A device, system and method for intelligent monitoring of the service state of a flight bar chain

Abstract

The application discloses a kind of scraper chain service state intelligent monitoring device, system and method, belong to chain state monitoring management system and method.The stress detection device of the system is installed on split type scraper, for detecting the stress change at same coupling position of double chain system to determine whether fault occurs;Image monitoring module is provided with high-power industrial camera, installed in the same position of middle trough for obtaining the image characteristics of specific area of chain system;Chain calibration module is used to obtain the fault position of different service state scraper chain in real time;Wireless communication module is used for remote transmission of stress, image and label state parameters;Double chain buffer device is used for safety protection when scraper chain fault occurs;Intelligent management platform is used for information storage processing and overall management scheduling.The application takes strain, image and position label signal as reference, realizes scraper chain transmission system segmented monitoring, accurate fault positioning and real-time unified management, with strong reliability, high accuracy, and has wide application value.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of chain scraper, in particular to a scraper chain service state intelligent monitoring device, system and method. BACKGROUND

[0002] The scraper chain transmission system is the "artery" of mine production. As a typical continuous closed transmission system, it mainly plays a role in traction and load bearing when transporting coal or gangue and other materials underground, and has the outstanding characteristics of long distance, large capacity and high strength. The chain transmission device is a typical double-chain traction flexible continuous transportation mechanism, which has many components and complex structure. Its working state directly determines whether the scraper can operate safely and reliably. The failure of the scraper chain is a key factor causing the failure of the scraper conveyor, accounting for about 52.2% of the total number of scraper accidents, which seriously reduces the production efficiency of the coal mine and poses a major threat to the safety of underground workers.

[0003] At present, the existing scraper chain state monitoring methods are mostly based on theoretical algorithm analysis of the tension of the scraper chain at a specific position and static measurement at a fixed point in an experimental environment. The theoretical algorithm is complicated and has poor applicability, and the fixed-point monitoring lacks practicality. The existing dynamic monitoring methods have obvious limitations. Chinese invention patent No. CN201711078198.5, "Scraper Conveyor Chain Breakage Real-time Monitoring System and Monitoring Method", was published on March 9, 2018. It uses strain gauges and node positioning modules to measure the tension and node position information of the scraper chain ring, aiming to monitor the chain breakage of the scraper conveyor in the mine environment in real time.

[0004] The problems in this scheme are as follows:

[0005] 1. In terms of structure, the strain gauges are easily damaged by the scraper and raw coal due to being flatly pasted in the flat chain ring groove, making it difficult to measure real-time stress changes. The power supply of this monitoring system is also not sustainable, and needs to be replaced regularly, making it difficult to be used for a long time.

[0006] 2. In terms of implementation principle, the stress between the scraper chains is fluctuating under normal working conditions. It is not feasible to determine whether the chain breakage fault occurs or not based on the stress difference AF of the left and right nodes. In addition, the chain jamming fault also accompanies a sudden change in strain. The position of the data transmission node changes in real time with the synchronous operation of the scraper chain. It is difficult to achieve real-time monitoring through relay data transmission.

[0007] 3. In terms of implementability, the scraper chain breakage will cause a chain reaction collapse of the entire chain system, leading to multiple component failures. Without any safety protection measures, the monitoring work has poor implementation effect.

[0008] Considering the limitations of the coal mine production environment and the hazards of equipment accidents, it is essential to explore comprehensive evaluation methods and maintenance strategies for the service status of scraper chains to ensure the safe and reliable operation of the chain drive system. Summary of the Invention

[0009] This invention provides a flexible, accurate, and reliable intelligent monitoring device, system, and method for the service status of scraper chains. By analyzing strain, image, and position tag parameter signals in real time, it achieves "strain prediction and comprehensive evaluation," thereby effectively monitoring the service status of scraper chains and formulating management strategies.

[0010] To achieve the above objectives, the present invention is implemented according to the following technical solution:

[0011] In a first aspect, the present invention discloses an intelligent monitoring device for the service status of a scraper chain, comprising:

[0012] The scraper chain drive device mainly consists of a drive sprocket, scraper, circular chain and central trough. It transmits motion and power through the meshing action between the drive sprocket and the circular chain, and the scraper drives the material to circulate and transport along the central trough. The central trough is arranged in parallel and divided into equally spaced blocks with uniform numbering.

[0013] The stress detection device is installed on two parallel circular chains and can move with the circular chains to detect stress changes at the same coupling position of the two chains in order to determine whether a fault has occurred.

[0014] The image monitoring module is used to acquire real-time image features of the scraper and circular chain in a specific area;

[0015] The chain link calibration module is used to obtain the fault location of the scraper chain under different service conditions in real time.

