WO2017197875A1 - 一种刮板输送机链条张力监测装置及方法 - Google Patents

一种刮板输送机链条张力监测装置及方法 Download PDF

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Publication number
WO2017197875A1
WO2017197875A1 PCT/CN2016/108844 CN2016108844W WO2017197875A1 WO 2017197875 A1 WO2017197875 A1 WO 2017197875A1 CN 2016108844 W CN2016108844 W CN 2016108844W WO 2017197875 A1 WO2017197875 A1 WO 2017197875A1
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WIPO (PCT)
Prior art keywords
chain
tension
scraper conveyor
wireless
signal
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PCT/CN2016/108844
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English (en)
French (fr)
Inventor
江帆
朱真才
李伟
曹国华
周公博
彭玉兴
沈刚
吴孙阳
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中国矿业大学
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Publication of WO2017197875A1 publication Critical patent/WO2017197875A1/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
    • B65G23/00—Driving gear for endless conveyors; 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
    • B65G19/00—Conveyors comprising an impeller or a series of impellers carried by an endless traction element and arranged to move articles or materials over a supporting surface or underlying material, e.g. endless scraper conveyors
    • B65G19/18—Details
    • B65G19/20—Traction chains, ropes, or cables
    • 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
    • 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
    • G—PHYSICS
    • G08—SIGNALLING
    • G08C—TRANSMISSION SYSTEMS FOR MEASURED VALUES, CONTROL OR SIMILAR SIGNALS
    • G08C17/00—Arrangements for transmitting signals characterised by the use of a wireless electrical link
    • G08C17/02—Arrangements for transmitting signals characterised by the use of a wireless electrical link using a radio link

Definitions

  • the invention relates to the technical field of monitoring and safety protection of a scraper conveyor, in particular to a chain tension monitoring device and method for a scraper conveyor.
  • 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. Its reliability directly affects the safety of modern coal mines. Efficient production.
  • the chain is the most prone to failure of the scraper conveyor, and its failure (chain breaking, chain scission and chain scission, etc.) accounts for about 40% of the total number of scraper conveyor failures.
  • chain breaking, chain scission and chain scission, etc. accounts for about 40% of the total number of scraper conveyor failures.
  • the required maintenance time is long, which seriously restricts the production efficiency of large coal mines in China.
  • An in-depth analysis found that an important reason for the failure of the chain is that it is difficult to effectively monitor its tension.
  • the tension of the scraper conveyor chain is indirectly obtained through the cylinder pressure, the chain suspension amount and the power at home and abroad. During the operation of the scraper conveyor, the chain is shaken, making it difficult to accurately measure the amount of drape.
  • the object of the present invention is to overcome the deficiencies of the prior art, and to provide a strip tension monitoring device and method for a scraper conveyor, which can improve the real-time and accuracy of the tension measurement of the scraper chain, and Technical support is provided for effective monitoring and control of the plate conveyor chain status.
  • a scraper conveyor chain tension monitoring device comprising a stress sensor mounted on the side of the sprocket tooth for measuring different tension of the chain during operation of the scraper conveyor Under the sprocket tooth stress data, the stress sensor is also connected with the wireless transmitting device, and the measured sprocket tooth stress data is transmitted to the wireless receiving device by wireless transmission, and the wireless receiving device transmits the received data through the USB interface.
  • the wireless transmitting device comprises a transmitting end power module, and the transmitting end power module is respectively connected to a signal conditioning circuit, a transmitting end MCU micro control chip and a wireless transmitting module, and the transmitting end MCU micro control chip is respectively connected to the signal conditioning circuit and the transmitting end Flash.
  • the storage module and the wireless sending module; the wireless receiving device comprises a receiving end power module, the receiving end power module is respectively connected to the wireless receiving module, the receiving end MCU micro control chip and the USB interface circuit, and the receiving end MCU micro control chip is respectively connected to the wireless receiving module The receiving end flash memory module and the USB interface circuit.
  • Scraper conveyor chain tension monitoring method based on the above monitoring device, including scraper conveyor chain tension
  • the size measurement and the tension measurement value realize two steps of judging the safety of the scraper conveyor chain tension.
  • the step of measuring the tension of the chain of the scraper conveyor is: firstly, establishing a correlation model between the tension of the chain of the scraper conveyor and the stress at the installation position of the stress sensor by the dynamic principle; and then installing by a standard tension sensor A good stress sensor is used for proofreading; finally, the chain tension of the scraper conveyor is obtained by the output of the stress sensor.
