WO2017197874A1 - 一种刮板输送机链条故障诊断系统及方法 - Google Patents

一种刮板输送机链条故障诊断系统及方法 Download PDF

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Publication number
WO2017197874A1
WO2017197874A1 PCT/CN2016/108843 CN2016108843W WO2017197874A1 WO 2017197874 A1 WO2017197874 A1 WO 2017197874A1 CN 2016108843 W CN2016108843 W CN 2016108843W WO 2017197874 A1 WO2017197874 A1 WO 2017197874A1
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Prior art keywords
chain
scraper conveyor
strain gauge
sprocket
fault
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PCT/CN2016/108843
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English (en)
French (fr)
Inventor
江帆
朱真才
李伟
吴孙阳
周公博
曹国华
彭玉兴
卢昊
花纯利
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China University of Mining and Technology CUMT
China University of Mining and Technology Beijing CUMTB
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China University of Mining and Technology CUMT
China University of Mining and Technology Beijing CUMTB
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Priority to US15/571,045 priority Critical patent/US10065804B1/en
Priority to RU2017146582A priority patent/RU2682952C2/ru
Priority to AU2016401399A priority patent/AU2016401399B2/en
Publication of WO2017197874A1 publication Critical patent/WO2017197874A1/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
    • 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
    • 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
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
    • G01L1/00—Measuring force or stress, in general
    • G01L1/20—Measuring force or stress, in general by measuring variations in ohmic resistance of solid materials or of electrically-conductive fluids; by making use of electrokinetic cells, i.e. liquid-containing cells wherein an electrical potential is produced or varied upon the application of stress
    • G01L1/22—Measuring force or stress, in general by measuring variations in ohmic resistance of solid materials or of electrically-conductive fluids; by making use of electrokinetic cells, i.e. liquid-containing cells wherein an electrical potential is produced or varied upon the application of stress using resistance strain gauges
    • G01L1/2206—Special supports with preselected places to mount the resistance strain gauges; Mounting of supports
    • G01L1/2218—Special supports with preselected places to mount the resistance strain gauges; Mounting of supports the supports being of the column type, e.g. cylindric, adapted for measuring a force along a single direction
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
    • G01L1/00—Measuring force or stress, in general
    • G01L1/20—Measuring force or stress, in general by measuring variations in ohmic resistance of solid materials or of electrically-conductive fluids; by making use of electrokinetic cells, i.e. liquid-containing cells wherein an electrical potential is produced or varied upon the application of stress
    • G01L1/22—Measuring force or stress, in general by measuring variations in ohmic resistance of solid materials or of electrically-conductive fluids; by making use of electrokinetic cells, i.e. liquid-containing cells wherein an electrical potential is produced or varied upon the application of stress using resistance strain gauges
    • G01L1/225—Measuring circuits therefor
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
    • G01L1/00—Measuring force or stress, in general
    • G01L1/20—Measuring force or stress, in general by measuring variations in ohmic resistance of solid materials or of electrically-conductive fluids; by making use of electrokinetic cells, i.e. liquid-containing cells wherein an electrical potential is produced or varied upon the application of stress
    • G01L1/22—Measuring force or stress, in general by measuring variations in ohmic resistance of solid materials or of electrically-conductive fluids; by making use of electrokinetic cells, i.e. liquid-containing cells wherein an electrical potential is produced or varied upon the application of stress using resistance strain gauges
    • G01L1/2268—Arrangements for correcting or for compensating unwanted effects
    • G01L1/2281—Arrangements for correcting or for compensating unwanted effects for temperature variations
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
    • G01L5/00—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes
    • G01L5/04—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes for measuring tension in flexible members, e.g. ropes, cables, wires, threads, belts or bands
    • G01L5/047—Specific indicating or recording arrangements, e.g. for remote indication, for indicating overload or underload
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
    • G01L5/00—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes
    • G01L5/04—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes for measuring tension in flexible members, e.g. ropes, cables, wires, threads, belts or bands
    • G01L5/10—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes for measuring tension in flexible members, e.g. ropes, cables, wires, threads, belts or bands using electrical means
