WO2017197876A1 - 一种刮板输送机链轮轮齿磨损监测装置和方法 - Google Patents

一种刮板输送机链轮轮齿磨损监测装置和方法 Download PDF

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WO2017197876A1
WO2017197876A1 PCT/CN2016/108845 CN2016108845W WO2017197876A1 WO 2017197876 A1 WO2017197876 A1 WO 2017197876A1 CN 2016108845 W CN2016108845 W CN 2016108845W WO 2017197876 A1 WO2017197876 A1 WO 2017197876A1
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photoelectric sensing
vertical
sprocket
horizontal
sensing module
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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
卢昊
吴孙阳
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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 CA2987475A priority Critical patent/CA2987475C/en
Priority to AU2016401397A priority patent/AU2016401397B2/en
Publication of WO2017197876A1 publication Critical patent/WO2017197876A1/zh
Priority to ZA2018/02656A priority patent/ZA201802656B/en
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
    • G01B11/06—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
    • G01B11/2416—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures of gears
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
    • G01B11/255—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures for measuring radius of curvature

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  • the invention relates to the technical field of monitoring and safety protection of a scraper conveyor device, in particular to a device and a method for monitoring the wear of a sprocket tooth of 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 scraper chain is the most prone to failure of the scraper conveyor, and its failure 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.
  • In-depth analysis found that when the sprocket teeth are severely worn, the scraper conveyor chain will be in contact with it, and there will be a risk of sprocket teeth breaking.
  • the detection technology of mature tooth wear Therefore, it is necessary to monitor the wear of the sprocket teeth in real time during the operation of the scraper conveyor.
  • the present invention provides a device and method for detecting the wear of a sprocket tooth of a sprocket conveyor for realizing the safety monitoring problem during use of the squeegee conveyor, thereby realizing real-time measurement of the wear amount of the sprocket teeth, in order to avoid Technical support is provided for the scraper conveyor chain skipping and sprocket tooth breaking due to severe wear of the sprocket teeth.
  • a scraper conveyor sprocket tooth wear monitoring device comprising: a top reflective patch, a vertical photoelectric sensing module, a side reflective patch, a horizontal photoelectric sensing module, and Data analysis module;
  • the top reflective patch is mounted on the top surface of the sprocket tooth.
  • the vertical photoelectric sensing module includes a vertical light source and a vertical photoelectric sensing element.
  • the vertical light source is used to emit light to the top reflective patch, and the vertical photoelectric sensing element is used to sense the top reflective patch reflection. The light coming back and outputting a level signal;
  • the side reflective patch is mounted on the side of the sprocket tooth
  • the horizontal photoelectric sensing module comprises a horizontal light source and a horizontal photoelectric sensing element
  • the horizontal light source is used for emitting light to the side reflective patch
  • the horizontal photoelectric sensing element is used for sensing the side reflective patch reflecting back. Light and output a level signal
  • the data analysis module includes a lower computer and an industrial computer, and the lower computer is used for collecting level signals of vertical photoelectric sensing elements and horizontal photoelectric sensing elements, and the industrial computer is used for analyzing the collected level signals to obtain sprocket teeth. Wear and tear.
  • the top reflective patch has the same shape as the sprocket tooth top surface
  • the side reflective patch has the same shape as the sprocket tooth side surface
  • the vertical light source and the horizontal light source are point light sources.
  • the vertical photoelectric sensing element has an arc shape
  • the horizontal photoelectric sensing element has the same shape as the side reflective patch.
  • the vertical photoelectric sensing module and the horizontal photoelectric sensing module further comprise a signal conditioning unit for amplifying and filtering the output level signal.
  • a method for monitoring the wear of a sprocket tooth of a scraper conveyor based on the above monitoring device comprising the following steps:
  • the vertical sampling module and the horizontal photoelectric sensing module are assigned the same sampling frequency, and the vertical photoelectric sensing module outputs a high level when receiving the reflected light of the top reflective patch, and vice versa, outputs a low level, setting the level.
  • the photoelectric sensing module outputs a high level when receiving the light reflected by the side reflective patch, and vice versa, outputs a low level;
  • the beneficial effects after the sprocket teeth wear, the structural size of the sprocket conveyor chain in the running direction becomes smaller.
  • the invention obtains the thickness data reflecting the sprocket teeth in real time through the high and low level signal length through the photoelectric sensing principle. Real-time sprocket tooth wear is obtained by comparison with the original thickness value.