  • the step of determining the tension safety condition of the scraper conveyor chain by the tension measurement value is:
  • the first-level safety threshold J 1 and the second-level safety threshold J 2 are set ;
  • the J 1 is the average value of the tension monitoring during the normal operation of the chain, and J 2 is 90 % chain rated tension value;
  • the wireless transmitting device when the wireless transmitting device outputs the tension overrun signal, continue to determine whether the scraper conveyor chain tension F is greater than or equal to the set secondary safety threshold J 2 , and if so, the wireless transmitting device outputs a suspected tension extreme over-limit danger signal, When the suspected tension extreme over-limit danger signal continues to appear within 5 seconds, the wireless transmitting device outputs a tension exceeding the limit danger signal;
  • the wireless signal transmission means If
  • the wireless transmitting device when the wireless transmitting device outputs the tension non-overrun signal and the chain normal signal, the measured scraper conveyor chain tension value is sent every 1 minute, and the tension measurement values of the other scraper conveyor chains are stored in the wireless Sending device to save power; when the wireless transmitting device outputs signals other than tension unloading and chain normal signal, the wireless transmitting device sends all the collected scraper conveyor chain tension values to the current time and the previous one minute.
  • the receiving device is further analyzed by the industrial computer.
  • the present invention converts the monitoring of the tension of the conveyor belt of the scraper into a real-time detection of the sprocket stress, so that The relevant staff can obtain the tension data of the scraper conveyor chain in real time, and based on the collected stress data, it can be judged whether the chain tension is over-limit, whether there is a chain breakage or a specific chain in which the chain break occurs.
  • the invention provides technical support for chain control and chain break prevention under extreme overload conditions such as a card chain, high precision, convenient installation and use, and low maintenance cost.
  • Figure 1 is a schematic view showing the structure of the apparatus of the present invention
  • FIG. 2 is a schematic structural diagram of a wireless transmitting apparatus of the present invention
  • FIG. 3 is a schematic structural diagram of a wireless receiving apparatus of the present invention.
  • Fig. 4 is a flow chart showing the method for monitoring the tension of the chain of the scraper conveyor of the present invention.
  • 1-stress sensor 2-wireless transmitting device
  • 3-wireless receiving device 4-industrial computer
  • 5-monitoring station 5-monitoring station
  • a scraper conveyor chain tension monitoring device of the present invention comprises a stress sensor 1 mounted on a side of a sprocket tooth.
  • each sprocket tooth has a same position on the same side of the sprocket tooth.
  • the fixed stress sensor 1 is installed by gluing.
  • the stress sensor 1 is used to measure the sprocket tooth stress data under different tensions of the chain during the operation of the scraper conveyor, and the stress sensor 1 is also connected to the wireless transmitting device 2, the wireless The transmitting device 2 is also attached to the drum in the same axial direction as the sprocket teeth by gluing, so that the measured sprocket tooth stress data is transmitted to the wireless receiving device 3 by wireless transmission, and the wireless receiving device 3 is fixed to On the monitoring station 5, the wireless receiving device 3 transmits the received data to the industrial computer 4 via the USB interface.
  • the wireless transmitting device 2 includes a transmitting power module, and the transmitting power module is respectively connected to a signal conditioning circuit, a transmitting MCU micro control chip, and a wireless transmitting module, and the transmitting MCU micro control chip respectively connects the signals. Conditioning circuit, transmitting end Flash memory module and wireless transmitting module.
  • the wireless receiving device 3 includes a receiving end power module, and the receiving end power module is respectively connected to the wireless receiving module, the receiving end MCU micro control chip and the USB interface circuit, and the receiving end MCU micro control chip is respectively connected to the wireless receiving module and the receiving end Flash storage module. And USB interface circuit.
  • the working principle of the monitoring device of the invention the scraper conveyor drives the chain by the rotating sprocket to realize the transportation of the coal, and the tension of the chain has a direct relationship with the deformation of the side of the sprocket, such as: the respective tension between the chains and the break
  • the tension mutation caused by the chain and the tension imbalance of the chain can be expressed in real time through the stress values at the corresponding positions of the sprocket.
