WO2022188283A1 - 一种基于扭簧透光量测量的刮板链条监测系统及方法 - Google Patents

一种基于扭簧透光量测量的刮板链条监测系统及方法 Download PDF

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WO2022188283A1
WO2022188283A1 PCT/CN2021/100006 CN2021100006W WO2022188283A1 WO 2022188283 A1 WO2022188283 A1 WO 2022188283A1 CN 2021100006 W CN2021100006 W CN 2021100006W WO 2022188283 A1 WO2022188283 A1 WO 2022188283A1
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torsion spring
laser
light
measurement
panel
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PCT/CN2021/100006
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English (en)
French (fr)
Inventor
卢昊
蒋辉
朱真才
曹国华
彭玉兴
周公博
沈刚
江帆
汤裕
李翔
王威
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中国矿业大学
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Priority claimed from CN202110417482.0A external-priority patent/CN113233131B/zh
Application filed by 中国矿业大学 filed Critical 中国矿业大学
Priority to AU2021426705A priority Critical patent/AU2021426705B2/en
Priority to US17/802,188 priority patent/US11807465B2/en
Publication of WO2022188283A1 publication Critical patent/WO2022188283A1/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
    • B65G19/18—Details
    • B65G19/20—Traction chains, ropes, or cables

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  • the invention relates to the field of scraper conveyor chain monitoring, in particular to a scraper chain monitoring system and method based on the measurement of light transmittance of a torsion spring.
  • the scraper conveyor is a typical flexible traction transportation equipment, which plays the role of loading and transportation, supporting the shearer, and guiding the shearer during fully mechanized coal mining.
  • the scraper chain is the most fault-prone component in the operation of the scraper conveyor.
  • the scraper chain failure accounts for 63% of the total failure of the scraper conveyor, and 42% of the downtime of the scraper conveyor is caused by the breakage of the scraper chain. . Once the scraper conveyor fails, it will directly affect the production capacity of the coal mining face.
  • Chinese patent CN106829390A a scraper conveyor broken chain detection device and method, it uses the infrared photoresistors on both sides of the chute to compare and detect the passing time of the two ends of the same scraper, to judge whether the scraper is inclined and whether the chain is broken, This method is to detect the broken chain from the perspective of the working state of the scraper.
  • Chinese patent CN104229427B a method for detecting chain breakage of scraper conveyor, which uses a stress sensor installed on the contact surface of the sprocket chain to determine whether the chain is broken or not. This patent detects chain breakage from a mechanical point of view.
  • Chinese patent CN107777288A a real-time detection system and monitoring method for chain breakage of scraper conveyor, monitor the relative displacement of two scraper chains by means of strain gauges and node positioning installed on the chain ring, so as to judge whether chain breakage occurs, Due to the harsh working environment of the scraper conveyor, the strain gauge installed on the chain link of the load part may be affected. This method is to detect and monitor the position change of the scraper chain.
  • the purpose of the present invention is to provide a new scraper chain monitoring system and method based on the measurement of light transmittance of torsion springs, which makes up for the low precision and reliability of the current scraper conveyor chain monitoring system.
  • the present invention adopts the following technical solutions:
  • the invention provides a scraper chain monitoring system based on the measurement of light transmittance of a torsion spring, including a sprocket torsion detection device, a fixing device, a wireless receiver, an A/D converter and an industrial computer;
  • the sprocket torsion detection device includes A transmission shaft with a sprocket fixed at both ends, a torsion spring is nested in the middle of the transmission shaft, the two ends of the torsion spring are respectively fixedly connected to the end face of the sprocket on one side of the transmission shaft through a bracket, and the middle part of the outer surface of the transmission shaft is A laser induction panel is pasted, the laser induction panel is covered by the torsion spring and has a certain distance from it, the fixing device is provided with a laser illuminator, and the irradiation end of the laser illuminator is aligned with the sensing area of the laser induction panel,
  • the fixing device is also provided with a signal collector, a
  • both ends of the torsion spring are respectively connected with the end face of the sprocket on one side close to the transmission shaft by welding and fixing.
