A system and method for online detection of lubrication of a horizontal axis cutting reducer

Abstract

The present invention belongs to the technical field of coal mine underground speed reducer maintenance equipment, and specifically is a horizontal axis cutting speed reducer lubrication online detection system and method, including a horizontal axis cutting speed reducer driven by a cutting motor, the lubricating oil outlet of the horizontal axis cutting speed reducer is connected to a lubrication pump, the lubrication pump is connected in sequence to a lubrication online detection device, a filter, a water cooler, and a lubrication distributor, the lubrication distributor is connected to each lubrication point of the horizontal axis cutting speed reducer via a pipeline and an oil pipe, the cutting motor and the lubrication online detection device are connected to a flameproof and intrinsically safe electrical control box, and the flameproof and intrinsically safe electrical control box is connected to an intrinsically safe sound and light alarm. The present invention utilizes the characteristic that the dielectric constant of the oil sensor in air and oil is different, and the oil sensor is placed at a high point in the system, so that the oil shortage state of the lubrication and cooling system can be detected and a timely warning can be issued.

Description

Technical Field

[0001] The invention belongs to the technical field of coal mine underground speed reducer maintenance equipment, and in particular relates to a transverse axis cutting speed reducer lubrication online detection system and method. Background Art

[0002] Full-rock tunneling has become a difficult task for both coal mines and non-coal mines. Currently, the most widely used and well-reputed machine is the cantilever horizontal axis roadheader. This machine uses a horizontal axis cutting section, which has better cutting stability. Compared with the longitudinal axis roadheader of the same power, the cutting tooth loss is low and the cutting efficiency can be increased by more than 1 times. The horizontal axis reducer has special working conditions. It is small in size but has a large power transmission and deceleration ratio. The closed self-cooling method cannot meet the thermal balance requirements, so a circulating forced cooling and lubrication system is used to meet the thermal balance. In actual use, the reducer often fails to heat up and is damaged. After analysis, it is determined that it is caused by untimely maintenance. Therefore, avoiding reducer failures caused by human factors has become an urgent problem to be solved. Summary of the Invention

[0003] In order to solve the problem of untimely lubrication and maintenance of a transverse-axis cutting reducer, the present invention provides an online lubrication detection system and method for a transverse-axis cutting reducer.

[0004] The present invention adopts the following technical solution: a transverse axis cutting reducer lubrication online detection system, including a transverse axis cutting reducer driven by a cutting motor, the lubricating oil outlet of the transverse axis cutting reducer is connected to the lubrication pump, the lubrication pump is connected to the lubrication online detection device, the filter, the water cooler and the lubrication distributor in sequence, the lubrication distributor is connected to the lubrication points of the transverse axis cutting reducer through pipelines and oil pipes, the cutting motor and the lubrication online detection device are connected to the explosion-proof and intrinsically safe electrical control box, and the explosion-proof and intrinsically safe electrical control box is connected to the intrinsically safe sound and light alarm.

[0005] Furthermore, the lubrication online detection device includes an explosion-proof temperature transmitter, an intrinsically safe oil quality sensor and a detection valve block. The detection valve block includes a lubricating oil interface, mounting hole I and mounting hole II, wherein the lubricating oil interface passes through the front and back of the detection valve block, mounting hole I and mounting hole II are located on the upper surface of the detection valve block, and are both connected to the lubricating oil interface. The explosion-proof temperature transmitter is installed on the front of the upper surface of the detection valve block through mounting hole I, and the intrinsically safe oil quality sensor is installed on the rear of the upper surface of the detection valve block through the mounting hole.

[0006] Furthermore, a lubrication pump is installed inside the transverse axis cutting reducer, and the power is provided by the transverse axis cutting reducer to extract the lubricating oil for circulation cooling.

[0007] Furthermore, a lubrication distributor is installed on the top of the transverse axis cutting reducer 2 to evenly distribute the lubricating oil.

[0008] A detection method for a transverse axis cutting reducer lubrication online detection system comprises the following steps:

[0009] S100: Establish an oil product database based on the relationship between the three key indicators of lubricating oil particle contamination, emulsification, and acidification and the dielectric constant, and build a data analysis and logical judgment module.