  • the invention can realize the real-time measurement of the wear amount of the sprocket teeth, and avoid the equipment abnormality, destruction and economic loss caused by the skipping of the scraper conveyor chain caused by the severe wear of the sprocket teeth.
  • Figure 1 is a schematic view of the structure of the present invention
  • FIG. 2 is a schematic view showing the installation of the vertical photoelectric sensing module of the present invention
  • FIG. 3 is a schematic view showing the installation of the horizontal photoelectric sensing module of the present invention.
  • Figure 4 is a schematic diagram of the system composition of the present invention.
  • a scraper conveyor sprocket tooth wear monitoring device of the present invention comprises: a top reflective patch, a vertical photoelectric sensing module, a side reflective patch, and a horizontal photoelectric sensing module. And data analysis module.
  • the top reflective patch is mounted on the top surface of the sprocket tooth, and the top reflective patch has the same shape as the top surface of the sprocket tooth.
  • the vertical photoelectric sensing module comprises a vertical light source and a vertical photoelectric sensing element, and the vertical light source is a point light source, and the vertical The light source is used to emit light to the top reflective patch.
  • the vertical photoelectric sensing element has an arc shape, and the vertical photoelectric sensing element is used to sense the light reflected by the top reflective patch and output a level signal.
  • the vertical photo sensing module further includes a signal conditioning unit for amplifying and filtering the output level signal. The vertical source and signal conditioning unit are powered by a power source.
  • the side reflective patch is mounted on the side surface of the sprocket wheel, the side reflective patch has the same shape as the side surface of the sprocket wheel, the horizontal photoelectric sensing module comprises a horizontal light source and a horizontal photoelectric sensing element, and the horizontal light source is a point light source.
  • the horizontal light source is used to emit light to the side reflective patch, and the horizontal photoelectric sensing element has the same shape as the side reflective patch.
  • the horizontal photoelectric sensing element is used to sense the light reflected by the side reflective patch and output a level signal.
  • the horizontal photo sensing module further includes a signal conditioning unit for amplifying and filtering the output level signal.
  • the horizontal light source and signal conditioning unit are powered by a power source.
  • the data analysis module includes a lower computer and an industrial computer.
  • the lower computer and the industrial computer are powered by a power supply, and the lower computer is used for collecting level signals of vertical photoelectric sensing elements and horizontal photoelectric sensing elements, and the industrial computer is used for collecting the level signals. Analyze to obtain sprocket tooth wear.
  • the sprocket corresponding to each chain of the scraper conveyor head and the tail of the machine is provided with a set of vertical photoelectric sensing modules and top reflective patches, a set of horizontal photoelectric sensing modules and side reflective patches.
  • the vertical photoelectric sensing module and the horizontal photoelectric sensing module are suspended by a fixed pipe bracket, and the sprocket teeth and the chain of the space are not fitted to each other; the side reflective patches are respectively installed on the left side of the left sprocket tooth.
  • the top reflective patches are mounted on the left sprocket top and the right sprocket on the left sprocket, respectively.
  • the scraper conveyor drives the material through the rotating sprocket to drive the material.
  • the sprocket teeth When the sprocket teeth are severely worn, the chain will be skipped, resulting in unbalanced tension between the chains of the scraper conveyor, eventually causing chain scission. Faults such as blade bending affect the effective operation of the normal operation and transportation functions of the scraper conveyor.
  • the structural size of the sprocket conveyor chain in the running direction becomes smaller.
  • the invention obtains the thickness data reflecting the sprocket teeth in real time through the high and low level signal length through the principle of photoelectric induction, and The raw thickness value comparison gives real-time sprocket tooth wear.
  • the method for monitoring the sprocket tooth wear of the scraper conveyor of the above monitoring device comprises the following steps:
  • the vertical sampling module and the horizontal photoelectric sensing module are assigned the same sampling frequency, and the vertical photoelectric sensing module outputs a high level when receiving the reflected light of the top reflective patch, and vice versa, outputs a low level, setting the level.