  • the welding points at both ends of the torsion spring are kept at a certain safety distance from the fixing device, so as to prevent the torsion spring from contacting and colliding with the fixing device under extreme deformation.
  • the type of the torsion spring is of a separate winding type, and there is a gap between the coils.
  • the torsion spring is in a relaxed state during installation, and the illumination area of the laser induction panel accounts for 50% of its total area.
  • the torsion spring is the same as the transmission shaft.
  • the shaft is mounted and kept a certain distance from the surface of the drive shaft.
  • the fixing device is a square box, and the wireless transmitter, the signal collector and the power supply unit are all integrated in the square box.
  • the laser illuminator is installed in the middle of the upper end face of the fixing device, and emits visible light laser to the sensing area of the laser sensing panel when the system is working.
  • the coil of the torsion spring can completely cover the laser induction panel when it is fully retracted or extended.
  • the present invention also provides a scraper chain monitoring method based on the measurement of the light transmittance of the torsion spring, which specifically includes the following steps:
  • the scraper conveyor operates normally, and the signal collector collects the current signal I of the laser sensing panel in real time and transmits the signal to the industrial computer;
  • the industrial computer compares the obtained current signal I with each threshold current.
  • I1 ⁇ I ⁇ I2 it is judged that the light receiving area S of the laser sensing panel is greater than or equal to 5% and less than or equal to 25%
  • I2 ⁇ I ⁇ I3 it is judged that the laser The light-receiving area S of the sensor panel is greater than 25% and less than or equal to 45%.
  • I3 ⁇ I ⁇ I4 the light-receiving area S of the laser-sensing panel is judged to be greater than 45% and less than or equal to 55%.
  • I4 ⁇ I ⁇ I5 the light-receiving area of the laser-sensing panel is judged. S is greater than 55% and less than or equal to 75%
  • I5 ⁇ I ⁇ I6 it is judged that the light-receiving area S of the laser sensor panel is greater than 75% and less than or equal to 95%;
  • the industrial computer calculates the S range through the current signal I obtained in real time, and according to the formula Calculate the variation range of M; when 5% ⁇ S ⁇ 25%, M1 ⁇ M ⁇ M2; when 25% ⁇ S ⁇ 45%, M2 ⁇ M ⁇ M3; when 45% ⁇ S ⁇ 55%, M3 ⁇ M ⁇ M4; when 55% ⁇ S ⁇ 75%, M4 ⁇ M ⁇ M5; when 75% ⁇ S ⁇ 95%, M5 ⁇ M ⁇ M6;
  • M is the torsion moment received by the torsion spring, and the positive and negative values of M indicate whether the direction of the torque is the same as that of the torsion spring;
  • E is the elastic modulus of the torsion spring material;
  • d is the diameter of the torsion spring coil;
  • c is the work of the torsion spring The axial length of the number of turns;
  • a is the width of the laser sensing panel;
  • b is the length of the laser sensing panel;
  • H is the unfolded length of the torsion spring;
  • n0 is the original number of turns of the torsion spring;
  • S is the light-receiving area of the laser sensing panel;
  • the beneficial effect of the present invention is that: the various components of the monitoring system used in the present invention are installed on the transmission shaft, the torsion spring is only fixed to the inner side of one end face of the sprocket close to the transmission shaft, and the expansion and contraction of the torsion spring can indirectly and accurately reflect the working state of the sprocket chain,
  • the state of the scraper conveyor chain can be monitored with the industrial computer.
  • This method converts the relative torsion of the two sprockets into the density change of the torsion spring.
  • the laser sensing panel converts the light transmission area into the current size.
  • the industrial computer passes the preset threshold value.
  • the torque variation range is calculated with its own program to monitor the working condition of the chain. Compared with the direct measurement of the relative torsion of the two sprockets, the device is easy to install and less difficult to maintain later. Its concept is novel, the system is stable and reliable, and it has high promotion value.
  • FIG. 1 is a schematic structural diagram of a scraper chain monitoring system and method based on torsion spring light transmittance measurement according to an embodiment of the present invention
  • FIG. 2 is a schematic structural diagram of a torsion spring and a bracket provided by an embodiment of the present invention
  • FIG. 3 is a schematic diagram of signal transmission between a signal collector, a wireless receiver, an A/D converter, and an industrial computer provided by an embodiment of the present invention
  • FIG. 4 is a flowchart of a monitoring system provided by an embodiment of the present invention.
