Chain on-line wear detection method, detection system, control device and equipment

Abstract

The application provides a chain online wear detection method, a detection system, a control device and equipment, and relates to the technical field of sensor detection, to solve the technical problem that the existing technology needs to stop the operation of the conveyor when detecting the deformation and wear of the chain by using manual detection, which leads to the inability to realize real-time online detection of the deformation of the chain. The method comprises the following steps: determining whether the first detection device detects the signal of the push head on the chain; if yes, controlling the second detection device to detect the running position of another push head on the chain; and judging the wear condition of the chain according to the preset position and the running position. The application is used for realizing real-time online detection of the entire chain, avoiding the need to stop the conveyor chain for detection during manual detection, and avoiding other disadvantages existing in manual detection.

Description

Technical Field

[0001] This invention relates to the field of sensor detection technology, and in particular to an online chain wear detection method, detection system, control device, and equipment. Background Technology

[0002] Conveyor chains primarily function to transport suspended objects and transmit power, and are widely used in mechanized and automated logistics conveyor production lines. However, due to the rigid meshing motion of chain drives, conveyor chains are susceptible to wear and failure during use.

[0003] Traditional methods for detecting deformation and wear on conveyor chains involve manually measuring the distance between two pushers using instruments (such as vernier calipers), and judging the chain's deformation and wear based on the change in the pusher distance. Chain inspection is conducted periodically, when the chain is not running, and the inspection process involves randomly selecting a portion of the chain links for testing.

[0004] The applicant has found that the existing method of manually inspecting chain deformation and wear has at least the following technical problems:

[0005] 1) Manual inspection involves a large workload;

[0006] 2) Stopping regular inspections prevents real-time monitoring of deformations that occur during operation, leading to deformation accumulation and increasing the risk of major accidents;

[0007] 3) Random sampling data is unreliable;

[0008] 4) The accuracy of measurement using vernier calipers is low. Summary of the Invention

[0009] The purpose of this invention is to provide a method, system, control device, and equipment for online chain wear detection, in order to solve the technical problem in the prior art where manual detection of chain deformation and wear requires stopping the conveyor, thus preventing real-time online detection of chain deformation. 。 The preferred technical solutions among the many technical solutions provided by this invention can produce a variety of technical effects, which are described in detail below.

[0010] To achieve the above objectives, the present invention provides the following technical solution:

[0011] The present invention provides an online chain wear detection method, comprising the following steps: determining whether a first detection device detects a signal from a pusher on the chain; if so, controlling a second detection device to detect the running position of another pusher on the chain; and determining the wear condition of the chain based on a preset position and the running position.

[0012] Furthermore, the method also includes: determining whether the wear condition of the chain exceeds a preset safety range; if so, issuing a prompt and / or controlling the chain to stop moving.

[0013] Furthermore, the step of determining the wear condition of the chain based on the preset position and the running position includes the following: determining the chain deviation value X based on the preset position and the running position; determining whether the absolute value of the chain deviation value X is less than the preset reference deviation value Y; if not, determining that the wear of the chain is not within the preset safety range.

[0014] Furthermore, the method further includes: calculating the actual length value L of the chain between the two pushers based on the chain deviation value X and the pre-stored standard chain length values ​​M of the two pushers; and storing the actual length value L.

[0015] Furthermore, the method also includes: determining one or more large values ​​at the beginning of the stored actual length value L; and displaying the large value and the corresponding push-head information.

[0016] Furthermore, the first detection device and the second detection device respectively detect two adjacent push heads along the running direction; when the length of the chain between two adjacent push heads is the standard length value M, the distance between the center of the detection head of the first detection device and the center of the detection head of the second detection device is MN; where N is the distance of the chain walking system reaction time, and the system reaction time is the time taken for the first detection device to detect the push head and control the second detection device to detect the other push head.

[0017] This invention provides a detection system, including a main control device, a first detection device, and a second detection device. Both the first and second detection devices are connected to the main control device and are mounted on the track of a conveyor chain. When the first detection device detects a pusher on the chain, it transmits a signal to the main control device, enabling the main control device to control the second detection device to detect the running position of another pusher on the chain. The main control device can determine the wear condition of the chain based on a preset position and the running position.

[0018] Furthermore, the detection system also includes a display device, which is connected to the main control device.

[0019] Furthermore, the detection system also includes a communication device, through which both the first detection device and the second detection device are communicatively connected to the main control device.

[0020] Furthermore, the first detection device is a laser sensor; the second detection device is a laser micrometer.