    • G01L5/101—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes for measuring tension in flexible members, e.g. ropes, cables, wires, threads, belts or bands using electrical means using sensors inserted into the flexible member
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M13/00—Testing of machine parts
    • G01M13/02—Gearings; Transmission mechanisms
    • G01M13/023—Power-transmitting endless elements, e.g. belts or chains
    • 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
    • B65G19/04—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 for moving bulk material in open troughs or channels
    • B65G19/06—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 for moving bulk material in open troughs or channels the impellers being scrapers similar in size and shape to the cross-section of the trough or channel
    • B65G19/08—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 for moving bulk material in open troughs or channels the impellers being scrapers similar in size and shape to the cross-section of the trough or channel and attached to a single belt, rope or chain
    • 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
    • B65G19/22—Impellers, e.g. push-plates, scrapers; Guiding means therefor
    • 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
    • B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
    • B65G2203/02—Control or detection
    • B65G2203/0266—Control or detection relating to the load carrier(s)
    • B65G2203/0275—Damage on the load carrier
    • 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
    • B65G23/02—Belt- or chain-engaging elements
    • B65G23/04—Drums, rollers, or wheels
    • B65G23/06—Drums, rollers, or wheels with projections engaging abutments on belts or chains, e.g. sprocket wheels

Definitions

  • the invention relates to the technical field of health monitoring and safety protection of a scraper conveyor, in particular to a fault diagnosis system and method for a scraper conveyor chain.
  • the scraper conveyor is the main production and transportation equipment for the coal mine underground mining face. It undertakes the important task of transporting coal, providing the fulcrum for the hydraulic support and providing the walking track for the shearer. The reliability directly affects the safety and efficiency of the modern coal mine. produce.
  • the scraper chain is the most prone to failure of the scraper conveyor, and its failure (broken chain, wrong chain and chain, etc.) accounts for about 40% of the total number of scraper conveyor failures. After the wrong chain of the scraper conveyor chain occurs, the squeegee will be tilted, causing the chain to break or damage the scraper conveyor. In the event of a fault such as a broken chain, the required maintenance time is long, which seriously restricts the production efficiency of large coal mines in China.
  • the tension of the scraper conveyor chain is indirectly obtained through the cylinder pressure, the chain suspension amount and the power.
  • the chain is shaken, making it difficult to accurately measure the amount of drape.
  • Only the total tension of the two chains of the scraper can be obtained by the cylinder pressure and the cylinder pressure, but it is difficult to detect faults such as chain breakage.
  • the existing state detection of the scraper conveyor is mostly directed to the broken chain fault, and the faults such as the wrong chain, the jump chain and the card chain cannot be simultaneously monitored.
  • the patent number is ZL 201410503491.1, and the chain fault detection is realized by installing a stress sensor on the tooth surface of the sprocket which is in contact with the chain.
  • the invention patent of patent number ZL201110052986.3 realizes the prediction and detection of the broken chain fault caused by the inclination of the conveyor belt of the scraper by the principle of electromagnetic induction. The detection result is seriously interfered by the environment, and the chain and chain of the chain cannot be chained. The fault is diagnosed.
  • the object of the present invention is to overcome the deficiencies of the prior art and to provide a scraper conveyor chain fault diagnosis system and method, which solves the scraper conveyor chain, chain breakage, wrong chain and jump chain, etc. It is difficult to detect the problem in real time.
  • a scraper conveyor chain fault diagnosis system the scraper conveyor includes a scraper conveyor drum, and two chains are arranged on the scraper conveyor drum.
  • the wheel and the sprocket are double-row gears, and one chain is mounted on each of the sprockets.
  • the diagnostic system includes strain flowers attached to the top end faces of the sprocket teeth of the scraper conveyor, and the strain flowers are fixed by the shield wires to be fixed on the scraper.
  • the signal acquisition unit on the machine drum, the wireless transmission module of the signal acquisition unit transmits the collected signal to the wireless receiving device by wireless transmission, and the wireless receiving device transmits the obtained acquisition signal to the industrial computer through the USB interface;
  • the strain gauge comprises a 90° strain gauge arranged parallel to the central axis of the sprocket and arranged perpendicular to the 90° strain gauge 0° strain gauge.