  • the tension of the chain is directly related to the deformation of the side of the sprocket. By correlating the tension of the scraper conveyor chain with the stress change at the key position of the sprocket tooth, the tension of the chain can be measured.
  • the scraper chain tension has a certain rated value.
  • the chain overload can be monitored to realize the fault detection of the chain. Prevents chain breakage of extreme overloads from occurring.
  • the scraper conveyor usually one chain is broken first, and the broken chain is broken. The force suddenly drops, and the tension of the other chain suddenly increases to ensure that the traction force does not change. Therefore, the ratio of the stress of the two chains to the gear teeth of the sprocket is abrupt, and the output stress is small for the failure of the chain.
  • the chain, the other chain is the normal chain. Therefore, by judging the measurement of the sprocket tooth stress, the secondary threshold and the sprocket stress ratio can be used to monitor the chain chain, overload and chain breakage.
  • a method for monitoring the tension of a chain conveyor of a scraper conveyor based on the above monitoring device comprises the steps of measuring the tension of the chain of the scraper conveyor and determining the tension safety of the conveyor belt of the scraper by the tension measurement value.
  • the step of measuring the tension of the chain of the scraper conveyor is as follows: firstly, establishing a relationship between the tension of the chain of the scraper conveyor and the stress at the installation position of the stress sensor; and then installing through a standard tension sensor. The stress sensor is proofread; finally, the chain tension of the scraper conveyor is obtained by the output of the stress sensor.
  • the step of determining the traction condition of the scraper conveyor chain by the chain tension measurement value is:
  • the first-level safety threshold J 1 and the second-level safety threshold J 2 are set ;
  • the J 1 is the average value of the tension monitoring during the normal operation of the chain, and J 2 is 90 % chain rated tension value;