[0021] The present invention provides a control device, comprising: a trigger module, used to control a second detection device to detect the running position of another pusher on the chain after a first detection device detects a pusher signal on the chain; a judgment module, used to judge the wear condition of the chain based on a preset position and the running position; and a control module, used to issue prompts and / or control the running state of the chain.

[0022] The present invention provides a device for detecting chain wear, comprising: one or more memories storing an executable program thereon; and one or more processors for executing the executable program in the memories to implement the steps of the method.

[0023] The technical solution of the present invention can produce at least the following technical effects: The present invention uses the push head on the chain as a reference for online detection. The positions of the first detection device and the second detection device are fixed. When the chain moves, the push head continuously passes through the first detection device and the second detection device, which can continuously detect the length of the chain between the two push heads, realize real-time online detection of the entire chain, avoid the need to stop the conveyor chain for detection during manual detection, and avoid other drawbacks of manual detection. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a flowchart illustrating an online chain wear detection method according to an exemplary embodiment;

[0026] Figure 2 This is a schematic diagram illustrating the structure of a first detection device and a second detection device mounted on a chain track according to an exemplary embodiment;

[0027] Figure 3 yes Figure 2 A front view schematic diagram showing the positional relationship between the first and second detection devices and the pusher head;

[0028] Figure 4 This is a control flowchart illustrating a detection system for detecting chain wear according to an exemplary embodiment;

[0029] Figure 5This is a block diagram illustrating a detection system for detecting chain wear according to an exemplary embodiment;

[0030] Figure 6 This is a block diagram illustrating a control device for detecting chain wear according to an exemplary embodiment;

[0031] Figure 7 This is a block diagram illustrating a device for detecting chain wear according to an exemplary embodiment.

[0032] In the diagram: 101. Chain; 102. Track; 103. Pusher head one; 104. Pusher head two; 105. Trolley; 106. Mounting bracket;

[0033] 2. Control device; 201. Trigger module; 202. Judgment module; 203. Control module;

[0034] 3. Device; 301. Memory; 302. Processor;

[0035] 401. First detection device; 402. Second detection device; 403. Communication device; 404. Main control device; 405. Display device. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0037] Traditional methods for detecting conveyor chain deformation and wear involve manually measuring the distance between two pushers using instruments (such as vernier calipers) and judging the chain's deformation and wear based on the change in the pusher distance. Chain inspection is done periodically, during chain stoppage, and the inspection process involves randomly selecting a subset of chain links. Periodic inspections cannot monitor deformation occurring during operation in real time. To address these problems, this invention provides an online chain wear detection method that enables real-time online detection of the chain while it is in motion. The specific detection method includes: determining whether a first detection device 401 detects a signal from a pusher on the chain; if so, controlling a second detection device 402 to detect the running position of another pusher on the chain; and judging the chain's wear condition based on a preset position and the running position.

[0038] The online wear detection method for conveyor chains can be applied to conveyor chains, which are forged and easily detachable chains whose main function is to transport suspended objects and transmit power. A number of pushers are evenly spaced on the chain 101. This invention uses these pushers as references for online detection. The positions of the first detection device 401 and the second detection device 402 are fixed. As the chain 101 moves, pushers continuously pass through the first detection device 401 and the second detection device 402. For example, the pusher detected by the first detection device 401 is called pusher one 103, and the pusher detected by the second detection device 402 is called pusher two 104. That is, the online detection method provided by this invention can detect the chain length corresponding to pushers one 103 and pusher two 104, and detect whether the chain segment shows wear. While the chain 101 moves, the chain length between the two pushers can be continuously detected, achieving real-time online detection of the entire chain. This avoids the need to stop the conveyor chain for manual detection and avoids other drawbacks of manual detection.

[0039] In one example, the method further includes: determining whether the wear condition of the chain exceeds a preset safety range; if so, issuing a prompt and / or controlling the chain to stop moving.

[0040] During real-time chain monitoring, if the wear condition of the chain length between two pushers exceeds the preset safety range, a warning will be issued. The warning can be an audible signal, a visual signal, or a displayed warning message, and the chain will be stopped to prevent accidents.

[0041] In one example, determining the wear condition of the chain based on the preset position and the running position includes the following: determining the chain deviation value X based on the preset position and the running position; determining whether the absolute value of the chain deviation value X is less than the preset reference deviation value Y; if not, determining that the wear of the chain is not within the preset safety range.