  • the signal collection unit comprises a power module, and the power module is respectively connected to a signal conditioning circuit, an MCU micro control chip and a wireless transmission module, and the MCU micro control chip is respectively connected to the signal conditioning circuit, the storage module and the wireless transmission module.
  • the 0° strain gauge and the 90° strain gauge are both self-contained temperature-compensated resistance strain gauges.
  • a fault diagnosis method for a scraper conveyor chain based on the above diagnosis system which comprises three steps of fault chain, jump chain fault judgment, chain break fault judgment and card chain fault judgment:
  • Fault chain, jump chain fault judgment Calculate the difference between the 90° strain gauge measurement results of the top end faces of the two teeth on the same sprocket If
  • Card chain fault judgment When the 0° strain gauge measurement results of the top end faces of the two gear teeth on the same position on the two sprockets increase sharply synchronously and exceed the set threshold J 4 , the 0° strain gauge measurement result does not appear in the cycle. If the size of the sex changes alternately, it is judged that the card chain fault occurs; the J 4 is 1.5 times of the corresponding 0° strain gauge measurement result under normal conditions.
  • the scraper conveyor drives the chain by rotating the sprocket to realize the transportation of coal.
  • the running state of the chain has a direct relationship with the deformation of the sprocket. For example, when the chain is broken, the two sprocket teeth The deformation difference in the traction direction of the chain becomes larger; when the card chain fault occurs, the deformation of the two sprocket teeth in the chain traction direction increases sharply; when the fault chain and the jump chain fail, the two sprocket teeth In the chain pulling direction and the axial direction of the scraper conveyor roller, there is a large deformation at the same time.
  • the invention is based on the above principle, and measures the strain in different directions of the sprocket teeth in real time, and transmits the collected signal to the industrial control through wireless transmission means. Based on the obtained stress data, the machine dynamically diagnoses the faults such as the chain, the wrong chain, the jump chain and the broken chain of the scraper conveyor chain, and provides technical support for comprehensive monitoring of the state of the scraper conveyor chain.
  • Figure 1 is a schematic view showing the structure of the system of the present invention
  • FIG. 2 is a schematic structural diagram of a signal acquisition unit of the present invention.
  • a scraper conveyor chain fault diagnosis system of the present invention includes a scraper conveyor drum, and two sprocket wheels are arranged on the scraper conveyor drum.
  • the wheel is a double-row gear, and a chain is mounted on each sprocket.
  • the diagnostic system includes a strain flower 1 attached to the top end surface of the sprocket of the scraper conveyor, and the strain flower 1 is fixed by the shield wire 2 to be fixed on the scraper.
  • the signal acquisition unit 3 on the machine drum and the wireless transmission module of the signal acquisition unit 3 transmit the collected signals to the wireless receiving device 4 through wireless transmission, and the wireless receiving device 4 transmits the obtained acquisition signals to the industrial computer 5 through the USB interface.
  • the strain gauge includes a 90° strain gauge disposed parallel to the sprocket center axis and a 0° strain gauge disposed perpendicular to the 90° strain gauge. Both the 0° strain gauge and the 90° strain gauge are self-contained temperature-compensated resistance strain gauges.
  • the 0° strain gauge measures the deformation of the sprocket teeth in the chain running direction; the 90° strain gauge measures the deformation of the sprocket teeth in the direction perpendicular to the chain running direction.
  • the signal acquisition unit 3 includes a power module, and the power module is respectively connected to a signal conditioning circuit, an MCU micro control chip, and a wireless transmission module, and the MCU micro control chip is respectively connected to the signal conditioning circuit, the storage module, and the wireless transmission module.
  • the scraper conveyor chain fault diagnosis method includes three steps of fault chain, jump chain fault judgment, chain break fault judgment and card chain fault judgment:
  • Card chain fault judgment When a card chain fault occurs, the tension between the two chains suddenly becomes large, and there is no periodic alternating size change. When the two sprockets have the same position on the top end of the two teeth 0 ° The measurement results of the strain gauge increase sharply synchronously, and after the set threshold value J 4 is exceeded, the 0° strain gauge measurement result does not change periodically, and the card chain fault is judged; the J 4 is normal. 1.5 times the corresponding 0° strain gauge measurement.

