Chain tension adjustment device and method based on the swing amount of the tail chain of a scraper conveyor

Abstract

A chain tension adjustment device based on the oscillation of the scraper conveyor tail chain includes an image acquisition module installed on the scraper conveyor tail to collect the oscillation of the scraper conveyor tail chain, a displacement information acquisition module to acquire pressure and displacement information of the hydraulic cylinder assembly, and a calculation and control output module to determine the chain tension and control the oscillation degree. A chain tension adjustment method based on the oscillation of the scraper conveyor tail chain is also provided. This method uses image recognition combined with scraper conveyor torque and hydraulic cylinder assembly pressure to form a specific control method, achieving the goal of maintaining the scraper conveyor chain at an ideal tension, thereby reducing the probability of chain breakage accidents and extending the service life of the chain and sprocket shaft assembly.

Description

Technical Field

[0001] This invention relates to the field of scraper conveyor technology, and in particular to a chain tension adjustment device and method based on the swing amount of the tail chain of a scraper conveyor. Background Technology

[0002] Scraper conveyors are essential equipment in underground coal mining. Their main function is to drive two motors, one at the head and one at the tail, via frequency converters, causing the chain to move repeatedly. During coal mining, as the conveying capacity increases, the scraper conveyor chain experiences elastic stretching. This stretching is amplified by the tail motor, accumulating near the tail end of the chain and causing it to slack and oscillate. Excessive oscillation can lead to chain jamming, skipped teeth, or even chain breakage. Insufficient oscillation results in an overly tight chain, causing chain aging and accelerating wear on components such as sprockets and central grooves.

[0003] Currently, some scraper conveyors at the working face are equipped with telescopic tail sections. The extension and retraction of the tail cylinders counteracts the chain overfeeding caused by increased conveying capacity. Some scraper conveyors are equipped with automatic control systems, but these are all based on cylinder pressure or torque control and cannot directly detect the tail chain status, thus failing to achieve the purpose of accurately adjusting the chain tension. Summary of the Invention

[0004] In order to solve the technical problems existing in the above-mentioned technologies, it is necessary to provide a chain tension adjustment device based on the swing amount of the tail chain of a scraper conveyor.

[0005] A chain tension adjustment device based on the swing amount of the tail chain of a scraper conveyor includes an image acquisition module, a calculation control output module, a displacement information acquisition module, and a hydraulic cylinder assembly.

[0006] The image acquisition module is installed on the tail of the scraper conveyor and is used to acquire the swing amount of the tail chain of the scraper conveyor.

[0007] The displacement information acquisition module is used to acquire the pressure and displacement information of the hydraulic cylinder assembly;

[0008] The calculation and control output module is used to determine the tension of the scraper chain based on the data of the swaying amount of the tail chain, combined with the current coal loading amount of the scraper conveyor, the pressure and displacement data of the hydraulic cylinder assembly, and to control the extension and retraction of the hydraulic cylinder assembly to control the swaying degree of the chain.

[0009] Preferably, the calculation control output module includes a calculation control module, an information receiving module, and an information output module;

[0010] The information receiving module is used to receive data on the swing amount of the scraper conveyor tail chain and the pressure and displacement data of the hydraulic cylinder assembly.

[0011] The calculation and control module is used to calculate and determine the tension of the scraper conveyor chain and control the extension and retraction of the hydraulic cylinder assembly;

[0012] The information output module is used to transmit the control signals from the calculation and control module to the hydraulic cylinder assembly to control the degree of chain oscillation.

[0013] It is also necessary to provide a method for adjusting chain tension based on the swing amount of the scraper conveyor tail chain.

[0014] A method for adjusting chain tension based on the swing amount of the scraper conveyor tail chain, wherein the method is implemented using the chain tension adjustment device based on the swing amount of the scraper conveyor tail chain as described in any one of claims 1 to 2, and the specific steps are as follows:

[0015] S1: When the scraper conveyor is running under no-load, read and record the baseline values ​​of tail torque T0, hydraulic cylinder assembly pressure P0, and chain sway S0.