  • the wireless transmitting device when the wireless transmitting device outputs the tension overrun signal, continue to determine whether the scraper conveyor chain tension F is greater than or equal to the set secondary safety threshold J 2 , and if so, the wireless transmitting device outputs a suspected tension extreme over-limit danger signal, When the suspected tension extreme over-limit danger signal continues to appear within 5 seconds, the wireless transmitting device outputs a tension exceeding the limit danger signal;
  • the wireless signal transmission means If
  • the wireless transmitting device transmits the collected tension value of all the scraper conveyor chains in the current time and the previous one minute to the wireless receiving device for further analysis by the industrial computer.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Computer Networks & Wireless Communication (AREA)
  • Control Of Conveyors (AREA)
  • Escalators And Moving Walkways (AREA)
  • Devices For Conveying Motion By Means Of Endless Flexible Members (AREA)

Abstract

一种刮板输送机链条张力监测装置，包括安装在链轮轮齿侧面的应力传感器（1），用于测量刮板输送机运行过程中链条不同张力下的链轮轮齿应力数据，应力传感器（1）还与无线发送装置（2）相连接，实现将测量的链轮轮齿应力数据通过无线传输方式发送给无线接收装置（3），无线接收装置（3）将接收的数据通过USB接口传输给工控机。该装置将刮板输送机链条张力的监测转换为链轮应力的实时检测，使得相关工作人员能够实时获得刮板输送机链条的张力数据，基于采集的应力数据可判断链条张力是否超限、是否出现断链以及断链发生的具体链条。还提供一种刮板输送机链条张力监测方法。

Description

一种刮板输送机链条张力监测装置及方法 技术领域
本发明涉及刮板输送机监测与安全保障技术领域，尤其涉及一种刮板输送机链条张力监测装置及方法。
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，其可靠性直接影响到现代化煤矿的安全高效生产。
链条是刮板输送机最容易出现故障的机构，其故障(断链、跳链和掉链等)约占刮板输送机故障总数的40％。刮板输送机链条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。深入分析发现，链条出现故障的一个重要原因是难以对其张力进行有效监测。目前，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。刮板输送机在运行过程中，链条存在晃动，使得其悬垂量难以准确测量。同时，通过油缸压力和功率仅能获得刮板输送机所有链条的总张力，对链条各自的张力难以实现有效监测。刮板输送机链条通过无极闭环移动实现煤炭的运输，传统的有线测量方式难以实现对链条张力进行实时的直接监测。
发明内容
发明目的：本发明的目的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张力监测装置及方法，实现提高对刮板链张力测量的实时性和准确性，为对刮板输送机链条状态进行有效的监测和控制提供技术支持。
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张力监测装置，包括安装在链轮轮齿侧面的应力传感器，用于测量刮板输送机运行过程中链条不同张力下的链轮轮齿应力数据，应力传感器还与无线发送装置相连接，实现将测量的链轮轮齿应力数据通过无线传输方式发送给无线接收装置，无线接收装置将接收的数据通过USB接口传输给工控机。
优选的，所述无线发送装置包括发送端电源模块，发送端电源模块分别连接信号调理电路、发送端MCU微控芯片和无线发送模块，发送端MCU微控芯片分别连接信号调理电路、发送端Flash存储模块和无线发送模块；所述无线接收装置包括接收端电源模块，接收端电源模块分别连接无线接收模块、接收端MCU微控芯片和USB接口电路，接收端MCU微控芯片分别连接无线接收模块、接收端Flash存储模块和USB接口电路。
一种基于上述监测装置的刮板输送机链条张力监测方法，包括刮板输送机链条张力 大小测量和通过张力测量值实现对刮板输送机链条张力安全情况进行判断两个步骤。
优选的，所述的刮板输送机链条张力大小测量步骤为：首先，通过动力学原理建立刮板输送机链条张力与应力传感器安装位置处应力的关联模型；然后，通过标准的拉力传感器对安装好的应力传感器进行校对；最后，通过应力传感器的输出获得刮板输送机的链条张力。