  • a scraper chain monitoring system based on the measurement of the light transmittance of the torsion spring, includes a sprocket torsion detection device, a fixing device 7, a wireless receiver 8, an A/D converter 9 and an industrial computer 10;
  • the sprocket torsion detection device includes a transmission shaft 6 with a sprocket 5 fixed at both ends, a torsion spring 4 is nested in the middle of the transmission shaft 6, and the two ends of the torsion spring 4 pass through the bracket 11 and the sprocket respectively. 5.
  • the end face of one side close to the transmission shaft 6 is fixedly connected.
  • the middle part of the outer surface of the transmission shaft 6 is pasted with a laser sensing panel 3.
  • the laser sensing panel 3 is covered by the torsion spring 4 and has a certain distance from it.
  • the fixing device 7 A laser illuminator 1 is provided in the middle position of the top, and the irradiation end of the laser illuminator 1 is aligned with the sensing area of the laser induction panel 3.
  • the fixing device 7 is also provided with a signal collector, a wireless transmitter and a power supply unit.
  • the laser illuminator 1, the signal collector and the wireless transmitter are respectively electrically connected with the power supply unit, the signal collector is electrically connected with the wireless transmitter, and the laser induction panel 3 is connected to the signal collector in the fixing device 7 through the shielded wire 2
  • the wireless receiver 8 , the A/D converter 9 and the industrial computer 10 are electrically connected in sequence.
  • Both ends of the torsion spring 4 are respectively connected with the end face of the sprocket 5 near the transmission shaft 6 by welding and fixing.
  • the welding points at both ends of the torsion spring 4 maintain a certain safety distance from the fixing device to prevent the torsion spring 4 from contacting and colliding with the fixing device 7 under extreme deformation.
  • the four types of torsion springs belong to the separate and surrounding type, and there is a gap between the coils.
  • the torsion springs 4 are in a relaxed state during installation, and the illumination area of the laser induction panel 3 accounts for 50% of the total area.
  • the torsion springs 4 and the transmission shaft 6 are installed coaxially and keep a certain distance from the surface of the transmission shaft 6.
  • the fixing device 7 is a square box, and the wireless transmitter, the signal collector and the power supply unit are all integrated in the square box.
  • the coils of the torsion springs 4 can completely cover the laser induction panel 3 when they are fully contracted or extended.
  • the laser illuminator 1 is installed in the middle of the upper end face of the fixing device 7, and emits visible light laser to the sensing area of the laser sensing panel 3 when the system is working.
  • the laser illuminator 1 is installed on the top of the fixing device 7, and the coil of the torsion spring 4 is kept at a safe distance from the laser induction panel.
  • the torsion spring 4 is deformed by the relative rotation of the sprocket, which changes the density of the working coil.
  • the illuminator 1 irradiates the laser on the laser induction panel 3 at the bottom of the coil through the gap between the working coils of the torsion spring 4, and the laser induction panel 3 generates currents of different sizes, realizing the transformation of the torque change of the sprocket to the current change; the fixing device 7
  • the wireless transmitter in the device transmits the collected current signal to the wireless receiver 8, the wireless receiver 8 transmits the signal to the A/D converter 9, and the A/D converter 9 transmits the digital signal after sampling, quantization and encoding.
  • the industrial computer 10 compares the magnitude of the current signal with the preset current threshold, calculates the torque range of the sprocket, and determines whether the chain of the scraper conveyor is stuck or broken.
  • the embodiment of the present invention also provides a scraper chain monitoring method based on the measurement of the light transmittance of the torsion spring, which specifically includes the following steps:
  • the scraper conveyor operates normally, and the signal collector collects the current signal I of the laser sensing panel 3 in real time and transmits the signal to the industrial computer 10;
  • the industrial computer 10 compares the obtained current signal I with each threshold current, and judges that the light-receiving area S of the laser sensing panel 3 is greater than or equal to 5% and less than or equal to 25% when I1 ⁇ I ⁇ I2, and when I2 ⁇ I ⁇ I3 It is judged that the light-receiving area S of the laser sensor panel 3 is greater than 25% and less than or equal to 45%.