[0010] S200: The explosion-proof temperature transmitter and intrinsically safe oil quality sensor respectively detect the real-time data of the lubricating oil and store the data through the data analysis module.

[0011] S300: When the temperature reaches the trigger condition, the cutting motor stops and the voice warning system is triggered in combination with the oil quality status.

[0012] S400: When the temperature does not reach the trigger condition but the oil quality reaches the trigger condition, the cutting motor operates normally and the voice warning system is triggered in combination with the oil quality status.

[0013] The warning information issued by the voice warning system in S300 includes:

[0014] S301: If the oil quality value is normal, a voice warning of "high temperature and water shortage" will be issued;

[0015] S302: When the oil quality value reaches oil quality trigger condition 1, a voice warning "high temperature and oil shortage" is issued;

[0016] S303: When the oil quality value reaches oil quality trigger condition 2, a voice warning of "high temperature pollution" is issued;

[0017] S304: When the oil quality value reaches oil quality trigger condition 3, a voice warning "high temperature oil change" is issued.

[0018] The warning information issued by the voice warning system in S400 includes:

[0019] S401: When the oil quality value reaches oil quality trigger condition 1, a voice warning "oil shortage" is issued;

[0020] S402: When the oil quality value reaches oil quality trigger condition 2, a voice warning "pollution" is issued;

[0021] S403: When the oil quality value reaches oil quality trigger condition 3, a voice warning "change oil" is issued.

[0022] Condition 1: The detection value of the intrinsically safe oil quality sensor is lower than 2 and lasts for 3 minutes; Condition 2: The detection value of the intrinsically safe oil quality sensor reaches 2.45 and lasts for 3 minutes; Condition 3: The detection value of the intrinsically safe oil quality sensor reaches 2.6 and lasts for 3 minutes.

[0023] Compared to existing technologies, this invention addresses the problem of damage to tunnel boring machine transverse-axis cutting reducers due to insufficient cooling and lubrication, providing an online lubrication detection system and method for transverse-axis cutting reducers. By establishing a database correlating lubricating oil particle contamination, emulsification, and acidification with dielectric constants, and using temperature and oil quality sensors to detect data in real time, this database is combined with an online oil detection and early warning system to provide timely warnings, maintenance, and oil change prompts, thereby preventing human factors that can lead to reducer failures due to untimely maintenance. The application of this system and method will significantly improve the reliability of tunnel boring equipment components and provide valuable insights into the reliability design of equipment operating in similar conditions.

[0024] The system and method of the present invention are based on a forced cooling and lubrication system of a transverse axis reducer, and the detection instrument is placed behind the cutting part to avoid damage to the detection equipment caused by harsh working conditions, thereby having high reliability.

[0025] The present invention simplifies online detection items by establishing a database that associates three indicators of lubricating oil particle contamination, emulsification, and acidification with the dielectric constant. It uses temperature and oil quality sensors to detect data in real time, and combines the database to complete the oil online detection and early warning system, thereby avoiding human factors such as untimely maintenance that lead to reducer failure.

[0026] The present invention utilizes the different dielectric constants of the oil sensor in air and in oil, and places the oil sensor at a high point in the system to detect the oil shortage state of the lubrication and cooling system and provide timely warning. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 Structural block diagram of the online detection system for lubrication of the horizontal axis cutting reducer;

[0028] Figure 2 Workflow diagram of the online detection system for lubrication of the horizontal axis cutting reducer;

[0029] Figure 3 Structural diagram of lubrication online detection device;

[0030] Figure 4 Main view of the lubrication online detection device;

[0031] Figure 5 Left view of the lubrication online detection device;

[0032] Figure 6 Top view of the lubrication online detection device;

[0033] Figure 7 Detection valve block structure diagram;

[0034] Figure 8 Database logical relationship diagram

[0035] As shown in the figure, 1 cutting motor; 2 horizontal axis cutting reducer; 3 lubrication pump; 4 lubrication distributor; 5 water cooler; 6 filter; 7 lubrication online detection device; 8 intrinsically safe sound and light alarm; 9 flameproof and intrinsically safe electrical control box; 10 flameproof temperature transmitter; 11 intrinsically safe oil quality sensor; 12 detection valve block; 13 lubricating oil interface; 14 mounting hole I; 15 mounting hole II. DETAILED DESCRIPTION

