An embedded anti-overload test sensing system for tracked travel structures

Abstract

The present invention belongs to the technical field of monitoring track structures of coal mining machinery, and solves the problem of difficulty in collecting stress data of the steel track plate under test in the track structure. An embedded anti-overload test sensor system for a track structure is provided, comprising a tested combined track plate, a stress acquisition device, and a host computer. At least one tested combined track plate is installed on the track ring of the track structure, and the tested combined track plates on the two track rings are symmetrical relative to the track structure. The stress acquisition device comprises a strain bridge, an acquisition and transmission module, and a power supply module, wherein the strain bridge is bonded to the tested chain track section of the tested combined track plate, the acquisition and transmission module and the power supply module are built into the tested combined track plate, the acquisition and transmission module wirelessly uploads the collected stress data to the host computer, and the power supply module is used to power the strain bridge and the acquisition and transmission module. The system realizes the measurement and wireless transmission of real-time stress data at the tested chain track section of the track.

Description

Technical Field

[0001] The invention belongs to the technical field of monitoring crawler travel structures of coal mining machinery, and in particular relates to an embedded anti-overload test sensor system for crawler travel structures. Background Art

[0002] During the coal mining process, the mechanical crawler travel structure plays an important role in bearing the weight of the entire machine and ensuring the stable operation of the equipment. Failure of the crawler structure means that the entire machine cannot continue to work. The failure of the crawler structure is mostly related to fatigue wear and fracture of the crawler chain track segments due to large dynamic loads. Therefore, it is very necessary to use the sensing system to collect real-time stress data of the crawler chain track segments and timely grasp the dynamic load change status of the crawler travel structure in order to perform real-time health monitoring of the crawler travel structure.

[0003] Considering that the underground crawler traveling structure is located in the complex terrain of coal and rock bottom, strong vibration, high impact, collision, low frequency and large amplitude, high humidity, signal transmission harmonic interference and limited working space, it is difficult to directly use sensors to collect stress.

[0004] Most existing embedded track patents involve structural modifications to steel track shoes, integrating both strain gauges and sensing systems. However, this approach places stringent requirements on track shoe thickness and is unsuitable for a wide range of track shoe sizes. Furthermore, excessive grooving within a steel track shoe can severely damage the structure, impacting its lifespan. Furthermore, due to the high stiffness and strength of steel track shoes, deformation during driving is minimal, making it difficult to directly use track shoe strain inversion to determine dynamic load changes on the track structure.

[0005] How to design an embedded overload test sensor system with an ingenious structure, high reliability and the ability to accurately collect and transmit real-time stress data at the track chain links under harsh working conditions underground without damaging the steel track shoe structure is a problem that needs to be solved at present. Summary of the Invention

[0006] In view of the deficiency that stress data of steel track plates in crawler travel structures is difficult to collect, the purpose of the present invention is to provide an embedded anti-overload test sensing system for crawler travel structures, in which a strain bridge is bonded to the tested link of the track ring to test the tension between the chain plates, and an acquisition and transmission module and a power supply module are built into the tested combined track plate to realize the measurement and wireless transmission of real-time stress data at the tested link of the track.

[0007] To achieve the above-mentioned purpose, the present invention adopts the following technical scheme: an embedded anti-overload test sensor system for a crawler traveling structure, comprising a tested combined track shoe, a stress acquisition device and a host computer, wherein at least one tested combined track shoe is installed on the track ring of the crawler traveling structure, and the tested combined track shoes on the two track rings are symmetrical relative to the crawler traveling structure; the tested combined track shoe comprises a tested steel track shoe, a clamping plate and a base arranged in sequence along the direction away from the track ring, and the tested chain track segment is fixed at one end of the tested steel track shoe away from the clamping plate; the stress acquisition device comprises a strain bridge, an acquisition and transmission module and a power supply module, wherein the strain bridge is bonded to the tested chain track segment at the tested combined track shoe, the acquisition and transmission module and the power supply module are built into the tested combined track shoe, the acquisition and transmission module uploads the collected stress data to the host computer, and the power supply module is used to power the strain bridge and the acquisition and transmission module.