  • I3 ⁇ I ⁇ I4 it is judged that the light-receiving area S of the laser sensor panel 3 is greater than 45% and less than or equal to 55%.
  • I4 ⁇ I ⁇ I5 it is judged that the laser The light-receiving area S of the induction panel 3 is greater than 55% and less than or equal to 75%.
  • I5 ⁇ I ⁇ I6 it is determined that the light-receiving area S of the laser sensing panel 3 is greater than 75% and less than or equal to 95%;
  • the industrial computer 10 calculates the S range through the current signal I obtained in real time, and according to the formula Calculate the variation range of M; when 5% ⁇ S ⁇ 25%, M1 ⁇ M ⁇ M2; when 25% ⁇ S ⁇ 45%, M2 ⁇ M ⁇ M3; when 45% ⁇ S ⁇ 55%, M3 ⁇ M ⁇ M4; when 55% ⁇ S ⁇ 75%, M4 ⁇ M ⁇ M5; when 75% ⁇ S ⁇ 95%, M5 ⁇ M ⁇ M6;
  • M is the torsion moment received by the torsion spring, and the positive and negative values of M indicate whether the direction of the torque is the same as that of the torsion spring;
  • E is the elastic modulus of the torsion spring material;
  • d is the diameter of the torsion spring coil;
  • c is the work of the torsion spring The axial length of the number of turns;
  • a is the width of the laser sensor panel;
  • b is the length of the laser sensor panel;
  • H is the unfolded length of the torsion spring (excluding the brackets 11 at both ends);
  • n0 is the original number of turns of the torsion spring;
  • S is the light received by the laser sensor panel area;
  • the industrial computer 10 judges whether the chain of the scraper conveyor is broken or stuck according to the calculated S range:

Abstract

本发明公开了一种基于扭簧透光量测量的刮板链条监测系统及方法，本系统包括链轮扭转检测装置、固定装置、无线接收器、A/D转换器以及工业计算机；本方法将两个链轮的相对扭转转换成扭转弹簧的疏密变化，激光感应面板将透光面积转换成电流大小，工业计算机通过预设阈值和自身程序计算出扭矩变化范围，以此监测链条工作情况，其构思新颖，系统稳定可靠，具有较高的推广价值。