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  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
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  • Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
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Abstract

一种刮板输送机链条故障诊断系统，该诊断系统包括贴在刮板输送机链轮轮齿顶部端面的应变花（1），应变花（1）通过屏蔽导线（2）连接固定在刮板输送机滚筒上的信号采集单元（3），信号采集单元（3）通过无线传输方式将采集的信号发送给无线接收装置（4），无线接收装置（4）通过USB接口将获得的采集信号传输给工控机（5）；该诊断方法包括，错链、跳链故障判断、断链故障判断和卡链故障判断三个步骤。通过实时测量链轮轮齿不同方向上的应变量，并通过无线传输手段将采集信号传输给工控机（5），而后基于获得的应力数据，对刮板输送机链条的卡链、错链、跳链和断链等故障进行动态诊断，为对刮板输送机链条状态进行综合监测提供技术支持。

Description

一种刮板输送机链条故障诊断系统及方法 技术领域
本发明涉及刮板输送机健康监测和安全保障技术领域，尤其涉及一种刮板输送机链条故障诊断系统及方法。
背景技术
刮板输送机是煤矿井下综采工作面主要的生产运输设备，承担着运输煤炭、为液压支架提供推移支点以及为采煤机提供行走轨道的重要任务，可靠性直接影响到现代化煤矿的安全高效生产。刮板链是刮板输送机最容易出现故障的机构，其故障(断链、错链和卡链等)约占刮板输送机故障总数的40％。刮板输送机链条出现错链后，会出现刮板倾斜，严重时致使链条断链或者损坏刮板输送机。一旦出现断链等故障，所需的维修时间长，严重制约了我国大型煤矿的生产效率。
国内外主要通过油缸压力、链条悬垂量和功率等间接获得刮板输送机链条张力。刮板输送机运行过程中，链条存在晃动，使得其悬垂量难以准确测量。通过油缸压力和油缸压力仅能获得刮板机两根链条的总张力，但对链条断链等故障难以检测。现有的刮板输送机状态检测大多针对的是断链故障，不能对错链、跳链和卡链等故障进行同时监测。如：专利号为ZL 201410503491.1发明专利，通过在与链条接触的链轮轮齿面安装应力传感器实现断链故障检测，由于测量传感器与链条接触并存在相对滑动，存在磨损失效的可能，且难以检测链条卡链、错链和跳链等故障。专利号为ZL201110052986.3的发明专利，通过电磁感应原理实现对因刮板输送机链条倾斜导致的断链故障进行预示和检测，检测结果受环境干扰严重，且不能对链条卡链和错链等故障进行诊断。
发明内容
发明目的：本发明的目的在于是克服已有技术存在的不足之处，提供一种刮板输送机链条故障诊断系统及方法，解决刮板输送机卡链、断链、错链和跳链等故障难以实时检测问题。
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故障诊断系统，该刮板输送机包括刮板输送机滚筒，在刮板输送机滚筒上间隔设置的两个链轮，链轮为双排齿轮，每个链轮上安装一根链条，该诊断系统包括贴在刮板输送机链轮轮齿顶部端面的应变花，应变花通过屏蔽导线连接固定在刮板输送机滚筒上的信号采集单元，信号采集单元的无线发送模块通过无线传输方式将采集的信号发送给无线接收装置，无线接收装置通过USB接口将获得的采集信号传输给工控机；
所述应变花包括平行于链轮中心轴线布置的90°应变计以及垂直于90°应变计布置 的0°应变计。
优选的，所述信号采集单元包括电源模块，电源模块分别连接信号调理电路、MCU微控芯片和无线发送模块，MCU微控芯片分别连接信号调理电路、存储模块和无线发送模块。
优选的，所述0°应变计和90°应变计均为自带温度补偿的电阻应变计。