[0008] Preferably, the steel track shoe and the splint to be tested are provided with cable channels, the acquisition and transmission module and the power supply module are built into the base, a shock-absorbing rubber block is provided at the end of the base away from the splint, the shock-absorbing rubber block, the base, the splint and the steel track shoe to be tested are connected in sequence by bolts, and the two ends of the splint are respectively tightly fitted with the base and the steel track shoe to be tested.

[0009] Preferably, the substrate is a metal substrate, wherein an installation groove for a built-in acquisition and transmission module and a power supply module is provided at one end of the metal substrate close to the splint, and electromagnetic wave transmission holes are provided on both sides of the metal substrate corresponding to the positions of the acquisition and transmission modules, and the electromagnetic wave transmission holes are sealed by insulating polyurethane side panels; an annular groove is provided at one end of the splint close to the steel track shoe to be measured corresponding to the position of the acquisition and transmission module, and a splint through hole for passing the cable connecting the strain bridge and the acquisition and transmission module is provided in the middle of the annular groove, and an O-ring is installed in the annular groove for achieving waterproof and dustproof sealing of the acquisition and transmission module and the power supply module; the metal strain gauge in the strain bridge is bonded to the chain track section to be measured.

[0010] Preferably, a plurality of heat dissipation holes are provided on both sides of the metal substrate at positions corresponding to the power modules, and the heat dissipation holes are blocked by silicone plugs and sealed by epoxy glue.

[0011] Preferably, the insulating polyurethane side panels and the metal base are connected by mechanical screws, and the contact parts are sealed by sealant.

[0012] Preferably, the matrix is ​​a polyformaldehyde matrix, and the acquisition and transmission module includes an amplification and detection module with the functions of simultaneously acquiring three-way stress data and realizing amplification, low-pass filtering and A / D conversion of the three-way weak signals, and a WiFi integrated module that can upload the three-way stress data to a host computer, wherein the polyformaldehyde matrix is ​​provided with a accommodating groove for the built-in amplification and detection module, the WiFi integrated module and the power module at one end close to the splint; the splint is provided with a splint through-hole for passing the cable connecting the strain bridge and the acquisition and transmission module, and a double-sided protective coil is installed in the splint through-hole for sealing protection of the cable in the through-hole; the strain rosette in the strain bridge is bonded to the chain track section to be measured.

[0013] Preferably, a rectangular shallow groove is provided on the outer periphery of the accommodating groove, and a sealing strip for sealing is installed in the rectangular shallow groove.

[0014] Preferably, the interior of the polyformaldehyde matrix and the gaps between the modules are sealed and fixed by epoxy resin glue.

[0015] Compared with the prior art, the present invention has the following beneficial effects:

[0016] 1. This system bonds a strain bridge to the track link under test to test the tension between the chain plates. The acquisition and transmission module and power supply module are built into the tested modular track plate to measure and wirelessly transmit real-time stress data at the track link under test.

[0017] 2. Through the embedded anti-overload test sensor system, long-term monitoring of the dynamic stress changes of the track shoes is achieved, which mainly solves the problem of difficulty in collecting stress data of the steel track shoes in the crawler travel structure.

[0018] 3. This system provides multi-layer sealing composite protection and multi-level buffering packaging protection for the tested modular track shoe, enabling it to cope with extreme working conditions such as complex coal and rock bottom terrain, strong vibration, high impact, collision, low-frequency large amplitude, high humidity, signal transmission harmonic interference, and limited working space. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0020] Figure 1 It is a working principle diagram of the present invention;

[0021] Figure 2 is a schematic diagram of an explosion at the tested combined track shoe of Example 1;

[0022] Figure 3 is a schematic diagram of the assembly structure of the tested combined track shoe of Example 1;

[0023] Figure 4 Schematic diagram of the installation position of the metal strain gauge in Example 1;

[0024] Figure 5 Schematic diagram of the structure of the metal base and the clamping plate of Example 1;

[0025] Figure 6 is a schematic diagram of an explosion at the tested combined track shoe of Example 2;

[0026] Figure 7 Schematic diagram of the installation position of the strain gauge rosette of Example 2.