Description

一种基于扭簧透光量测量的刮板链条监测系统及方法 技术领域
本发明涉及刮板输送机链条监测领域，具体涉及一种基于扭簧透光量测量的刮板链条监测系统及方法。
背景技术
刮板输送机是一种典型的挠性牵引运输设备，在煤矿综采工作时起到了装载运输、支撑采煤机、为采煤机导向等作用。刮板链是刮板输送机运行中最容易发生故障的部件，刮板链故障占刮板输送机总故障的63％，刮板输送机42％的停机时间是由刮板链断裂所造成的。一旦刮板输送机发生故障则将直接影响采煤工作面的生产能力。
中国专利CN106829390A，一种刮板输送机断链检测装置及其方法，其通过溜槽两边的红外光敏电阻对比检测同一根刮板两端通过的时间，来判断刮板是否发生倾斜以及是否断链，此方法是从刮板工作状态角度检测断链。中国专利CN104229427B，一种刮板输送机断链检测方法，其通过安装在链轮链条接触面上的应力传感器来判断链条是否发生断链，该专利是从力学角度检测断链。
中国专利CN107777288A，一种刮板输送机断链实时检测系统及监测方法，通过安装在链环上的应变片和节点定位来监测两条刮板链相对偏移情况，从而判断是否发生断链，由于刮板输送机工作环境恶劣，作为安装在负载零件链环上的应变片可能受到影响，该方法是从刮板链位置变化角度对其进行检测和监测。
发明内容
针对上述基于不同角度的检测方法，本发明的目的是提供一种新的基于扭簧透光量测量的刮板链条监测系统及方法，其弥补了目前刮板输送机链条监测 系统精度低、可靠性低的缺点。
为解决上述技术问题，本发明采用如下技术方案：
本发明提供一种基于扭簧透光量测量的刮板链条监测系统，包括链轮扭转检测装置、固定装置、无线接收器、A/D转换器以及工业计算机；所述链轮扭转检测装置包括两端固定有链轮的传动轴，所述传动轴中部嵌套有扭转弹簧，所述扭转弹簧的两端分别通过支架与链轮靠近传动轴一侧端面固定连接，所述传动轴外表面中部黏贴有激光感应面板，所述激光感应面板被扭转弹簧覆盖并与其设有一定距离，所述固定装置上设有激光照明器，所述激光照明器的照射端对准激光感应面板感应区域，所述固定装置内还设有信号采集器、无线发射器以及供电单元，所述激光照明器、信号采集器、无线发射器分别与供电单元电性连接，信号采集器与无线发射器电性连接，所述激光感应面板通过屏蔽导线与固定装置内的信号采集器电性连接，所述无线接收器、A/D转换器以及工业计算机依次电性连接。
优选地，所述扭转弹簧的两端分别与链轮靠近传动轴一侧端面采用焊接固定的方式连接。
优选地，所述扭转弹簧两端的焊接点与固定装置保持一定的安全距离，防止扭转弹簧在极限形变下与固定装置发生接触碰撞。
优选地，所述扭转弹簧种类属于分开围绕式，其线圈之间留有间隙，安装时扭转弹簧处于松弛状态并且此时激光感应面板光照面积占其总面积的50％，扭转弹簧与传动轴同轴安装并与传动轴表面保持一定距离。
优选地，所述固定装置为方形盒，所述无线发射器、信号采集器、供电单元均集成在方形盒内。
优选地，所述激光照明器安装于固定装置上端面中部，在系统工作时向激光感应面板的感应区域发射可见光激光。
优选地，所述扭转弹簧的线圈在极限收缩、极限伸展时均能够完全覆盖激 光感应面板。
本发明还提供一种基于扭簧透光量测量的刮板链条监测方法，具体包括以下步骤：
S1、初始化工业计算机并设置阈值电流I1、I2、I3、I4、I5、I6，依次对应激光感应面板受光面积为5％、25％、45％、55％、75％、95％时所产生的不同电流值I；
S2、刮板输送机正常运作，信号采集器实时采集激光感应面板的电流信号I并将信号传输至工业计算机；
S3、工业计算机将得到的电流信号I与各阈值电流进行对比，当I1≤I≤I2时判断激光感应面板受光面积S大于等于5％且小于等于25％，当I2<I≤I3时判断激光感应面板受光面积S大于25％且小于等于45％，当I3<I≤I4时判断激光感应面板受光面积S大于45％且小于等于55％，当I4<I≤I5时判断激光感应面板受光面积S大于55％且小于等于75％，当I5<I≤I6时判断激光感应面板受光面积S大于75％且小于等于95％；
S4、工业计算机通过实时得到的电流信号I计算出S范围，根据公式