优选的，所述的通过张力测量值实现对刮板输送机链条张力安全情况进行判断的步骤为：
a)链条超载故障监测:
a1)根据链条额定张力和正常运行下链条张力的历史数据设定一级安全阈值J1、二级安全阈值J2；所述的J1为链条正常工作时的张力监测均值、J2为90％的链条额定张力值；
a2)判断刮板输送机链条张力F是否大于等于设定的一级安全阈值J1，如果否，无线发送装置输出张力未超限信号，如果是，无线发送装置输出疑似张力超限信号，当疑似张力超限信号在15秒内持续出现，无线发送装置输出张力超限信号；
a3)当无线发送装置输出张力超限信号时，继续判断刮板输送机链条张力F是否大于等于设定的二级安全阈值J2，如果是，无线发送装置输出疑似张力极度超限危险信号，当疑似张力极度超限危险信号在5秒内持续出现，无线发送装置输出张力极度超限危险信号；
b)断链故障监测：
b1)计算两条链条啮合链轮轮齿对应位置上的应力传感器输出数据的差值ΔK＝F1-F2，设定断链判定阈值J3，其计算公式可设计为J3＝(F1+F2)/8。
b2)如果|ΔK|≤J3，则判断未出现断链故障，无线发送装置输出链条正常信号；如果|ΔK|＞J3，则无线发送装置输出疑似断链故障信号，当疑似断链故障信号在5秒内持续出现，则判断出现了断链故障；
b3)出现断链故障后，如果ΔK为负，则F1对应的链条出现断链故障；如果ΔK为正，则F2对应的链条出现断链故障。
优选的，当无线发送装置输出为张力未超限信号和链条正常信号时，每隔1分钟发送一次测量的刮板输送机链条张力值，而其它刮板输送机链条的张力测量值存储在无线发送装置，以节省电量；当无线发送装置输出为张力未超载和链条正常信号以外的其他信号时，无线发送装置将当前时刻及以前1分钟内所有采集的刮板输送机链条张力值发送给无线接收装置，供工控机进一步分析。
有益效果：本发明将刮板输送机链条张力的监测转化为链轮应力的实时检测，使得 相关工作人员能够实时获得刮板输送机链条的张力数据，基于采集的应力数据可判断链条张力是否超限、是否出现断链以及断链发生的具体链条。本发明为卡链等极端超载情况下的链条控制和断链预防提供技术支持，精度高，安装和使用方便，维护成本低。
附图说明
图1是本发明装置的结构示意图；
图2是本发明的无线发送装置结构原理图；
图3是本发明的无线接收装置结构原理图；
图4是本发明的刮板输送机链条张力监测方法流程图。
图中：1-应力传感器，2-无线发送装置，3-无线接收装置，4-工控机，5-监控台。
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所示，本发明的一种刮板输送机链条张力监测装置，包括安装在链轮轮齿侧面的应力传感器1，具体实施时每一个链轮轮齿同一侧面相同位置处都有一个通过胶粘方式安装固定的应力传感器1，应力传感器1用于测量刮板输送机运行过程中链条不同张力下的链轮轮齿应力数据，应力传感器1还与无线发送装置2相连接，该无线发送装置2同样通过胶粘方式安装于与链轮轮齿位于同一轴向的滚筒上，实现将测量的链轮轮齿应力数据通过无线传输方式发送给无线接收装置3，无线接收装置3固定于监控台5上，无线接收装置3将接收的数据通过USB接口传输给工控机4。
如图2和3所示，所述无线发送装置2包括发送端电源模块，发送端电源模块分别连接信号调理电路、发送端MCU微控芯片和无线发送模块，发送端MCU微控芯片分别连接信号调理电路、发送端Flash存储模块和无线发送模块。所述无线接收装置3包括接收端电源模块，接收端电源模块分别连接无线接收模块、接收端MCU微控芯片和USB接口电路，接收端MCU微控芯片分别连接无线接收模块、接收端Flash存储模块和USB接口电路。
本发明监测装置的工作原理：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，链条的张力与链轮侧面的变形有着直接的关联关系，如：链条间各自张力大小以及断链产生的张力突变和链条张力不平衡等都可通过链轮相应位置处的应力值实时表现。链条的张力与链轮侧面的变形有着直接的关联关系，通过将刮板输送机链条的张力与链轮轮齿关键位置的应力变化进行关联，可实现对链条张力的测量。刮板链张力都具有一定的额定值，超出额定值一定范围将发生极度超载情况下的断链故障，通过设定二级阈值张力监测方法可实现对链条超载进行监测，实现卡链故障检测和防止极端超载的断链故障发生。刮板输送机运行过程中，通常某一条链条先断链，发生断链的链条张 力突然下降，另一条链条的张力则会突然增大从而确保中的牵引力不变，因此，两条链条对应链轮轮齿应力的比值出现突变，且输出应力值小的为发生断链故障的链条，另一条链条则为正常链条。因此，通过判断链轮轮齿应力的测量，二级阈值和链轮应力比值可实现链条卡链、超载和断链故障的监测。
一种基于上述监测装置的刮板输送机链条张力监测方法，包括刮板输送机链条张力大小测量和通过张力测量值实现对刮板输送机链条张力安全情况进行判断两个步骤。
如图4所示，所述的刮板输送机链条张力大小测量步骤为：首先，建立刮板输送机链条张力与应力传感器安装位置处应力的关联关系；然后，通过标准的拉力传感器对安装好的应力传感器进行校对；最后，通过应力传感器的输出获得刮板输送机的链条张力。
所述的通过链条张力测量值实现对刮板输送机链条牵引情况进行判断的步骤为：
a)链条超载故障监测:
a1)根据链条额定张力和正常运行下链条张力的历史数据设定一级安全阈值J1、二级安全阈值J2；所述的J1为链条正常工作时的张力监测均值、J2为90％的链条额定张力值；