[0016] S2: Determine the chain swing amount ΔS based on the chain specifications and scraper conveyor length parameters;

[0017] S3: Divide the conveying capacity of the scraper conveyor into 5 segments, and determine the swing amount and tail torque corresponding to the conveying capacity of each segment;

[0018] S4: Obtain the scraper image through the image acquisition module and obtain the real-time chain offset D;

[0019] S5: Determine the real-time offset range of the chain and the corresponding hydraulic cylinder assembly pressure range within different tail torque ranges;

[0020] S6: Based on the corresponding tail torque value and the real-time offset value of the chain, obtain the corresponding hydraulic cylinder assembly pressure value, and dynamically adjust the hydraulic cylinder assembly action according to the hydraulic cylinder assembly pressure value to achieve dynamic tension adjustment of the chain.

[0021] Preferably, in step S3, the swing amounts corresponding to each segment of the transport volume are as follows:

[0022] When the scraper conveyor is operating at 20% capacity, obtain the tail torque T1 and the oscillation ΔS1.

[0023] When the scraper conveyor is operating at 40% capacity, obtain the tail torque T2 and the oscillation ΔS2.

[0024] When the scraper conveyor is operating at 60% capacity, obtain the tail torque T3 and the oscillation ΔS3.

[0025] When the scraper conveyor is operating at 80% capacity, obtain the tail torque T4 and the oscillation ΔS4.

[0026] When the scraper conveyor is operating at 100% capacity, obtain the tail torque T5 and the oscillation ΔS5.

[0027] Preferably, in step S5, the real-time offset range of the chain and the corresponding hydraulic cylinder assembly pressure range values ​​within different tail torque ranges are as follows:

[0028] Tail torque 0≤T≤T1: Cylinder pressure P0≤P≤1.1P0, chain offset D=0;

[0029] Tail torque T1<T≤T2: Cylinder pressure 1.1P0<P≤1.2P0, chain offset 0≤D≤ΔS1;

[0030] Tail torque T2<T≤T3: Cylinder pressure 1.2P0<P≤1.3P0, chain offset ΔS1<D≤ΔS2;

[0031] Tail torque T3<T≤T4: Cylinder pressure 1.3P0<P≤1.4P0, chain offset ΔS2<D≤ΔS3;

[0032] Tail torque T4<T≤T5: Cylinder pressure 1.4P0<P≤1.5P0, chain offset ΔS3<D≤ΔS4;

[0033] Tail torque T5 < T: Cylinder pressure 1.5P0 < P ≤ 1.6P0, chain offset ΔS4 < D ≤ ΔS5.

[0034] Preferably, in step S2, the chain swing amount ΔS is calculated using the following formula:

[0035] ΔS=F·k -1 ·tan(β×Z+σ);

[0036] Where,

[0037] F -- Chain traction force;

[0038] k -- Chain deformation performance coefficient;

[0039] β, Z, σ -- Chain, equipment, and operating condition correction parameters;

[0040] ΔS -- Chain swing amount.

[0041] Preferably, the formula for calculating the chain sway ΔS is derived from the following formula:

[0042]

[0043] W = F·V

[0044]

[0045] In the formula,

[0046] W -- Power consumption, in kW;

[0047] L -- Length of the working surface, in meters;

[0048] V -- Scraper chain speed, m / s;

[0049] Q -- Transport capacity, t / h;

[0050] q b --Weight of coal per meter, kN / m;

[0051] q k --Weight per meter of scraper chain, kN / m;

[0052] α -- Angle, °;

[0053] I -- Lateral tilt rate;

[0054] C -- Conveyor curvature;

[0055] C o -- Resistance coefficient of the upper chain path;

[0056] C u --Lower chain resistance coefficient;

[0057] C t --Chain elasticity coefficient;

[0058] d -- Chain diameter, in meters;

[0059] A -- Transmission efficiency.

[0060] As can be seen from the above technical solution, the chain tension adjustment device and method based on the swing amount of the scraper conveyor tail chain provided by the present invention, through image recognition method, combined with the scraper conveyor torque and the pressure of the hydraulic cylinder assembly, forms a specific control method to achieve the goal of controlling the scraper conveyor chain to always be at the ideal tension, thereby reducing the probability of chain breakage accidents and extending the service life of the chain and sprocket shaft assembly. Attached Figure Description

[0061] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments 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.

[0062] Figure 1 This is a schematic diagram showing the changes in the tail chain as the conveying capacity of the scraper conveyor increases.

[0063] Figure 2 This is a schematic diagram illustrating the principle of scraper image acquisition.

[0064] Figure 3 This is a schematic diagram for measuring chain offset. Detailed Implementation

[0065] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0066] In the description of this invention, it should be understood that the terms "upper", "middle", "outer", "inner", "lower", etc., which indicate orientation or positional relationship, are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the components or elements referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting this invention.