Figure PCTCN2021100006-appb-000001
计算出M变化范围；当5％≤S≤25％时，M1≤M≤M2；当25％<S≤45％时，M2<M≤M3；当45％<S≤55％时，M3<M≤M4；当55％<S≤75％时，M4<M≤M5；当75％<S≤95％时，M5<M≤M6；
式中，M为扭转弹簧受到的扭力矩，M值的正负表示扭矩方向是否与扭转弹簧旋向相同；E为扭转弹簧材料的弹性模量；d为扭转弹簧线圈直径；c为扭转弹簧工作圈数的轴向长度；a为激光感应面板宽度；b为激光感应面板长度；H为扭转弹簧展开长度；n0为扭转弹簧原始圈数；S为激光感应面板受光面积；
S5、工业计算机根据计算出的S范围判断刮板输送机链条是否断链或卡链：
当I1<I≤I2即M1<M≤M2或I5<I≤I6即M5<M≤M6时，则判定刮板输送机链条发生断链；
当I2<I≤I3即M2<M≤M3或I4<I≤I5即M4<M≤M5时，则判定刮板输送机 链条发生卡链；
当I3<I≤I4即M3<M≤M4时，则判定刮板输送机链条正常运行；
S6、重复步骤S2-S5，实时监测刮板输送机链条。
本发明的有益效果在于：本发明使用的监测系统各个部件安装在传动轴上，扭转弹簧只与链轮靠近传动轴一端面内侧固定，扭转弹簧伸缩量可间接准确反映链轮链条的工作状态，配合工业计算机便可监测刮板输送机链条状态，本方法将两个链轮的相对扭转转换成扭转弹簧的疏密变化，激光感应面板将透光面积转换成电流大小，工业计算机通过预设阈值和自身程序计算出扭矩变化范围，以此监测链条工作情况，相比较直接测量两链轮相对扭转量，该装置安装方便且后期维护难度低，其构思新颖，系统稳定可靠，具有较高的推广价值。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本发明实施例提供的一种基于扭簧透光量测量的刮板链条监测系统及方法的结构示意图；
图2为本发明实施例提供的扭转弹簧和支架的结构示意图；
图3为本发明实施例提供的信号采集器、无线接收器、A/D转换器以及工业计算机之间信号传递示意图；
图4为本发明实施例提供的监测系统流程图。
附图标记说明：
1、激光照明器，2、屏蔽导线，3、激光感应面板，4、扭转弹簧，5、链轮，6、传动轴，7、固定装置，8、无线接收器，9、A/D转换器，10、工业计算机，11、支架。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
如图1至图4所示，一种基于扭簧透光量测量的刮板链条监测系统，包括链轮扭转检测装置、固定装置7、无线接收器8、A/D转换器9以及工业计算机10；所述链轮扭转检测装置包括两端固定有链轮5的传动轴6，所述传动轴6中部嵌套有扭转弹簧4，所述扭转弹簧4的两端分别通过支架11与链轮5靠近传动轴6一侧端面固定连接，所述传动轴6外表面中部黏贴有激光感应面板3，所述激光感应面板3被扭转弹簧4覆盖并与其设有一定距离，所述固定装置7顶部中间位置设有激光照明器1，所述激光照明器1的照射端对准激光感应面板3感应区域，所述固定装置7内还设有信号采集器、无线发射器以及供电单元，所述激光照明器1、信号采集器、无线发射器分别与供电单元电性连接，信号采集器与无线发射器电性连接，所述激光感应面板3通过屏蔽导线2与固定装置7内的信号采集器电性连接，所述无线接收器8、A/D转换器9以及工业计算机10依次电性连接。
所述扭转弹簧4的两端分别与链轮5靠近传动轴6一侧端面采用焊接固定的方式连接。
所述扭转弹簧4两端的焊接点与固定装置保持一定的安全距离，防止扭转弹簧4在极限形变下与固定装置7发生接触碰撞。
所述扭转弹簧4种类属于分开围绕式，其线圈之间留有间隙，安装时扭转弹簧4处于松弛状态并且此时激光感应面板3光照面积占其总面积的50％，扭转弹簧4与传动轴6同轴安装并与传动轴6表面保持一定距离。
所述固定装置7为方形盒，所述无线发射器、信号采集器、供电单元均集成在方形盒内。
所述扭转弹簧4的线圈在极限收缩、极限伸展时均能够完全覆盖激光感应面板3。
所述激光照明器1安装于固定装置7上端面中部，在系统工作时向激光感应面板3的感应区域发射可见光激光。