[0036] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are part of the embodiments of the present invention, not all the embodiments; based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0037] like Figure 1 As shown, a transverse axis cutting reducer lubrication online detection system includes a transverse axis cutting reducer 2 driven by a cutting motor 1, the lubricating oil outlet of the transverse axis cutting reducer 2 is connected to the lubrication pump 3, the lubrication pump 3 is connected to the lubrication online detection device 7, the filter 6, the water cooler 5 and the lubrication distributor 4 in sequence, the lubrication distributor 4 is connected to the lubrication points of the transverse axis cutting reducer 2 through pipelines and oil pipes, the cutting motor 1 and the lubrication online detection device 7 are connected to the explosion-proof and intrinsically safe electrical control box 9, and the explosion-proof and intrinsically safe electrical control box 9 is connected to the intrinsically safe sound and light alarm 8.

[0038] like Figure 3-7 As shown, the lubrication online detection device 7 includes a flameproof temperature transmitter 10, an intrinsically safe oil quality sensor 11 and a detection valve block 12. The detection valve block 12 includes a lubricating oil interface 13, a mounting hole I 14 and a mounting hole II 15, wherein the lubricating oil interface 13 passes through the front and back of the detection valve block, the mounting hole I 14 and the mounting hole II 15 are located on the upper surface of the detection valve block and are both connected to the lubricating oil interface 13, the flameproof temperature transmitter 10 is installed on the front part of the upper surface of the detection valve block 12 through the mounting hole I 14, and the intrinsically safe oil quality sensor 11 is installed on the rear part of the upper surface of the detection valve block 12 through the mounting hole.

[0039] The cutting motor is a special motor for the cutting part of the tunnel boring machine, and its output end is connected to the horizontal axis cutting reducer and provides power.

[0040] The shape and strength of the horizontal axis cutting reducer are designed according to the cutting power of the whole machine, and a circulating forced cooling and lubrication system is adopted to meet the thermal balance.

[0041] The lubrication pump is installed inside the horizontal axis cutting reducer, and the power is provided by the horizontal axis cutting reducer to extract the lubricating oil for circulation cooling.

[0042] The distributor is installed on the top of the horizontal axis cutting reducer, connected to the lubrication points of the reducer through oil pipes, and evenly distributes the lubricating oil.

[0043] The water cooler is a plate-fin cooler, which performs cooling through large-area heat exchange between lubricating oil and cooling water.

[0044] The filter is a special filter for lubricating oil, which mainly plays the role of filtering pollutants generated by the lubricating oil system and those contaminated from the outside.

[0045] The lubrication online detection device consists of a flameproof temperature transmitter, an intrinsically safe oil quality sensor and a detection valve block. The flameproof temperature transmitter is installed on the front of the upper surface of the detection valve block through the mounting hole I, and the intrinsically safe oil quality sensor is installed on the rear of the upper surface of the detection valve block through the mounting hole.

[0046] The intrinsically safe sound and light alarm is an early warning device for the system, and mainly plays the role of a voice early warning prompt.

[0047] The flameproof and intrinsically safe electrical control box is a conventional component of a roadheader and mainly plays the role of electrical system logic control.

[0048] The flameproof temperature transmitter is a commonly used component in coal mines. Due to the particularity of the detection working conditions, an ultra-short temperature measuring rod design is adopted to meet space requirements.

[0049] The intrinsically safe oil quality sensor can monitor a range of oil qualities and conditions, detecting changes in comprehensive physical and chemical indicators caused by factors such as water ingress, acidification, oxidation, additive failure, and wear particles. It is suitable for use in underground coal mines, where explosive environments such as gas and coal dust are present, and provides a basis for monitoring the operating status of coal mine equipment and analyzing fault causes.

[0050] The detection valve block is the base of the lubrication online detection device, including a lubricating oil interface, mounting hole I, and mounting hole II. The lubricating oil interface runs through the detection valve block from front to back, and mounting holes I and II are located on the upper surface of the detection valve block and are both connected to the lubricating oil interface.