[0016] A wireless communication module is used for the remote transmission of stress, image, and location tag status parameters;

[0017] A double-chain buffer device is used for safety protection when a scraper chain failure occurs.

[0018] In some embodiments, the stress detection device includes:

[0019] The split scraper includes a cover plate, two embedded plates and a pressure plate. The top surface of the cover plate has a cover plate groove in the middle. The two embedded plates are symmetrically installed on both sides of the cover plate, and the embedded plates have a traveling component. The pressure plate is installed on the bottom surface of the cover plate, and a circular chain groove for assembling a circular chain and stress plate is provided between the cover plate and the pressure plate.

[0020] Two coupling collars are symmetrically installed in the circular chain groove of the split scraper, and each of the inner walls of the coupling collars is provided with a strain groove weak coupling contact point on the upper and lower sides.

[0021] Strain gauges are pasted on the weak coupling contact points of the strain grooves to obtain the strain of the corresponding circular chain, and are installed at the same position in any split blade;

[0022] Strain acquisition instrument and micro battery are installed in the cover plate groove, and the strain acquisition instrument is connected with the strain gauge through a lead wire.

[0023] In some embodiments, the double-chain buffer device comprises:

[0024] The buffer supports are installed on the split blades, four buffer supports are arranged on one split blade, two buffer supports are symmetrically arranged on the two side surfaces of one end of the split blade, and the other two buffer supports are symmetrically arranged on the two side surfaces of the other end of the split blade.

[0025] The connecting edge chains are installed between two adjacent split blades, and the free ends of the connecting edge chains are connected with the corresponding buffer supports.

[0026] In some embodiments, the buffer support comprises:

[0027] The fixed support plate is used for fixed connection with the split blade;

[0028] The connecting shaft is provided with a thread at one end and is installed on the fixed support plate in a threaded manner, and is provided with a flange structure at the other end.

[0029] The open link ring is sleeved on the connecting shaft and can move parallel to the connecting shaft, and the other end is connected with the connecting edge chain.

[0030] A pair of buffer springs are sleeved on the connecting shaft, one buffer spring is installed between the fixed support plate and the open link ring, and the other buffer spring is installed between the flange structure and the open link ring.

[0031] In some embodiments, the image monitoring module comprises:

[0032] The bottom plate is used for fixing along the side of the coal baffle groove;

[0033] A pair of side plates are symmetrically arranged on the bottom plate and are installed in a perpendicular manner;

[0034] A pair of support plates are arranged in a symmetrical manner between the two side plates, and the support plates are connected together with the adjacent side plates, and a plurality of fixing sleeves are installed between the two support plates.

[0035] The high-magnification industrial network camera is installed between the two support plates.

[0036] The section calibration module comprises:

[0037] RFID reader, installed on the coal baffle groove side of the middle groove along with the image monitoring module and the same number;

[0038] Passive electronic tags with unique ID numbers are arranged on the upper surface of the split scraper and can run synchronously with the scraper.

[0039] In the second aspect, the application discloses a scraper chain service state intelligent monitoring management system, comprising:

[0040] The scraper chain service state intelligent monitoring device described above;

[0041] The intelligent management platform is used for information storage and processing and overall management and scheduling, and comprises:

[0042] The communication server is used for acquiring strain, image and position information in the service process of the scraper chain;

[0043] The network cloud platform is used for downloading, storing and interacting performance index parameters and characteristic variables;

[0044] The computer processing terminal is used for data processing of performance index parameters and characteristic variables, service state evaluation and equipment management.

[0045] In the third aspect, the application discloses a management method based on the above-mentioned scraper chain service state intelligent monitoring management system, and the management method comprises:

[0046] (1) initializing parameter information of the scraper chain service state intelligent monitoring management system; the parameter information comprises a strain change rate threshold, a frame image pixel difference threshold, an edge standard line angle difference threshold and a positioning tag ID;

[0047] (2) signal monitoring of the parameter information when the stress detection device and the chain system are synchronously operated;

[0048] (3) determining the service state of the scraper chain according to the parameter information;

[0049] (4) if it is determined that a fault occurs, positioning and emergency treatment of the fault are performed;

[0050] (5) repeating the above steps, real-time monitoring of the service state of the scraper chain and intelligent management are performed.

[0051] In some embodiments, the signal monitoring of the parameter information when the stress detection device and the chain system are synchronously operated comprises:

[0052] The stress detection device and the chain system are synchronously operated, and strain variables at positions corresponding to the split scraper and the left and right meshing circular chain grooves of the scraper chain are acquired;

[0053] The image monitoring module acquires real-time images of the middle groove in the equidistant section and matches the edge standard line of the mobile split-type scraper;

[0054] The chain calibration module acquires the ID number of the mobile split-type scraper and determines the position information of the corresponding scraper;

[0055] The independently acquired signals are uniformly transmitted to the intelligent management platform by the wireless communication module for data extraction, analysis and storage.