工作原理：激光照明器1安装在固定装置7的顶部，扭转弹簧4线圈与激光感应面板保持安全距离，扭转弹簧4因链轮的相对转动而产生形变，改变了工作线圈的疏密程度，激光照明器1透过扭转弹簧4工作线圈的间隙将激光照射在线圈底部的激光感应面板3上，激光感应面板3产生不同大小的电流，实现了链轮扭矩变化向电流变化的转化；固定装置7中的无线发射器将采集到的电流信号传输给无线接收器8，无线接收器8将信号传输给A/D转换器9，A/D转换器9经过采样、量化、编码后将数字信号传输给工业计算机10；工业计算机10根据电流信号大小与预设的电流阈值比较，计算出链轮的扭矩范围，判断刮板输送机链条是否发生卡链、断链。
本发明实施例还提供一种基于扭簧透光量测量的刮板链条监测方法，具体包括以下步骤：
S1、初始化工业计算机10并设置阈值电流I1、I2、I3、I4、I5、I6，依次对应激光感应面板3受光面积为5％、25％、45％、55％、75％、95％时所产生的不同电流值I；
S2、刮板输送机正常运作，信号采集器实时采集激光感应面板3的电流信号I并将信号传输至工业计算机10；
S3、工业计算机10将得到的电流信号I与各阈值电流进行对比，当I1≤I≤I2时判断激光感应面板3受光面积S大于等于5％且小于等于25％，当I2<I≤I3时判断激光感应面板3受光面积S大于25％且小于等于45％，当I3<I≤I4时判断激光感应面板3受光面积S大于45％且小于等于55％，当I4<I≤I5时判断激光感应面板3受光面积S大于55％且小于等于75％，当I5<I≤I6时判断激光感应面板3受光面积S大于75％且小于等于95％；
S4、工业计算机10通过实时得到的电流信号I计算出S范围，根据公式
Figure PCTCN2021100006-appb-000002
计算出M变化范围；当5％≤S≤25％时，M1≤M≤M2；当25％<S≤45％时，M2<M≤M3；当45％<S≤55％时，M3<M≤M4；当55％<S≤75％时，M4<M≤M5；当75％<S≤95％时，M5<M≤M6；
式中，M为扭转弹簧受到的扭力矩，M值的正负表示扭矩方向是否与扭转弹簧旋向相同；E为扭转弹簧材料的弹性模量；d为扭转弹簧线圈直径；c为扭转弹簧工作圈数的轴向长度；a为激光感应面板宽度；b为激光感应面板长度；H为扭转弹簧展开长度(不包括两端支架11)；n0为扭转弹簧原始圈数；S为激光感应面板受光面积；
S5、工业计算机10根据计算出的S范围判断刮板输送机链条是否断链或卡链：
当I1<I≤I2即M1<M≤M2或I5<I≤I6即M5<M≤M6时，则判定刮板输送机链条发生断链；
当I2<I≤I3即M2<M≤M3或I4<I≤I5即M4<M≤M5时，则判定刮板输送机链条发生卡链；
当I3<I≤I4即M3<M≤M4时，则判定刮板输送机链条正常运行；
S6、重复步骤S2-S5，实时监测刮板输送机链条。
显然，本领域的技术人员可以对本发明进行各种改动和变型而不脱离本发明的精神和范围。这样，倘若本发明的这些修改和变型属于本发明权利要求及其等同技术的范围之内，则本发明也意图包含这些改动和变型在内。

Claims (8)

  1. 一种基于扭簧透光量测量的刮板链条监测系统，其特征在于，包括链轮扭转检测装置、固定装置(7)、无线接收器(8)、A/D转换器(9)以及工业计算机(10)；所述链轮扭转检测装置包括两端固定有链轮(5)的传动轴(6)，所述传动轴(6)中部嵌套有扭转弹簧(4)，所述扭转弹簧(4)的两端分别通过支架(11)与链轮(5)靠近传动轴(6)一侧端面固定连接，所述传动轴(6)外表面中部黏贴有激光感应面板(3)，所述激光感应面板(3)被扭转弹簧(4)覆盖并与其设有一定距离，所述固定装置(7)上设有激光照明器(1)，所述激光照明器(1)的照射端对准激光感应面板(3)感应区域，所述固定装置(7)内还设有信号采集器、无线发射器以及供电单元，所述激光照明器(1)、信号采集器、无线发射器分别与供电单元电性连接，信号采集器与无线发射器电性连接，所述激光感应面板(3)通过屏蔽导线(2)与固定装置(7)内的信号采集器电性连接，所述无线接收器(8)、A/D转换器(9)以及工业计算机(10)依次电性连接。