[0027] In the figure: 1- host computer; 2- steel track shoe under test; 3- track link under test; 4- clamping plate; 4.1- annular groove; 4.2- clamping plate through hole; 5- metal substrate; 5.1- mounting slot; 5.2- electromagnetic wave transmission hole; 5.3- heat dissipation hole; 6- acquisition and transmission module; 6.1- amplification and detection module; 6.2- WiFi integrated module; 7- power module; 8- insulating polyurethane side panel; 9- shock-absorbing rubber block; 10- O-ring; 11- metal strain gauge; 12- silicone plug; 13- machine screw; 14- polyoxymethylene substrate; 14.1- accommodation groove; 14.2- rectangular shallow groove; 15- double-sided protective coil; 16- strain rosette; 17- sealing strip. DETAILED DESCRIPTION

[0028] The technical solutions in the embodiments of the present invention are clearly and completely described in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. All other implementations derived by ordinary technicians in this field based on the embodiments of the present invention without creative work are within the scope of protection of the present invention.

[0029] It should be noted that the structures, proportions, sizes, etc. illustrated in the drawings in this specification are only used to match the contents disclosed in the specification for people familiar with this technology to understand and read, and are not used to limit the conditions under which the present invention can be implemented. Therefore, they have no substantive technical significance. Any structural modification, change in proportional relationship or adjustment of size should still fall within the scope of the technical content disclosed in the present invention without affecting the efficacy and purpose that can be achieved by the present invention. It should be noted that in this specification, relational terms such as first and second are only used to distinguish one entity from other entities, and do not necessarily require or imply any actual relationship or order between these entities.

[0030] Example 1:

[0031] like Figure 1 As shown, an embedded anti-overload test sensing system for a crawler traveling structure includes a tested combined track shoe, a stress acquisition device and a host computer 1. At least one tested combined track shoe is installed on the track ring of the crawler traveling structure, and the tested combined track shoes on the two track rings are symmetrical relative to the crawler traveling structure; the host computer 1 includes a receiving antenna and a computer, wherein the receiving antenna is used to receive stress data transmitted from the stress acquisition device, and the computer is responsible for storing and processing the collected stress data; the stress acquisition device includes a strain bridge, an acquisition and transmission module 6 and a power supply module 7, wherein the strain bridge is bonded to the tested chain track segment 3 at the tested combined track shoe, the acquisition and transmission module 6 and the power supply module 7 are built into the tested combined track shoe, the acquisition and transmission module 6 wirelessly uploads the collected stress data to the host computer 1, and the power supply module 7 is used to power the strain bridge and the acquisition and transmission module 6.

[0032] like Figure 2 、 Figure 3 and Figure 5 As shown, the tested combined track shoe includes a tested steel track shoe 2, a clamping plate 4 and a metal base 5 arranged in sequence along the direction away from the track ring, wherein the metal base 5 is provided with a mounting groove 5.1 for the built-in acquisition and transmission module 6 and the power module 7 at one end close to the clamping plate 4. In order to fully reflect the overload resistance of the test sensor system, the material of the metal base 5 is selected to be Q345, which is a steel with high strength and hardness to protect the internal acquisition and transmission module 6 and the power module 7.

[0033] Example 1 is a single-channel stress data test and acquisition solution. In this embodiment, the acquisition and transmission module 6 is a single-channel module that can be connected to a half-bridge to collect unidirectional stress data on the tested steel track shoe 2 and the tested track link 3. The strain bridge is protected by a coating. The arrangement of the half-bridge on the tested track link 3 is as follows: Figure 4 As shown; after the acquisition and transmission module 6 amplifies the stress data, performs low-pass filtering and A / D conversion, it packages the stress data and transmits it to the host computer 1 for processing through the internal WiFi integrated module.