  • the photoelectric sensing module outputs a high level when receiving the light reflected by the side reflective patch, and vice versa, outputs a low level;

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Control Of Conveyors (AREA)
  • Length Measuring Devices By Optical Means (AREA)
  • Escalators And Moving Walkways (AREA)

Abstract

一种刮板输送机链轮（8、9）轮齿磨损监测装置和方法，该装置包括顶端反光贴片（4、5）、垂直光电感应模块（3、6）、侧面反光贴片（2）、水平光电感应模块（1、7）和数据分析模块（10）；顶端反光贴片（4、5）安装在链轮（8、9）轮齿顶面，垂直光电感应模块（3、6）包括垂直光源（12）和垂直光电感应元件（11），侧面反光贴片（2）安装在链轮（8、9）轮齿顶面，水平光电感应模块（1、7）包括水平光源（14）和水平光电感应元件（13），数据分析模块（10）包括下位机和工控机；该装置和方法通过高低电平信号长度实时获得反映链轮（8、9）轮齿的厚度数据，通过与原始厚度值对比获得实时的链轮（8、9）轮齿磨损量。该装置和方法实现对链轮（8、9）轮齿磨损量的实时测量，避免因链轮（8、9）轮齿严重磨损产生的刮板输送机链条跳牙带来的设备异常、毁坏和经济损失。

Description

一种刮板输送机链轮轮齿磨损监测装置和方法 技术领域
本发明涉及刮板输送机设备监测与安全保障技术领域，尤其涉及一种刮板输送机链轮轮齿磨损监测装置和方法。
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。
刮板链是刮板输送机最容易出现故障的机构，其故障约占刮板输送机故障总数的40％。刮板链一旦出现故障，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，当链轮轮齿出现严重磨损后，刮板输送机链条在与其啮合是会出现跳牙现象，同时，存在链轮轮齿断裂的风险，但目前国内外并没有针对链轮轮齿磨损量成熟的检测技术。因此，有必要对刮板输送机运行过程中链轮轮齿的磨损情况进行实时监测。
发明内容
发明目的：本发明针对刮板输送机使用过程中存在的安全监测问题，提供一种刮板输送机链轮轮齿磨损监测装置和方法，实现对链轮轮齿磨损量的实时测量，为避免因链轮轮齿严重磨损产生的刮板输送机链条跳牙和链轮轮齿断链提供技术支持。
为了实现上述目的，本发明采用了如下的技术方案：一种刮板输送机链轮轮齿磨损监测装置，包括：顶端反光贴片、垂直光电感应模块、侧面反光贴片、水平光电感应模块和数据分析模块；
顶端反光贴片安装在链轮轮齿顶面，垂直光电感应模块包括垂直光源和垂直光电感应元件，垂直光源用于向顶端反光贴片发射光线，垂直光电感应元件用于感应顶端反光贴片反射回来的光线并输出电平信号；
侧面反光贴片安装在链轮轮齿侧面，水平光电感应模块包括水平光源和水平光电感应元件，水平光源用于向侧面反光贴片发射光线，水平光电感应元件用于感应侧面反光贴片反射回来的光线并输出电平信号；
数据分析模块包括下位机和工控机，下位机用于采集垂直光电感应元件和水平光电感应元件输出的电平信号，工控机用于对采集到的电平信号进行分析，以获得链轮轮齿磨损情况。
优选的，所述的顶端反光贴片与链轮轮齿顶面形状一致，所述的侧面反光贴片与链轮轮齿侧面形状一致。
优选的，所述的垂直光源和水平光源均为点光源。
优选的，所述垂直光电感应元件呈圆弧状，所述水平光电感应元件与侧面反光贴片的形状一致。
优选的，所述的垂直光电感应模块和水平光电感应模块还包括用于对输出电平信号进行放大、滤波操作的信号调理单元。
一种基于上述监测装置的刮板输送机链轮轮齿磨损监测方法，它包括以下步骤：
首先，给垂直光电感应模块和水平光电感应模块分配相同的采样频率，设定垂直光电感应模块接收到顶端反光贴片的反射光线时输出高电平，反之，则输出低电平，设定水平光电感应模块接收到侧面反光贴片反射回来的光线时输出高电平，反之，则输出低电平；