[0067] This invention provides a method for adjusting chain tension based on the swing amount of the tail chain of a scraper conveyor, which is implemented by a chain tension adjustment device based on the swing amount of the tail chain of a scraper conveyor.

[0068] The chain tension adjustment device based on the swing of the scraper conveyor tail chain includes an image acquisition module, a calculation and control output module, a displacement information acquisition module, and a hydraulic cylinder assembly. The image acquisition module is installed on the tail of the scraper conveyor and is used to acquire the swing of the scraper conveyor tail chain. The displacement information acquisition module is used to obtain the pressure and displacement information of the hydraulic cylinder assembly. The calculation and control output module is used to determine the tension of the scraper conveyor chain based on the data information of the swing of the tail chain, combined with the current coal loading of the scraper conveyor, the pressure and displacement data of the hydraulic cylinder assembly, and to control the extension and retraction of the hydraulic cylinder assembly to control the swing of the chain.

[0069] The calculation control output module includes a calculation control module, an information receiving module, and an information output module. The information receiving module is used to receive data on the oscillation of the scraper conveyor tail chain and the pressure and displacement data of the hydraulic cylinder assembly. The calculation control module is used to calculate and determine the tension of the scraper conveyor chain and control the extension and retraction of the hydraulic cylinder assembly. The information output module is used to transmit the control signal from the calculation control module to the hydraulic cylinder assembly to control the oscillation of the chain.

[0070] The method for adjusting chain tension based on the chain sway of the scraper conveyor tail is illustrated below, taking a 260-meter-long SGZ1000 / 3×1200 scraper conveyor in the Mengyu mining area as an example.

[0071] S1: When the scraper conveyor is running under no-load, read and record the baseline values ​​of tail torque T0, hydraulic cylinder assembly pressure P0, and chain sway S0.

[0072] S2: Determine the chain oscillation amount ΔS based on the chain specifications and scraper conveyor length parameters; whereby the chain oscillation amount ΔS is calculated using the following formula:

[0073]

[0074] W = F·V

[0075]

[0076] ΔS=F·k -1 ·tan(β×Z+σ);

[0077] Where,

[0078] W -- Power consumption, value taken here: 3600kW;

[0079] L--Length of the working face, the value used in this calculation is: 260m;

[0080] V -- Scraper chain speed, the value used in this calculation is 1.8 m / s;

[0081] Q -- Transport capacity, the value used in this calculation is 3500t / h;

[0082] q b --Weight of coal per meter, calculated in this case: 5.29 kN / m;

[0083] q k --Weight per meter of scraper chain, the value used in this calculation is: 1.51 kN / m;

[0084] α -- Angle, taken as 0° in this case;

[0085] I -- Lateral inclination rate, range (0~2), value used in this calculation: 1;

[0086] C -- Conveyor curvature, value range (0~2), value used in this calculation: 1.08;

[0087] C o --The resistance coefficient of the upper chain, with a value range of (0~1), is 0.42 in this calculation;

[0088] C u --Lower chain resistance coefficient, with a value range of (0~1), and a value of 0.4 used in this calculation;

[0089] C t--Chain elasticity coefficient, with a range of 10 to 600, and a value of 350 used in this calculation;

[0090] d -- Chain diameter, the value used in this calculation is 0.048m;

[0091] A -- Transmission efficiency, range (0~1), value used in this calculation: 0.855;

[0092] F -- Chain traction force;

[0093] k -- Chain deformation performance coefficient, with a value range of (0~10), and a value of 3 in this calculation;

[0094] β -- Chain correction parameter, value range (0~1), value used in this calculation: 0.4;

[0095] Z -- Equipment correction parameter, value range (0~1), value used in this calculation: 0.6;

[0096] σ -- Operating condition correction parameter, value range (0~1), value used in this calculation: 0.5;

[0097] ΔS -- Chain swing amount;

[0098] Based on the above values, the chain traction force F = 2319.8 kN is calculated.

[0099] Therefore, the chain swing ΔS = 9.987 mm;

[0100] S3: Divide the conveying capacity of the scraper conveyor into 5 segments, and determine the oscillation amount and tail torque corresponding to each segment; the oscillation amount corresponding to each segment is as follows:

[0101] When the scraper conveyor is operating at 20% capacity, the scraper conveyor capacity is 700t / h. The tail torque T1 is read and recorded, and the swing amount ΔS1 = 15mm is calculated by the formula in step 3.