[0034] Taking into account the shielding effect of the closed metal cavity on electromagnetic waves, electromagnetic wave transmission holes 5.2 are opened on both sides of the metal base 5 corresponding to the positions of the collection and transmission modules 6. Electromagnetic waves can transmit higher power through holes of specific sizes. Since electromagnetic waves can propagate through insulating materials, the electromagnetic wave transmission holes 5.2 are sealed by insulating polyurethane side panels 8. At the same time, considering the sealing performance of the sensing system, the insulating polyurethane side panels 8 and the metal base 5 are connected by mechanical screws 13, and the contact parts are sealed by sealant. The insulating polyurethane side panels 8 ensure that while achieving waterproof packaging, the attenuation of electromagnetic wave wireless transmission can be minimized; multiple heat dissipation holes 5.3 are set on both sides of the metal base 5 corresponding to the positions of the power module 7. Considering that the crawler driving structure is in a complex road condition of being flooded by mine water underground, the heat dissipation holes 5.3 are blocked by silicone plugs 12 and sealed by epoxy glue. The flange side of the silicone plug 12 also has the function of fixing the power module 7.

[0035] A shock-absorbing rubber block 9 is provided at one end of the metal base 5 away from the plywood 4. When the track traveling structure is running normally, the two shock-absorbing rubber blocks 9 on both sides of the outside are in direct contact with the ground and transmit force. The two shock-absorbing rubber blocks 9 can lift the metal base 5 so that it does not contact the ground, so as to reduce the force and vibration of the entire tested combined track shoe, especially the collection and transmission module 6 and the power supply module 7 inside the metal base 5; the shock-absorbing rubber block 9, the metal base 5, the plywood 4 and the tested steel track shoe 2 are connected in sequence by bolts, and the two ends of the plywood 4 are tightly fitted with the metal base 5 and the tested steel track shoe 2 respectively.

[0036] The track link 3 to be tested is welded and fixed to the end of the steel track shoe 2 to be tested away from the clamping plate 4, and the metal strain gauge 11 is bonded to the position between the two pins of the track link 3 to be tested. The steel track shoe 2 to be tested has a cable channel; the clamping plate 4 is made of polyurethane to reduce the collision force between the metal base 5 and the steel track shoe 2 to be tested, and to protect the internal data acquisition and transmission module 6 and power supply module 7; an annular groove 4.1 is provided at the position corresponding to the data acquisition and transmission module 6 near the end of the steel track shoe 2 to be tested, and a clamping plate through hole 4.2 is provided in the middle of the annular groove 4.1 for the cable connecting the strain bridge and the data acquisition and transmission module to pass through. An O-ring 10 is installed in the annular groove 4.1 to achieve waterproof and dustproof sealing of the data acquisition and transmission module 6 and the power supply module 7.

[0037] Example 2:

[0038] Example 2 is a three-channel stress data acquisition solution. When the crawler structure travels on complex road conditions, the track link 3 of the tested steel track shoe 2 may be subjected to forces at multiple angles, causing the principal stress direction to change. Therefore, a three-channel stress acquisition combined track shoe can be selected and connected to the strain gauge rosette 16 to determine the principal stress direction of the tested track link 3.

[0039] like Figure 6 As shown, the tested modular track shoe includes a tested steel track shoe 2, a clamping plate 4, and a polyformaldehyde matrix 14, which are sequentially arranged in a direction away from the track ring. The acquisition and transmission module 6 includes an amplification detection module 6.1 capable of simultaneously acquiring three-channel stress data and amplifying, low-pass filtering, and A / D converting the three-channel weak signals, and a WiFi integration module 6.2 capable of wirelessly uploading the three-channel stress data to the host computer 1. A receiving groove 14.1 for housing the amplification detection module 6.1, the WiFi integration module 6.2, and the power module 7 is provided at one end of the polyformaldehyde matrix 14 near the clamping plate 4, and a shock-absorbing rubber block 9 is provided at the end of the polyformaldehyde matrix 14 away from the clamping plate 4.