其次，当链轮轮齿无任何磨损时，测量其顶端端面相应位置的原始尺寸LD-0，同时，获得此时单个链轮轮齿对应垂直光电感应模块输出的高电平长度L1-0和水平光电感应模块输出的低电平L2-0，计算比值因子kD＝LD-0/L1-0；
然后，实际测量链轮轮齿磨损量时，假设单个链轮轮齿通过时垂直光电感应模块输出的高电平长度为L1-1、水平光电感应模块输出的低电平长度为L2-1，计算比值因子Δk＝L2-0/L2-1，如果刮板输送机匀速运行，有Δk＝1，因此，定义Δk为修正因子，消除测量时变转速对链轮轮齿磨损量测量的影响；计算LD-1＝Δk×kD×L1-1，则链轮轮齿磨损量ΔLD＝LD-0-LD-1；
最后，设定链轮轮齿的磨损阈值J，当ΔLD＜J时，链轮轮齿磨损量未超限，可继续正常使用；当ΔLD≥J时，链轮轮齿磨损超限，输出磨损危险报警信号。
有益效果：链轮轮齿出现磨损后，其在刮板输送机链条运行方向上的结构尺寸变小，本发明通过光电感应原理，通过高低电平信号长度实时获得反映链轮轮齿的厚度数据，通过与原始厚度值对比获得实时的链轮轮齿磨损量。本发明可实现对链轮轮齿磨损量的实时测量，避免因链轮轮齿严重磨损产生的刮板输送机链条跳牙带来的设备异常、毁坏和经济损失。
附图说明
图1是本发明的结构示意图；
图2是本发明的垂直光电感应模块的安装示意图；
图3是本发明的水平光电感应模块的安装示意图；
图4是本发明的系统组成示意图。
图中：1、7-水平光电感应模块，2-侧面反光贴片，3、6-垂直光电感应模块，4、5-顶端反光贴片，8-左链轮，9-右链轮，10-数据分析模块，11-垂直光电感应元件，12-垂 直光源，13-水平光电感应元件，14-水平光源。
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、2、3和4所示，本发明的一种刮板输送机链轮轮齿磨损监测装置，包括：顶端反光贴片、垂直光电感应模块、侧面反光贴片、水平光电感应模块和数据分析模块。
顶端反光贴片安装在链轮轮齿顶面，所述的顶端反光贴片与链轮轮齿顶面形状一致，垂直光电感应模块包括垂直光源和垂直光电感应元件，垂直光源为点光源，垂直光源用于向顶端反光贴片发射光线，所述垂直光电感应元件呈圆弧状，垂直光电感应元件用于感应顶端反光贴片反射回来的光线并输出电平信号。垂直光电感应模块还包括用于对输出电平信号进行放大、滤波操作的信号调理单元。垂直光源和信号调理单元由电源供电。
侧面反光贴片安装在链轮轮齿侧面，所述的侧面反光贴片与链轮轮齿侧面形状一致，水平光电感应模块包括水平光源和水平光电感应元件，所述的水平光源为点光源，水平光源用于向侧面反光贴片发射光线，水平光电感应元件与侧面反光贴片的形状一致，水平光电感应元件用于感应侧面反光贴片反射回来的光线并输出电平信号。水平光电感应模块还包括用于对输出电平信号进行放大、滤波操作的信号调理单元。水平光源和信号调理单元由电源供电。
数据分析模块包括下位机和工控机，下位机和工控机由电源供电，下位机用于采集垂直光电感应元件和水平光电感应元件输出的电平信号，工控机用于对采集到的电平信号进行分析，以获得链轮轮齿磨损情况。
本实施例中，刮板输送机机头和机尾处每一条链条对应的链轮都设有一组垂直光电感应模块和顶端反光贴片、一组水平光电感应模块和侧面反光贴片。垂直光电感应模块和水平光电感应模块通过固定管支架等悬空安装，其空间所对的链轮轮齿与链条运行时互不拟合；侧面反光贴片分别安装在左链轮轮齿的左侧面和右链轮轮齿的右侧面，顶端反光贴片分别安装在左链轮上的左边轮齿顶部和右链轮上的右边轮齿顶部。
刮板输送机通过转动的链轮带动链条的移动实现运输物料，当链轮轮齿出现严重磨损后，链条会出现跳牙现象，导致刮板输送机链条间的张力失衡，最终引发断链、刮板弯曲等故障，影响刮板输送机的正常运行和运输功能的有效实现。链轮轮齿出现磨损后，其在刮板输送机链条运行方向上的结构尺寸变小，本发明通过光电感应原理，通过高低电平信号长度实时获得反映链轮轮齿的厚度数据，通过与原始厚度值对比获得实时的链轮轮齿磨损量。
基上述监测装置的刮板输送机链轮轮齿磨损监测方法，它包括以下步骤：