[0051] The operating principle and process of this invention involves establishing an oil quality database based on the relationship between three key indicators of lubricating oil—particulate contamination, emulsification, and acidification—and the dielectric constant. Trigger conditions are set based on this database, and a data analysis and logic judgment module is constructed. A temperature transmitter and an oil quality sensor respectively detect real-time oil data. This data is stored in the data module, analyzed, and logically judged, ultimately generating multiple instruction combinations to execute the corresponding commands. To avoid misjudgments caused by fluctuations in the detection data, an average value over a period of time is used as the conditional trigger comparison data.

[0052] During operation, the cutting motor starts, and the lubrication pump rotates along with the reducer. Lubricating oil is then drawn from the reducer and sequentially passes through the online lubrication monitoring device, filter, and water cooler. The oil is then evenly distributed to the various lubrication points of the reducer by a distributor, ultimately converging into the reducer's oil reservoir. The online lubrication monitoring device is located at the lubrication pump outlet, collecting data that more closely reflects the reducer's internal conditions. If the detection data does not meet the trigger conditions, only the data is stored.

[0053] like Figure 2 As shown, a detection method for a transverse axis cutting reducer lubrication online detection system includes the following steps.

[0054] S100: Through a large number of oil sample testing and comparison experiments, an oil database was established based on the relationship between the three key indicators of lubricating oil particle contamination, emulsification, and acidification and the dielectric constant (see Figure 8 ), set trigger conditions based on the oil product database and the correspondence between fault phenomena and data in practice, and build a data analysis and logic judgment module.

[0055] S200: The flameproof temperature transmitter 10 and the intrinsically safe oil quality sensor 11 respectively detect real-time data of the lubricating oil and store the data through the data analysis module.

[0056] S300: When the temperature reaches the trigger condition, the cutting motor 1 stops and, combined with the oil quality status, triggers the voice warning system. The warning messages issued by the voice warning system in S300 include: S301: If the oil quality value is normal, a voice warning of "high temperature and water shortage" is issued; S302: If the oil quality value reaches oil quality trigger condition 1, a voice warning of "high temperature and oil shortage" is issued; S303: If the oil quality value reaches oil quality trigger condition 2, a voice warning of "high temperature contamination" is issued; S304: If the oil quality value reaches oil quality trigger condition 3, a voice warning of "high temperature oil change" is issued.

[0057] S400: When the temperature does not reach the trigger condition but the oil quality does, the cutting motor operates normally, and the voice warning system is triggered in conjunction with the oil quality status. The voice warning system in S400 issues warning messages such as: S401: When the oil quality value reaches oil quality trigger condition 1, a voice warning of "oil shortage" is issued; S402: When the oil quality value reaches oil quality trigger condition 2, a voice warning of "contamination" is issued; and S403: When the oil quality value reaches oil quality trigger condition 3, a voice warning of "oil change" is issued.

[0058] Oil quality trigger condition 1 is: at this time, the detection value of the intrinsically safe oil quality sensor is lower than 2 and lasts for 3 minutes. According to practical experience, it can be judged that the lubricating oil is lacking and the lubrication pump sucks in air, causing the lubricating oil to mix with air during the circulation process.

[0059] Oil quality trigger condition 2 is: at this time, the detection value of the intrinsically safe oil quality sensor reaches 2.45 and the duration reaches 3 minutes. Figure 8 It can be seen that the value has risen from 2.2 to the minimum limit of the three oil deterioration conditions of lubricating oil particle contamination, emulsification or acidification, indicating that the oil has a tendency to deteriorate and should be paid attention to and repaired in time.

[0060] Oil quality trigger condition 3 is: at this time, the detection value of the intrinsically safe oil quality sensor reaches 2.6 and the duration reaches 3 minutes. Figure 8 It can be seen that the value has risen from 2.2 to the upper limit of the three oil deterioration conditions of lubricating oil particle contamination, emulsification or acidification, indicating that the oil has deteriorated and should be replaced in time.