[0102] When the scraper conveyor is running at 40% capacity, the scraper conveyor capacity is 1400t / h. The tail torque T2 is read and recorded, and the swing amount ΔS2 = 25mm is calculated by the formula in step 3.

[0103] When the scraper conveyor is running at 60% capacity, the scraper conveyor capacity is 2100t / h. The tail torque T3 is read and recorded, and the swing amount ΔS3 = 40mm is calculated by the formula in step 3.

[0104] When the scraper conveyor is running at 80% capacity, the scraper conveyor capacity is 2800t / h. The tail torque T4 is read and recorded, and the swing amount ΔS4 = 60mm is calculated by the formula in step 3.

[0105] When the scraper conveyor is running at 100% capacity, the scraper conveyor capacity is 3500t / h. The tail torque T5 is read and recorded, and the swing amount ΔS5 = 80mm is calculated by the formula in step 3.

[0106] S4: Obtain scraper images through the image acquisition module and acquire the real-time chain offset D; use infrared imaging method, by installing an infrared light source and industrial camera above the scraper conveyor at the tail end, and using a global exposure lens and ultra-short exposure mode. By reducing the exposure time of each frame, motion blur is reduced, and image clarity and measurement accuracy are improved. After acquiring the scraper image, the images of the two scraper chains are detected and segmented separately using deep learning-based target detection technology. The endpoints of the vertical chain links are identified using a key point recognition algorithm, and they are connected in sequence to form the scraper chain skeleton. The chain offset D is calculated based on this.

[0107] Please see Figure 3 Using the center of the flat ring of the fixed scraper as a reference, the line connecting the key points closest to the two scrapers is used as the measurement reference line. Under normal conditions, the key points of each vertical chain link should be located within a fixed range on both sides of the connecting line. When a deviation occurs, the distance from each key point to the measurement reference line is measured, and the distance with the largest distance is taken as the deviation of that chain segment, which serves as the basis for judging the chain tension.

[0108] S5: Determine the real-time chain offset range and the corresponding hydraulic cylinder assembly pressure range for different tail torque ranges; the real-time chain offset range and the corresponding hydraulic cylinder assembly pressure range for different tail torque ranges are as follows:

[0109] Tail torque 0≤T≤T1: Cylinder pressure P0≤P≤1.1P0, chain offset D=0;

[0110] Tail torque T1<T≤T2: Cylinder pressure 1.1P0<P≤1.2P0, chain offset 0≤D≤ΔS1;

[0111] Tail torque T2<T≤T3: Cylinder pressure 1.2P0<P≤1.3P0, chain offset ΔS1<D≤ΔS2;

[0112] Tail torque T3<T≤T4: Cylinder pressure 1.3P0<P≤1.4P0, chain offset ΔS2<D≤ΔS3;

[0113] Tail torque T4<T≤T5: Cylinder pressure 1.4P0<P≤1.5P0, chain offset ΔS3<D≤ΔS4;

[0114] Tail torque T5 < T: Cylinder pressure 1.5P0 < P ≤ 1.6P0, chain offset ΔS4 < D ≤ ΔS5;

[0115] S6: Based on the corresponding tail torque value and the real-time offset value of the chain, obtain the corresponding hydraulic cylinder assembly pressure value, and dynamically adjust the hydraulic cylinder assembly action according to the hydraulic cylinder assembly pressure value to achieve dynamic tension adjustment of the chain.

[0116] The above-disclosed embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of the invention. Those skilled in the art will understand that implementing all or part of the above-described embodiments and making equivalent changes in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A method for adjusting chain tension based on the swing amount of the tail chain of a scraper conveyor, characterized in that: Includes an image acquisition module, a calculation and control output module, a displacement information acquisition module, and a hydraulic cylinder assembly; The image acquisition module is installed on the tail of the scraper conveyor and is used to acquire the swing amount of the tail chain of the scraper conveyor. The displacement information acquisition module is used to acquire the pressure and displacement information of the hydraulic cylinder assembly; The calculation and control output module is used to determine the tension of the scraper conveyor chain based on the data of the tail chain's sway, combined with the current coal loading amount of the scraper conveyor and the pressure and displacement data of the hydraulic cylinder assembly. It then controls the extension and retraction of the hydraulic cylinder assembly to control the degree of chain sway. The specific steps are as follows: S1: When the scraper conveyor is running under no-load, read and record the baseline values ​​of tail torque T0, hydraulic cylinder assembly pressure P0, and chain sway S0. S2: Determine the chain swing amount ΔS based on the chain specifications and scraper conveyor length parameters; S3: Divide the conveying capacity of the scraper conveyor into 5 segments, and determine the swing amount and tail torque corresponding to the conveying capacity of each segment; S4: Obtain the scraper image through the image acquisition module and obtain the real-time chain offset D; S5: Determine the real-time offset range of the chain and the corresponding hydraulic cylinder assembly pressure range within different tail torque ranges; S6: Based on the corresponding tail torque value and the real-time offset value of the chain, obtain the corresponding hydraulic cylinder assembly pressure value, and dynamically adjust the hydraulic cylinder assembly action according to the hydraulic cylinder assembly pressure value to achieve dynamic tension adjustment of the chain.