首先，给垂直光电感应模块和水平光电感应模块分配相同的采样频率，设定垂直光电感应模块接收到顶端反光贴片的反射光线时输出高电平，反之，则输出低电平，设定水平光电感应模块接收到侧面反光贴片反射回来的光线时输出高电平，反之，则输出低电平；
其次，当链轮轮齿无任何磨损时，测量其顶端端面相应位置的原始尺寸LD-0，同时，获得此时单个链轮轮齿对应垂直光电感应模块输出的高电平长度L1-0和水平光电感应模块输出的低电平L2-0，计算比值因子kD＝LD-0/L1-0；
然后，实际测量链轮轮齿磨损量时，假设单个链轮轮齿通过时垂直光电感应模块输出的高电平长度为L1-1、水平光电感应模块输出的低电平长度为L2-1，计算比值因子Δk＝L2-0/L2-1，如果刮板输送机匀速运行，有Δk＝1，因此，定义Δk为修正因子，消除测量时变转速对链轮轮齿磨损量测量的影响；计算LD-1＝Δk×kD×L1-1，则链轮轮齿磨损量ΔLD＝LD-0-LD-1；
最后，设定链轮轮齿的磨损阈值J，当ΔLD＜J时，链轮轮齿磨损量未超限，可继续正常使用；当ΔLD≥J时，链轮轮齿磨损超限，输出磨损危险报警信号。
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. 一种刮板输送机链轮轮齿磨损监测装置，其特征在于，包括：顶端反光贴片、垂直光电感应模块、侧面反光贴片、水平光电感应模块和数据分析模块；
    顶端反光贴片安装在链轮轮齿顶面，垂直光电感应模块包括垂直光源和垂直光电感应元件，垂直光源用于向顶端反光贴片发射光线，垂直光电感应元件用于感应顶端反光贴片反射回来的光线并输出电平信号；
    侧面反光贴片安装在链轮轮齿侧面，水平光电感应模块包括水平光源和水平光电感应元件，水平光源用于向侧面反光贴片发射光线，水平光电感应元件用于感应侧面反光贴片反射回来的光线并输出电平信号；
    数据分析模块包括下位机和工控机，下位机用于采集垂直光电感应元件和水平光电感应元件输出的电平信号，工控机用于对采集到的电平信号进行分析，以获得链轮轮齿磨损情况。
  2. 根据权利要求1所述的一种刮板输送机链轮轮齿磨损监测装置，其特征在于：所述的顶端反光贴片与链轮轮齿顶面形状一致，所述的侧面反光贴片与链轮轮齿侧面形状一致。
  3. 根据权利要求1所述的一种刮板输送机链轮轮齿磨损监测装置，其特征在于：所述的垂直光源和水平光源均为点光源。
  4. 根据权利要求1所述的一种刮板输送机链轮轮齿磨损监测装置，其特征在于：所述垂直光电感应元件呈圆弧状，所述水平光电感应元件与侧面反光贴片的形状一致。
  5. 根据权利要求1所述的一种刮板输送机链轮轮齿磨损监测装置，其特征在于：所述的垂直光电感应模块和水平光电感应模块还包括用于对输出电平信号进行放大、滤波操作的信号调理单元。
  6. 一种基于权利要求1所述监测装置的刮板输送机链轮轮齿磨损监测方法，其特征在于，它包括以下步骤：
    首先，给垂直光电感应模块和水平光电感应模块分配相同的采样频率，设定垂直光电感应模块接收到顶端反光贴片的反射光线时输出高电平，反之，则输出低电平，设定水平光电感应模块接收到侧面反光贴片反射回来的光线时输出高电平，反之，则输出低电平；
    其次，当链轮轮齿无任何磨损时，测量其顶端端面相应位置的原始尺寸LD-0，同时，获得此时单个链轮轮齿对应垂直光电感应模块输出的高电平长度L1-0和水平光电感应模块输出的低电平L2-0，计算比值因子kD＝LD-0/L1-0；
    然后，实际测量链轮轮齿磨损量时，假设单个链轮轮齿通过时垂直光电感应模块输出的高电平长度为L1-1、水平光电感应模块输出的低电平长度为L2-1，计算比值因子 Δk＝L2-0/L2-1，如果刮板输送机匀速运行，有Δk＝1，因此，定义Δk为修正因子，消除测量时变转速对链轮轮齿磨损量测量的影响；计算LD-1＝Δk×kD×L1-1，则链轮轮齿磨损量ΔLD＝LD-0-LD-1；
    最后，设定链轮轮齿的磨损阈值J，当ΔLD＜J时，链轮轮齿磨损量未超限，可继续正常使用；当ΔLD≥J时，链轮轮齿磨损超限，输出磨损危险报警信号。
    。
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