  2. 如权利要求1所述的一种基于扭簧透光量测量的刮板链条监测系统，其特征在于，所述扭转弹簧(4)的两端分别与链轮(5)靠近传动轴(6)一侧端面采用焊接固定的方式连接。
  3. 如权利要求2所述的一种基于扭簧透光量测量的刮板链条监测系统，其特征在于，所述扭转弹簧(4)两端的焊接点与固定装置(7)保持一定的安全距离，防止扭转弹簧(4)在极限形变下与固定装置(7)发生接触碰撞。
  4. 如权利要求1所述的一种基于扭簧透光量测量的刮板链条监测系统，其特征在于，所述扭转弹簧(4)种类属于分开围绕式并且其线圈之间留有间隙，安装时扭转弹簧(4)处于松弛状态并且此时激光感应面板(3)受光照面积占其总面积的50％，扭转弹簧(4)与传动轴(6)同轴安装并与传动轴(6)表面保持一定距离。
  5. 如权利要求1所述的一种基于扭簧透光量测量的刮板链条监测系统， 其特征在于，所述固定装置(7)为方形盒，所述无线发射器、信号采集器、供电单元均集成在方形盒内。
  6. 如权利要求1所述的一种基于扭簧透光量测量的刮板链条监测系统，其特征在于，所述扭转弹簧(4)的线圈在极限收缩、极限伸展时均能够完全覆盖激光感应面板(3)。
  7. 如权利要求1所述的一种基于扭簧透光量测量的刮板链条监测系统，其特征在于，所述激光照明器(1)安装于固定装置(7)上端面中部，在系统工作时向激光感应面板(3)感应区域发射可见光激光。
  8. 一种基于扭簧透光量测量的刮板链条监测方法，其特征在于，具体包括以下步骤：
    S1、初始化工业计算机(10)并设置阈值电流I1、I2、I3、I4、I5、I6，依次对应激光感应面板(3)受光面积为5％、25％、45％、55％、75％、95％时所产生的不同电流值I；
    S2、刮板输送机正常运作，信号采集器实时采集激光感应面板(3)的电流信号I并将信号传输至工业计算机(10)；
    S3、工业计算机(10)将得到的电流信号I与各阈值电流进行对比，当I1≤I≤I2时判断激光感应面板(3)受光面积S大于等于5％且小于等于25％，当I2<I≤I3时判断激光感应面板(3)受光面积S大于25％且小于等于45％，当I3<I≤I4时判断激光感应面板(3)受光面积S大于45％且小于等于55％，当I4<I≤I5时判断激光感应面板(3)受光面积S大于55％且小于等于75％，当I5<I≤I6时判断激光感应面板(3)受光面积S大于75％且小于等于95％；
    S4、工业计算机(10)通过实时得到的电流信号I计算出S范围，根据公式
    Figure PCTCN2021100006-appb-100001
    计算出M变化范围；当5％≤S≤25％时，M1≤M≤M2；当25％<S≤45％时，M2<M≤M3；当45％<S≤55％时，M3<M≤M4；当55％<S≤75％时，M4<M≤M5；当75％<S≤95％时，M5<M≤M6；
    式中，M为扭转弹簧受到的扭力矩，M值的正负表示扭矩方向是否与扭转 弹簧旋向相同；E为扭转弹簧材料的弹性模量；d为扭转弹簧线圈直径；c为扭转弹簧工作圈数的轴向长度；a为激光感应面板宽度；b为激光感应面板长度；H为扭转弹簧展开长度；n0为扭转弹簧原始圈数；S为激光感应面板受光面积；
    S5、工业计算机10根据计算出的S范围判断刮板输送机链条是否断链或卡链：
    当I1<I≤I2即M1<M≤M2或I5<I≤I6即M5<M≤M6时，则判定刮板输送机链条发生断链；
    当I2<I≤I3即M2<M≤M3或I4<I≤I5即M4<M≤M5时，则判定刮板输送机链条发生卡链；
    当I3<I≤I4即M3<M≤M4时，则判定刮板输送机链条正常运行；
    S6、重复步骤S2-S5，实时监测刮板输送机链条。
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CN212149136U (zh) * 2020-04-07 2020-12-15 上海钧正网络科技有限公司 非接触感应式链条检测装置及链条驱动装置

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