2. The chain tension adjustment method based on the swing amount of the scraper conveyor tail chain according to claim 1, characterized in that: In step S3, the swing amounts corresponding to each segment of the transport volume are as follows: When the scraper conveyor is operating at 20% capacity, obtain the tail torque T1 and the oscillation ΔS1. When the scraper conveyor is operating at 40% capacity, obtain the tail torque T2 and the oscillation ΔS2. When the scraper conveyor is operating at 60% capacity, obtain the tail torque T3 and the oscillation ΔS3. When the scraper conveyor is operating at 80% capacity, obtain the tail torque T4 and the oscillation ΔS4. When the scraper conveyor is operating at 100% capacity, obtain the tail torque T5 and the oscillation ΔS5.

3. The chain tension adjustment method based on the swing amount of the scraper conveyor tail chain according to claim 2, characterized in that: In step S5, the real-time offset range of the chain and the corresponding hydraulic cylinder assembly pressure range values ​​within different tail torque ranges are as follows: Tail torque 0≤T≤T1: Cylinder pressure P0≤P≤1.1P0, chain offset D=0; Tail torque T1<T≤T2: Cylinder pressure 1.1P0<P≤1.2P0, chain offset 0≤D≤ΔS1; Tail torque T2<T≤T3: Cylinder pressure 1.2P0<P≤1.3P0, chain offset ΔS1<D≤ΔS2; Tail torque T3<T≤T4: Cylinder pressure 1.3P0<P≤1.4P0, chain offset ΔS2<D≤ΔS3; Tail torque T4<T≤T5: Cylinder pressure 1.4P0<P≤1.5P0, chain offset ΔS3<D≤ΔS4; Tail torque T5 < T: Cylinder pressure 1.5P0 < P ≤ 1.6P0, chain offset ΔS4 < D ≤ ΔS5.

4. The chain tension adjustment method based on the swing amount of the scraper conveyor tail chain according to claim 1, characterized in that: In step S2, the chain swing amount ΔS is calculated using the following formula: ΔS=F·k -1 ·tan(β×Z+σ); In the formula, F -- Chain traction force; k -- Chain deformation performance coefficient; β, Z, σ -- Chain, equipment, and operating condition correction parameters; ΔS -- Chain swing amount.

5. The chain tension adjustment method based on the swing amount of the scraper conveyor tail chain according to claim 4, characterized in that: The formula for calculating the chain sway ΔS is derived from the following formula: W = F·V In the formula, W -- Power consumption, in kW; L -- Length of the working surface, in meters; V -- Scraper chain speed, m / s; Q -- Transport capacity, t / h; q b --Weight of coal per meter, kN / m; q k --Weight per meter of scraper chain, kN / m; α -- Angle, °; I -- Lateral tilt rate; C -- Conveyor curvature; C o -- Resistance coefficient of the upper chain path; C u --Lower chain resistance coefficient; C t --Chain elasticity coefficient; d -- Chain diameter, in meters; A--Transmission efficiency.

6. The chain tension adjustment method based on the swing amount of the scraper conveyor tail chain according to claim 1, characterized in that: The calculation control output module includes a calculation control module, an information receiving module, and an information output module; The information receiving module is used to receive data on the swing amount of the scraper conveyor tail chain and the pressure and displacement data of the hydraulic cylinder assembly. The calculation and control module is used to calculate and determine the tension of the scraper conveyor chain and control the extension and retraction of the hydraulic cylinder assembly; The information output module is used to transmit the control signals from the calculation and control module to the hydraulic cylinder assembly to control the degree of chain oscillation.

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