一种基于上述诊断系统的刮板输送机链条故障诊断方法，它包括错链、跳链故障判断、断链故障判断和卡链故障判断三个步骤：
错链、跳链故障判断：计算同一个链轮上相同位置的两个轮齿顶部端面90°应变计测量结果之间的差值
Figure PCTCN2016108843-appb-000001
如果|Δf90|≥J1，且连续多个链轮轮齿都出现上述情况，则判断刮板出现了倾斜；当刮板出现了倾斜时，进一步计算滚筒同一轴线上两个链轮上相同位置的两个轮齿顶部端面0°应变计测量结果之间的差值
Figure PCTCN2016108843-appb-000002
如果|Δf0|≤J2，则判断出现错链、跳链故障；所述的
Figure PCTCN2016108843-appb-000003
断链故障判断：计算滚筒同一轴线上两个链轮相同位置的轮齿顶部端面0°应变计测量结果之间的差值
Figure PCTCN2016108843-appb-000004
如果|Δf0|突然变大并超过设定阈值J2，且连续多个链轮轮齿都出现上述情况，则判断发生断链故障；所述的阈值J3可取
Figure PCTCN2016108843-appb-000005
卡链故障判断：当两个链轮上相同位置的两个轮齿顶部端面0°应变计测量结果同步地急剧增大，并超过设定阈值J4后，0°应变计测量结果未出现周期性的大小交替变化，则判断出现卡链故障；所述的J4为正常情况下相应0°应变计测量结果的1.5倍。
有益效果：刮板输送机通过转动的链轮带动链条的移动实现煤炭的运输，链条的运行状态与链轮的变形有着直接的关联关系，如：当出现断链后，两个链轮轮齿在链条牵引方向的变形差异变大；当出现卡链故障后，两个链轮轮齿在链条牵引方向的变形同步急剧增大；当出现错链和跳链故障后，两个链轮轮齿在链条牵引方向和刮板输送机滚筒轴向方向同时存在较大变形，本发明基于上述原理，通过实时测量链轮轮齿不同方向上的应变量，并通过无线传输手段将采集信号传输给工控机，而后基于获得的应力数据，对刮板输送机链条的卡链、错链、跳链和断链等故障进行动态诊断，为对刮板输送机链条状态进行综合监测提供技术支持。
附图说明
图1是本发明的系统结构示意图；
图2是本发明的信号采集单元结构原理图。
图中：1-应变花，2-屏蔽导线，3-信号采集单元，4-无线接收装置，5-工控机。
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1和2所示，本发明的一种刮板输送机链条故障诊断系统，该刮板输送机包括刮板输送机滚筒，在刮板输送机滚筒上间隔设置两个的链轮，链轮为双排齿轮，每个链轮上安装一根链条，该诊断系统包括贴在刮板输送机链轮轮齿顶部端面的应变花1，应变花1通过屏蔽导线2连接固定在刮板输送机滚筒上的信号采集单元3，信号采集单元3的无线发送模块通过无线传输方式将采集的信号发送给无线接收装置4，无线接收装置4通过USB接口将获得的采集信号传输给工控机5。
所述应变花包括平行于链轮中心轴线布置的90°应变计以及垂直于90°应变计布置的0°应变计。所述0°应变计和90°应变计均为自带温度补偿的电阻应变计。0°应变计测量链轮轮齿在链条运行方向上的变形；90°应变计测量链轮轮齿与链条运行方向垂直方向上的变形。
所述信号采集单元3包括电源模块，电源模块分别连接信号调理电路、MCU微控芯片和无线发送模块，MCU微控芯片分别连接信号调理电路、存储模块和无线发送模块。
基于上述诊断系统的刮板输送机链条故障诊断方法，它包括错链、跳链故障判断、断链故障判断和卡链故障判断三个步骤：
错链、跳链故障判断：正常运行时，刮板输送机两条链条间的张力基本一样，且同一个链轮上相同位置的两个轮齿顶部端面在与链条垂直方向上的变形相同，计算同一个链轮上相同位置的两个轮齿顶部端面90°应变计测量结果之间的差值
Figure PCTCN2016108843-appb-000006
如果|Δf90|≥J1，且连续多个链轮轮齿都出现上述情况，则判断刮板出现了倾斜；当刮板出现了倾斜时，进一步计算滚筒同一轴线上两个链轮上相同位置的两个轮齿顶部端面0°应变计测量结果之间的差值