a2)判断刮板输送机链条张力F是否大于等于设定的一级安全阈值J1，如果否，无线发送装置输出张力未超限信号，如果是，无线发送装置输出疑似张力超限信号，当疑似张力超限信号在15秒内持续出现，无线发送装置输出张力超限信号；
a3)当无线发送装置输出张力超限信号时，继续判断刮板输送机链条张力F是否大于等于设定的二级安全阈值J2，如果是，无线发送装置输出疑似张力极度超限危险信号，当疑似张力极度超限危险信号在5秒内持续出现，无线发送装置输出张力极度超限危险信号；
b)断链故障监测：
b1)计算两条链条啮合链轮轮齿对应位置上的应力传感器输出数据的差值ΔK＝F1-F2，设定断链判定阈值J3，其计算公式可设计为J3＝(F1+F2)/8。
b2)如果|ΔK|≤J3，则判断未出现断链故障，无线发送装置输出链条正常信号；如果|ΔK|＞J3，则无线发送装置输出疑似断链故障信号，当疑似断链故障信号在5秒内持续出现，则判断出现了断链故障；
b3)出现断链故障后，如果ΔK为负，则F1对应的链条出现断链故障；如果ΔK为正，则F2对应的链条出现断链故障。
在对刮板输送机链条牵引情况进行判断过程中，当无线发送装置输出为链条张力未超限信号和链条正常信号时，每隔1分钟发送一次测量的刮板输送机链条张力值，而其它刮板输送机链条的张力测量值存储在无线发送装置，以节省电量；当无线发送装置输 出为链条张力未超载和和链条正常信号以外的其他信号(疑似张力超限信号、张力超限信号、疑似张力极度超限危险信号、张力极度超限危险信号、疑似断链故障信号、断链故障信号)时，无线发送装置将当前时刻及以前1分钟内所有采集的刮板输送机链条张力值发送给无线接收装置，供工控机进一步分析。
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 (6)

  1. 一种刮板输送机链条张力监测装置，其特征在于：包括安装在链轮轮齿侧面的应力传感器(1)，用于测量刮板输送机运行过程中链条不同张力下的链轮轮齿应力数据，应力传感器(1)还与无线发送装置(2)相连接，实现将测量的链轮轮齿应力数据通过无线传输方式发送给无线接收装置(3)，无线接收装置(3)将接收的数据通过USB接口传输给工控机(4)。
  2. 根据权利要求1所述的一种刮板输送机链条张力监测装置，其特征在于：所述无线发送装置(2)包括发送端电源模块，发送端电源模块分别连接信号调理电路、发送端MCU微控芯片和无线发送模块，发送端MCU微控芯片分别连接信号调理电路、发送端Flash存储模块和无线发送模块；所述无线接收装置(3)包括接收端电源模块，接收端电源模块分别连接无线接收模块、接收端MCU微控芯片和USB接口电路，接收端MCU微控芯片分别连接无线接收模块、接收端Flash存储模块和USB接口电路。
  3. 一种基于权利要求1所述监测装置的刮板输送机链条张力监测方法，其特征在于：包括刮板输送机链条张力大小测量和通过张力测量值实现对刮板输送机链条张力安全情况进行判断两个步骤。
  4. 根据权利要求3所述的刮板输送机链条张力监测方法，其特征在于：所述的刮板输送机链条张力大小测量步骤为：首先，通过动力学原理建立刮板输送机链条张力与应力传感器安装位置处应力的关联模型；然后，通过标准的拉力传感器对安装好的应力传感器进行校对；最后，通过应力传感器的输出获得刮板输送机的链条张力。
  5. 根据权利要求3所述的刮板输送机链条张力监测方法，其特征在于：所述的通过张力测量值实现对刮板输送机链条张力安全情况进行判断的步骤为：
    a)链条超载故障监测:
    a1)根据链条额定张力和正常运行下链条张力的历史数据设定一级安全阈值J1、二级安全阈值J2；所述的J1为链条正常工作时的张力监测均值、J2为90％的链条额定张力值；
    a2)判断刮板输送机链条张力F是否大于等于设定的一级安全阈值J1，如果否，无线发送装置输出张力未超限信号，如果是，无线发送装置输出疑似张力超限信号，当疑似张力超限信号在15秒内持续出现，无线发送装置输出张力超限信号；
    a3)当无线发送装置输出张力超限信号时，继续判断刮板输送机链条张力F是否大于等于设定的二级安全阈值J2，如果是，无线发送装置输出疑似张力极度超限危险信号，当疑似张力极度超限危险信号在5秒内持续出现，无线发送装置输出张力极度超限危险信号；
    b)断链故障监测：
    b1)计算两条链条啮合链轮轮齿对应位置上的应力传感器输出数据的差值ΔK＝F1-F2，设定断链判定阈值J3，其计算公式可设计为J3＝(F1+F2)/8；
    b2)如果|ΔK|≤J3，则判断未出现断链故障，无线发送装置输出链条正常信号；如果|ΔK|＞J3，则无线发送装置输出疑似断链故障信号，当疑似断链故障信号在5秒内持续出现，则判断出现了断链故障；
    b3)出现断链故障后，如果ΔK为负，则F1对应的链条出现断链故障；如果ΔK为正，则F2对应的链条出现断链故障。
  6. 根据权利要求5所述的刮板输送机链条张力监测方法，其特征在于：当无线发送装置输出为张力未超限信号和链条正常信号时，每隔1分钟发送一次测量的刮板输送机链条张力值，而其它刮板输送机链条的张力测量值存储在无线发送装置，以节省电量；当无线发送装置输出为张力未超载和链条正常信号以外的其他信号时，无线发送装置将当前时刻及以前1分钟内所有采集的刮板输送机链条张力值发送给无线接收装置，供工控机进一步分析。
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