[0040] Because three-channel stress data transmission has higher requirements for wireless transmission power, the structure with holes and slits on the outside of the metal substrate 5 cannot effectively transmit the real-time wireless data of the three-channel stress of the strain gauge rosette. Therefore, the substrate material selected for three-channel stress data acquisition is polyoxymethylene. Polyoxymethylene (POM) is an excellent engineering plastic with slightly lower hardness and strength than metal, so it can be processed and manufactured on machine tools. At the same time, polyoxymethylene is an insulating and wave-transmitting material. Although the polyoxymethylene substrate is weaker than the metal substrate in terms of overload resistance, it is stronger than the metal substrate in terms of WiFi signal transmission. The power loss of wireless signals when passing through the polyoxymethylene material is much less than that of metal.

[0041] A splint through hole 4.2 is opened on the splint 4 for the passage of cables connecting the strain bridge and the acquisition and transmission module. A double-sided protective coil 15 is installed in the splint through hole 4.2 for sealing protection of the cables in the through hole. Due to the large number of cables, the double-sided protective coil 15 is used to achieve sealing protection of the cables in the splint through hole 4.2; the measured chain track segment 3 is fixed to the end of the measured steel track shoe 2 away from the splint 4, and the measured steel track shoe 2 has a cable channel, and the shock-absorbing rubber block 9, the polyformaldehyde matrix 14, the splint 4 and the measured steel track shoe 2 are connected in sequence by bolts, and the two ends of the splint 4 are tightly fitted with the polyformaldehyde matrix 14 and the measured steel track shoe 2 respectively.

[0042] In this embodiment, there are three strain bridges. The bonding position of the strain rosette 16 at the measured track link 3 is as follows: Figure 7As shown, since the output signal of the strain bridge is relatively weak, generally at the millivolt level, it needs to pass through the amplification and detection module 6.1 to simultaneously amplify the weak signal of the three stress information, low-pass filter and perform A / D conversion, and then input it into the WiFi integration module 6.2 through the SPI serial port. Then, it is transmitted to the host computer 1 in the form of a WiFi signal to complete the real-time collection and wireless transmission of stress data. In this embodiment, the power module 7 is a lithium battery that powers the amplification and detection module 6.1, the WiFi integration module 6.2 and the three strain bridges.

[0043] At the same time, when the tracked traveling structure is traveling on a rough road, the shock-absorbing rubber block 9 and the plywood 4 are respectively located at the upper and lower parts of the polyformaldehyde matrix 14, which can effectively protect the internal wireless sensor system when the tracked traveling structure is in a working state of strong vibration and collision; a rectangular shallow groove 14.2 is provided on the outer periphery of the accommodating groove 14.1, and a sealing strip 17 is installed in the rectangular shallow groove 14.2 to prevent water and dust.