[0042] Regarding the preset position, which refers to the preset position data pre-stored in the system, the chain deviation value X is calculated by comparing the preset position with the running position information of the second pusher 402 detected by the second detection device 402. The chain deviation value X can be zero, positive, or negative. The system determines whether the absolute value of the chain deviation value X is less than the preset reference deviation value Y. If it is less, it indicates that the chain wear between the two corresponding pushers is within the preset safety range. If the absolute value of the chain deviation value X is not less than the preset reference deviation value Y, it indicates that the chain wear is not within the preset safety range. The preset reference deviation value Y can be set differently for different conveyor chains.

[0043] See Figure 1 This is a flowchart illustrating the control method of an online chain wear detection method according to an exemplary embodiment.

[0044] S10. Determine whether the first detection device 401 has detected a signal from the pusher on the chain;

[0045] If the first detection device 401 detects a signal from the pusher on the chain, then S20 continues.

[0046] S20. Control the second detection device 402 to detect the running position of another pusher on the chain;

[0047] S30. Determine the chain deviation value X based on the preset position and the above-mentioned running position;

[0048] S40. Determine whether the absolute value of the chain deviation value X is less than the preset reference deviation value Y;

[0049] If the absolute value of the chain deviation value X is not less than the preset reference deviation value Y, then execute the following S50.

[0050] S50 then issues a prompt and / or controls the chain to stop moving.

[0051] In one example, the method further includes: calculating the actual length L of the chain between the two pushers based on the chain deviation value X and the pre-stored standard chain length values ​​M of the two pushers; and storing the actual length value L.

[0052] The specific details are as follows: Among the pushers in the conveyor chain, one pusher will be designated as the starting pusher, and its sequence number can be denoted as 001. The subsequent pushers can be numbered sequentially as 002, 003, 004, etc. During initial use, the position of the starting pusher can be manually determined. For example, when the operator confirms that the first pusher detected by the first detection device 401 is the starting pusher, the main control device 404 can record that the current pusher is the starting pusher 001. The main control device 404 can analyze the number of pushers detected to determine their sequence number and control the display device 405 to display the pusher sequence number. When the conveyor chain stops, the main control device 404 has a function to store and remember the pusher sequence number.

[0053] For example, when the first detection device 401 detects the starting pusher 001, the actual length of the chain detected is the actual length of the chain between the starting pusher 001 and the pusher 002, and the label of the pusher detected by the first detection device 401 corresponds to the data of the running position detected by the second detection device 402.

[0054] In one example, the method further includes: determining the first or more large values ​​in the stored actual length value L; and displaying the large value and its corresponding push-head information.

[0055] For example, the display device 405 can show the first five largest digits of the actual length value L, and simultaneously display the corresponding pusher number for those five digits of the actual length value L. This allows the user to monitor the chain's wear status in a timely manner.

[0056] In one example, the first detection device 401 and the second detection device 402 respectively detect two adjacent pushers along the running direction. When the length of the chain between the two adjacent pushers is the standard length value M, the distance between the center of the detection head of the first detection device 401 and the center of the detection head of the second detection device 402 is MN; where N is the distance of the chain walking system reaction time, and the system reaction time is the time taken for the first detection device 401 to detect the pusher and to control the second detection device 402 to detect another pusher.

[0057] See Figure 3 The diagram illustrates the relative positions of the first detection device 401 and the second detection device 402. Figure 3 The direction of the middle arrow indicates the direction of chain movement. Figure 3 The diagram illustrates the position of the left pusher (pusher one 103) detected by the first detection device 401. At this time, the first detection device 401 transmits a signal to the main control device 404, causing the main control device 404 to control the second detection device 402 to detect the running position of the right pusher (pusher two 104) on the chain. There is a system response time between the first detection device 401 detecting the pusher signal and the second detection device 402 detecting the running position of the other pusher. Considering this system response time, the distance between the center of the detection head of the first detection device 401 and the center of the detection head of the second detection device 402 is set to MN.

[0058] In other words, if the system response time is 0, then the distance between the center of the detection head of the first detection device 401 and the center of the detection head of the second detection device 402 is the standard length value M of the chain, which can be defined as... Figure 3 The distance between the right side of pusher head 103 and the right side of pusher head 104 is such that the center of the detection head of the first detection device 401 is aligned with the right side of pusher head 103, and the center of the detection head of the second detection device 402 is aligned with the right side of pusher head 104. However, in reality, the system reaction time cannot be zero. When the second detection device 402 detects the position of pusher head 104, the chain has already moved to the right for the system reaction time. Therefore, the length N of the chain walking system reaction time is calculated based on the system reaction time and the speed of the chain. Then, when the first detection device 401 and the second detection device 402 are installed, the distance between the center of the detection head of the first detection device 401 and the center of the detection head of the second detection device 402 is not M, but MN.