[0061] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A detection method for an online detection system for lubrication of a horizontal axis cutting reducer, characterized by: The system includes a transverse axis cutting reducer (2) driven by a cutting motor (1), a lubricating oil outlet of the transverse axis cutting reducer (2) is connected to a lubricating pump (3), the lubricating pump (3) is connected in sequence to a lubricating online detection device (7), a filter (6), a water cooler (5) and a lubricating distributor (4), the lubricating distributor (4) is connected to each lubricating point of the transverse axis cutting reducer (2) through an oil pipe, the cutting motor (1) and the lubricating online detection device (7) are connected to a flameproof and intrinsically safe electrical control box (9), and the flameproof and intrinsically safe electrical control box (9) is connected to an intrinsically safe sound and light alarm (8); The lubrication online detection device (7) includes a flameproof temperature transmitter (10), an intrinsically safe oil quality sensor (11) and a detection valve block (12), wherein the detection valve block (12) includes a lubricating oil interface (13), a mounting hole I (14) and a mounting hole II (15), wherein the lubricating oil interface (13) passes through the front and back of the detection valve block, the mounting hole I (14) and the mounting hole II (15) are located on the upper surface of the detection valve block and are both connected to the lubricating oil interface (13), the flameproof temperature transmitter (10) is installed on the front of the upper surface of the detection valve block (12) through the mounting hole I (14), and the intrinsically safe oil quality sensor (11) is installed on the rear of the upper surface of the detection valve block (12) through the mounting hole; The detection method comprises the following steps: S100: Establishes an oil product database based on the relationship between the three key indicators of lubricating oil particle contamination, emulsification, and acidification and the dielectric constant. It then sets trigger conditions based on the oil product database and builds a data analysis and logic judgment module. S200: The flameproof temperature transmitter (10) and the intrinsically safe oil quality sensor (11) respectively detect the real-time data of the lubricating oil and store the data through the data analysis module; S300: When the temperature reaches the trigger condition, the cutting motor (1) stops and the voice warning system is triggered in combination with the oil quality status; S400: When the temperature does not reach the trigger condition but the oil quality reaches the trigger condition, the cutting motor operates normally and the voice warning system is triggered in combination with the oil quality status.

2. The detection method of the online detection system for lubrication of a horizontal axis cutting reducer according to claim 1, characterized in that: The lubrication pump (3) is installed inside the transverse axis cutting reducer, and the power is provided by the transverse axis cutting reducer to extract the lubricating oil for circulation cooling.

3. The detection method of the online detection system for lubrication of a horizontal axis cutting reducer according to claim 1, characterized in that: The lubrication distributor (4) is installed on the top of the transverse axis cutting reducer (2) to evenly distribute the lubricating oil.

4. The detection method of the online detection system for lubrication of a horizontal axis cutting reducer according to claim 1, characterized in that: The warning information issued by the voice warning system in S300 includes: S301: If the oil quality value is normal, a voice warning "high temperature and water shortage" will be issued; S302: When the oil quality value reaches oil quality trigger condition 1, a voice warning "high temperature and oil shortage" is issued; S303: When the oil quality value reaches oil quality trigger condition 2, a voice warning "high temperature pollution" is issued; S304: When the oil quality value reaches oil quality trigger condition 3, a voice warning "high temperature oil change" is issued.

5. The detection method of the online detection system for lubrication of a horizontal axis cutting reducer according to claim 1, characterized in that: The warning information issued by the voice warning system in S400 includes: S401: When the oil quality value reaches oil quality trigger condition 1, a voice warning "oil shortage" is issued; S402: When the oil quality value reaches oil quality trigger condition 2, a voice warning "pollution" is issued; S403: When the oil quality value reaches oil quality trigger condition 3, a voice warning "change oil" is issued.

6. The detection method of the online detection system for lubrication of a horizontal axis cutting reducer according to claim 4 or 5, characterized in that: Oil quality trigger condition 1 is: the detection value of the intrinsically safe oil quality sensor (11) is lower than 2 and the duration reaches 3 minutes; Oil quality trigger condition 2 is: the detection value of the intrinsically safe oil quality sensor (11) reaches 2.45 and the duration reaches 3 minutes; Oil quality trigger condition 3 is: the detection value of the intrinsically safe oil quality sensor (11) reaches 2.6 and the duration reaches 3 minutes.

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