[0044] The foregoing description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications or substitutions that can be readily conceived by a person skilled in the art within the technical scope disclosed herein should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. An embedded anti-overload test sensor system for a crawler travel structure, characterized by: The invention comprises a combined crawler shoe to be tested, a stress collection device and a host computer (1), wherein at least one combined crawler shoe to be tested is installed on the crawler ring of the crawler travel structure, and the combined crawler shoes to be tested on the two crawler rings are symmetrical relative to the crawler travel structure; The tested combined crawler plate comprises a tested steel crawler plate (2), a clamping plate (4) and a base body which are sequentially arranged in a direction away from the crawler ring; the tested chain track segment (3) is fixed to one end of the tested steel crawler plate (2) away from the clamping plate (4); the tested steel crawler plate (2) and the clamping plate (4) are provided with a cable channel; a collection and transmission module (6) and a power supply module (7) are built into the base body; a shock-absorbing rubber block (9) is provided at one end of the base body away from the clamping plate (4); the shock-absorbing rubber block (9), the base body, the clamping plate (4) and the tested steel crawler plate (2) are connected by a plurality of channels. The bolts are connected in sequence and the two ends of the clamping plate (4) are respectively tightly fitted with the base and the steel track plate (2) to be tested; the stress acquisition device comprises a strain bridge, an acquisition and transmission module (6) and a power module (7), wherein the strain bridge is bonded to the tested link rail (3) at the tested combined track plate, the acquisition and transmission module (6) and the power module (7) are built into the tested combined track plate, the acquisition and transmission module (6) uploads the collected stress data to the host computer (1), and the power module (7) is used to supply power to the strain bridge and the acquisition and transmission module (6).

2. The embedded anti-overload test sensor system for a crawler traveling structure according to claim 1 is characterized in that: The base is a metal base (5), wherein an installation slot (5.1) for a built-in acquisition and transmission module (6) and a power supply module (7) is provided at one end of the metal base (5) close to the splint (4), and electromagnetic wave transmission apertures (5.2) are provided on both sides of the metal base (5) at positions corresponding to the acquisition and transmission modules (6), and the electromagnetic wave transmission apertures (5.2) are sealed by insulating polyurethane side panels (8); An annular groove (4.1) is provided at one end of the splint (4) close to the steel track shoe (2) to be tested, corresponding to the position of the acquisition and transmission module (6); a splint through hole (4.2) for passing a cable connecting the strain bridge and the acquisition and transmission module is provided in the middle of the annular groove (4.1); an O-ring (10) is installed in the annular groove (4.1) for achieving waterproof and dustproof sealing of the acquisition and transmission module (6) and the power module (7); and a metal strain gauge (11) in the strain bridge is bonded to the chain track section (3) to be tested.

3. The embedded anti-overload test sensor system for a crawler traveling structure according to claim 2 is characterized in that: A plurality of heat dissipation holes (5.3) are provided on both sides of the metal substrate (5) at positions corresponding to the power modules (7), and the heat dissipation holes (5.3) are blocked by silicone plugs (12) and sealed by epoxy glue.

4. The embedded anti-overload test sensor system for a crawler traveling structure according to claim 2 is characterized in that: The insulating polyurethane side plate (8) and the metal base (5) are connected via mechanical screws (13), and the contact portions are sealed via sealant.

5. The embedded anti-overload test sensor system for a crawler traveling structure according to claim 1 is characterized in that: The base is a polyformaldehyde base (14), and the acquisition and transmission module (6) includes an amplification detection module (6.1) capable of simultaneously acquiring three-way stress data and realizing amplification, low-pass filtering, and A / D conversion of the three-way weak signals, and a WiFi integration module (6.2) capable of uploading the three-way stress data to a host computer (1), wherein an end of the polyformaldehyde base (14) close to the splint (4) is provided with a receiving groove (14.1) for the built-in amplification detection module (6.1), the WiFi integration module (6.2), and the power module (7); The splint (4) is provided with a splint through hole (4.2) for passing a cable connecting the strain bridge and the acquisition and transmission module. A double-sided protective coil (15) is installed in the splint through hole (4.2) for sealing protection of the cable in the through hole. The strain rosette (16) in the strain bridge is bonded to the measured chain track section (3).

6. The embedded anti-overload test sensor system for a crawler travel structure according to claim 5, characterized in that: A rectangular shallow groove (14.2) is provided on the outer periphery of the accommodating groove (14.1), and a sealing strip (17) for sealing is installed in the rectangular shallow groove (14.2).

7. The embedded anti-overload test sensor system for a crawler travel structure according to claim 6, characterized in that: The interior of the polyformaldehyde matrix (14) and the gaps between the modules are sealed and fixed by epoxy resin glue.

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