[0059] When the length of the chain between the two pushers is the standard length value M, the first detection device 401 detects the position of the pusher. The preset position is the distance of the chain walking system reaction time, which is the position of the pusher detected by the second detection device 402.

[0060] The online chain wear detection method provided by this invention has the following advantages: high automatic measurement accuracy, capable of measuring wear as low as 0.001 mm; high efficiency, enabling online chain detection; and high safety, as automatic detection requires no human intervention. This invention provides a high-precision, online, and automatic detection method, offering abnormal alarms and fault information display, reducing fault repair time, while also accommodating real-time data display and storage analysis, providing a basis for remote diagnostics.

[0061] A detection system includes a main control device, a first detection device 401, and a second detection device 402. Both the first detection device 401 and the second detection device 402 are connected to the main control device. The first detection device 401 and the second detection device 402 are mounted on the track 102 of a conveyor chain. When the first detection device 401 detects a pusher on the chain, it transmits a signal to the main control device, enabling the main control device to control the second detection device 402 to detect the running position of another pusher on the chain. The main control device can determine the wear condition of the chain based on a preset position and the running position.

[0062] See Figure 2 The diagram illustrates the first detection device 401 and the second detection device 402. Mounting brackets 106 are provided on the track 102 of the conveyor chain, and the first detection device 401 and the second detection device 402 are respectively mounted on the two mounting brackets 106.

[0063] Regarding the first detection device 401, a laser sensor is preferred; regarding the second detection device 402, a CCD laser micrometer is preferred.

[0064] In one example, the detection system also includes a display device 405, which is connected to the main control device 404.

[0065] The chain length between two adjacent pushers of the conveyor chain is measured online, and the measurement results are stored in the PLC's internal register and simultaneously displayed on display device 405, which can be a touch screen display on an electrical cabinet. For example, all actual length values ​​L stored in the register are compared, and the largest value at the top is extracted and displayed on display device 4 along with the corresponding pusher number. This allows users to monitor the chain wear status in a timely manner.

[0066] In one example, the detection system also includes a communication device, through which both the first detection device 401 and the second detection device 402 are connected to the main control device. This communication connection allows for remote monitoring of the wear condition of the conveyor chain.

[0067] In one example, when the chain length between two adjacent pushers is the standard length value M, the distance between the center of the detection head of the first detection device 401 and the center of the detection head of the second detection device 402 is MN; where N is the distance of the chain walking system reaction time, and the system reaction time is the time taken for the first detection device 401 to detect the pusher and control the second detection device 402 to detect another pusher.

[0068] Please see Figure 4 , Figure 4 This is a control flowchart illustrating a detection system for detecting chain wear according to an exemplary embodiment.

[0069] The conveyor chain operates under real-time online monitoring by a detection system. When the laser sensor detects pusher head one, the PLC system controls a CCD laser micrometer to detect the running position of pusher head two. Based on the preset position and the running position, the PLC system determines the chain wear condition. If the wear condition is within a preset safety range, the chain length between the next two adjacent pushers is measured. The detection and calculation results are stored and displayed on a display device. If the PLC system determines that the chain wear condition is not within the preset safety range, it issues an alarm and stops the chain. Workers can then check for chain abnormalities. If no abnormality is found, the conveyor is restarted. If an abnormality is found, the chain is repaired before restarting the conveyor. When the PLC system determines the chain wear condition based on the preset position and running position, any abnormalities will be displayed on the display device.

[0070] Please see Figure 6 , Figure 6 This is a block diagram illustrating a control device for detecting chain wear according to an exemplary embodiment. Figure 6 As shown, the control device 2 includes: a trigger module 201, used to control a second detection device 402 to detect the running position of another pusher on the chain after the first detection device 401 detects a pusher signal on the chain; a judgment module 202, used to judge the wear condition of the chain according to a preset position and the running position; and a control module 203, used to issue prompts and / or control the running state of the chain.

[0071] Regarding the control device 2 in the above embodiments, the specific methods by which each module performs operations have been described in detail in the embodiments of the related methods described above, and will not be elaborated here.

[0072] Please see Figure 7 , Figure 7 This is a block diagram illustrating a device for detecting chain wear according to an exemplary embodiment. Figure 7 As shown, the device 3 for detecting chain wear includes: one or more memories 301 storing executable programs; and one or more processors 302 for executing the executable programs in the memories 301 to implement the steps of the method provided by the present invention.

