正常拨动测速齿轮与刮板输送机链轮组件同步旋转，此时可判定刮板输送机出现断链故障，PLC控制自动报警装置发出声光信号并对刮板输送机停机检查，进一步地，可通过数显模 块判断具体是哪一根链条发生断裂故障，由此完成一次刮板输送机链条断裂检测；
    d)、重复步骤b)至c)，实时检测刮板输送机链条断裂情况。
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