Figure PCTCN2016108843-appb-000007
如果|Δf0|≤J2，则判断出现错链、跳链故障；所述的
Figure PCTCN2016108843-appb-000008
断链故障判断：断链故障发生时，断链的链轮轮齿变形突然变小，未断链条的链轮轮齿变形突然变大，计算滚筒同一轴线上两个链轮相同位置的轮齿顶部端面0°应变计测量结果之间的差值
Figure PCTCN2016108843-appb-000009
如果|Δf0|突然变大并超过设定阈值J3，且连续多个链轮轮齿都出现上述情况，则判断发生断链故障；所述的阈值J3可取
Figure PCTCN2016108843-appb-000010
卡链故障判断：卡链故障发生时，两条链条间的张力突然同步变大，并且之后不会出现周期性的大小交替变化，当两个链轮上相同位置的两个轮齿顶部端面0°应变计测量结果同步地急剧增大，并超过设定阈值J4后，0°应变计测量结果未出现周期性的大小交替变化，则判断出现卡链故障；所述的J4为正常情况下相应0°应变计测量结果的1.5倍。
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 (4)

  1. 一种刮板输送机链条故障诊断系统，该刮板输送机包括刮板输送机滚筒，在刮板输送机滚筒上间隔设置的两个链轮，链轮为双排齿轮，每个链轮上安装一根链条，其特征在于：该诊断系统包括贴在刮板输送机链轮轮齿顶部端面的应变花(1)，应变花(1)通过屏蔽导线(2)连接固定在刮板输送机滚筒上的信号采集单元(3)，信号采集单元(3)的无线发送模块通过无线传输方式将采集的信号发送给无线接收装置(4)，无线接收装置(4)通过USB接口将获得的采集信号传输给工控机(5)；
    所述应变花包括平行于链轮中心轴线布置的90°应变计以及垂直于90°应变计布置的0°应变计。
  2. 根据权利要求1所述的一种刮板输送机链条故障诊断系统，其特征在于：所述信号采集单元(3)包括电源模块，电源模块分别连接信号调理电路、MCU微控芯片和无线发送模块，MCU微控芯片分别连接信号调理电路、存储模块和无线发送模块。
  3. 根据权利要求1所述的一种刮板输送机链条故障诊断系统，其特征在于：所述0°应变计和90°应变计均为自带温度补偿的电阻应变计。
  4. 一种基于权利要求1所述诊断系统的刮板输送机链条故障诊断方法，其特征在于，它包括错链、跳链故障判断、断链故障判断和卡链故障判断三个步骤：
    错链、跳链故障判断：计算同一个链轮上相同位置的两个轮齿顶部端面90°应变计测量结果之间的差值
    Figure PCTCN2016108843-appb-100001
    如果|Δf90|≥J1，且连续多个链轮轮齿都出现上述情况，则判断刮板出现了倾斜；当刮板出现了倾斜时，进一步计算滚筒同一轴线上两个链轮上相同位置的两个轮齿顶部端面0°应变计测量结果之间的差值
    Figure PCTCN2016108843-appb-100002
    如果|Δf0|≤J2，则判断出现错链、跳链故障；所述的
    Figure PCTCN2016108843-appb-100003
    断链故障判断：计算滚筒同一轴线上两个链轮相同位置的轮齿顶部端面0°应变计测量结果之间的差值
    Figure PCTCN2016108843-appb-100004
    如果|Δf0|突然变大并超过设定阈值J3，且连续多个链轮轮齿都出现上述情况，则判断发生断链故障；所述的阈值J3可取
    Figure PCTCN2016108843-appb-100005
    卡链故障判断：当两个链轮上相同位置的两个轮齿顶部端面0°应变计测量结果同步地急剧增大，并超过设定阈值J4后，0°应变计测量结果未出现周期性的大小交替变化，则判断出现卡链故障；所述的J4为正常情况下相应0°应变计测量结果的1.5倍。
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