[0073] Regarding device 3 in the above embodiments, the specific manner in which its processor 302 executes the program in memory 301 has been described in detail in the embodiments related to the method, and will not be elaborated here.

[0074] It is understood that the same or similar parts in the above embodiments can be referred to each other, and the contents not described in detail in some embodiments can be referred to the same or similar contents in other embodiments.

[0075] In the description of this invention, it should be noted that, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," "tail," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0076] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0077] Any process or method description in the flowchart or otherwise herein can be understood as: representing a module, segment, or portion of code comprising one or more executable instructions for implementing a particular logical function or process, and the scope of the preferred embodiments of this application includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the function involved, as should be understood by those skilled in the art to which embodiments of this application pertain.

[0078] It should be understood that various parts of this application can be implemented using hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented using software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0079] Those skilled in the art will understand that all or part of the steps of the methods in the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer-readable storage medium, and when executed, the program includes one or a combination of the steps of the method embodiments.

[0080] Furthermore, the functional units in the various embodiments of this application can be integrated into a processing module, or each unit can exist physically separately, or two or more units can be integrated into a module. The integrated module can be implemented in hardware or as a software functional module. If the integrated module is implemented as a software functional module and sold or used as an independent product, it can also be stored in a computer-readable storage medium.

[0081] The storage media mentioned above can be read-only memory, disk, or optical disk, etc.

[0082] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "a particular example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0083] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A chain on-line wear detection method, characterized by, The method comprises the following steps: determining whether the first detection device detects the signal of the pusher on the chain; if yes, controlling the second detection device to detect the running position of another pusher on the chain; judging the wear condition of the chain according to the preset position and the running position; the first detection device and the second detection device respectively detect two adjacent pushers in the running direction; when the length of the chain between the two adjacent pushers is a standard length value M, the distance between the center of the head detected by the first detection device and the center of the head detected by the second detection device is M-N; wherein N is the distance of the system reaction time, and the system reaction time is the time from the first detection device detecting the pusher to controlling the second detection device to detect another pusher.

2. The chain on-line wear detection method according to claim 1, characterized in that, The method further comprises: judging whether the wear condition of the chain exceeds the preset safe range; if yes, issuing a prompt and / or controlling the chain to stop moving.

3. The chain on-line wear detection method according to claim 1, characterized by, The method further comprises: judging whether the absolute value of the chain deviation value X is less than the preset reference deviation value Y; if no, judging that the wear of the chain is not within the preset safe range. The method further comprises:

4. The chain on-line wear detection method according to claim 3, characterized in that, calculating the actual length value L of the chain between the two pushers according to the chain deviation value X and the pre-stored standard length value M of the chain between the two pushers; storing the actual length value L. The method further comprises:

5. The chain on-line wear detection method according to claim 4, characterized in that, judging one or more large values in the stored actual length value L; displaying the large values and the corresponding pusher information. The detection system can apply the chain online wear detection method of any one of claims 1-5, comprising a master control device, a first detection device and a second detection device, wherein 6. A detection system characterized by, the first detection device and the second detection device are connected to the master control device, and the first detection device and the second detection device are installed on the track of the conveyor chain; when the first detection device detects the pusher on the chain, the first detection device can transmit a signal to the master control device, so that the master control device can control the second detection device to detect the running position of another pusher on the chain; the master control device can judge the wear condition of the chain according to the preset position and the running position. The detection system further comprises a display device connected to the master control device.

7. The detection system of claim 6, wherein, The detection system further comprises a communication device, and the first detection device and the second detection device are connected to the master control device through the communication device.

8. The detection system of claim 6, wherein, The first detection device is a laser sensor, and the second detection device is a laser micrometer.

9. The detection system of claim 6, wherein, The control device can apply the chain online wear detection method of any one of claims 1-5, comprising:

10. A control device characterized by comprising: a triggering module for controlling the second detection device to detect the running position of another pusher on the chain when the first detection device detects the pusher signal on the chain; a judging module for judging the wear condition of the chain according to the preset position and the running position. ​ A control module is configured to issue a prompt and / or control the running state of the chain.

11. An apparatus for detecting wear of a chain, characterized by The method comprises the steps of: one or more memories having stored thereon executable programs; one or more processors, configured to execute the executable programs stored in the memories to implement the steps of the method according to any one of claims 1-5.

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