[0056] In some embodiments, the determination of the service state of the scraper chain according to the parameter information comprises:

[0057] In the two states of shutdown and normal operation, the strain values of the strain grooves of the left and right engagement position rings in the coupling sleeve of the scraper chain transmission device are respectively ε Y1 , ε Y2 , ε N1 and ε N2 ;

[0058] The real-time strain change rates of the left and right engagement position strain grooves are respectively:

[0059] W 1l = λ0×(|ε X1 - ε Y1 |) / ε Y1 and W 1r = λ0×(|ε X2 - ε Y2 |) / ε Y2 ; wherein λ0 is a correction factor, and the correction factor λ0 = (εY1×εY2) / (εN1×ε N2 , which is used to eliminate the influence of the start-up and chain tension on the strain measurement;

[0060] The image monitoring module acquires real-time images of the middle groove in the equidistant section and matches the edge standard line of the mobile split-type scraper;

[0061] The image monitoring module acquires real-time images of the middle groove in the equidistant section and matches the edge standard line of the mobile split-type scraper;

[0062] According to the real-time strain change rate, the image pixel difference, and the angle between the longitudinal horizontal and vertical center line AB and the longitudinal center line A’B’ of the split-type scraper, it is determined whether a fault has occurred, which specifically comprises:

[0063] If the measured W 1l and W 1r are both greater than W0, and Z1 is less than Zl and If the strain of the weak coupling position of the double chain buffer device is greater than the threshold value, it can be determined that the scraper chain has a chain jamming failure.

[0064] If the measured W 1l or W 1r > W0, Z1> Z h and If the strain of the weak coupling position of the double chain buffer device is greater than the threshold value, it can be determined that the scraper chain has a chain jamming failure.

[0065] If the failure occurs, step (4) can be further performed, otherwise it can be determined that the failure is false, the change of the strain is caused by unstable factors, and steps (1)-(3) are repeatedly performed.

[0066] In some embodiments, if the failure occurs, the failure is located and emergency treatment is performed, specifically including:

[0067] Under normal working conditions, the double chain buffer device is always in a relaxed state; when the scraper chain has a chain jamming failure, the motor is automatically stopped in a stall state, when a chain breaking failure occurs, the angles of AB and A'B' are At this time, the open link ring of the double chain buffer device can move parallelly along the connecting shaft under the traction of the connecting edge chain, and release the chain breaking tension impact under the action of the buffer spring, so that the double chain system of the scraper continues to run safely and stably, and the chain breaking causes the chain jamming failure.

[0068] At the same time of the failure, the chain link calibration module arranged on the middle slot coal baffle bank can obtain the electronic tag ID number of the upper surface of the split scraper, and combined with the image information obtained by the image monitoring module, the failure position can be accurately determined, and the intelligent management platform remotely controls the emergency stop brake to complete the maintenance work.

[0069] The present application divides the scraper chain transmission device block, takes the strain characteristic parameter of the weak coupling contact position of the double chain as the determination standard, and evaluates the working state of the scraper chain combined with the monitored image and the calibration position information. Compared with the prior art, the monitoring device, system and method can realize real-time and reliable monitoring of the service state of the scraper chain and accurate failure positioning, and further intelligently realize segmented monitoring and unified management and scheduling of the chain transmission system of the scraper, thereby providing an effective basis for intelligent management and maintenance of the equipment, avoiding major safety accidents, greatly shortening the maintenance and repair period, improving the production efficiency of the equipment, and having a wide application prospect. BRIEF DESCRIPTION OF DRAWINGS

[0070] The accompanying drawings, which are part of the specification, serve to further understand the present application, and the schematic embodiments of the present application and the description thereof serve to explain the present application, but do not constitute undue limitations on the present application. Obviously, the drawings in the following description are only some embodiments, and other drawings can be obtained from these drawings by those of ordinary skill in the art without creative labor.

[0071] In the drawings:

[0072] Figure 1 The flowchart of the service state monitoring method of the scraper chain of the present application.

[0073] Figure 2 The principle diagram of the intelligent monitoring and management system of the service state of the scraper chain of the present application.

[0074] Figure 3 The installation diagram of the stress detection device of the present application.

[0075] Figure 4 The cover plate structure diagram of the split type scraper of the present application (the upper drawing is the front view, and the lower drawing is the back view).

[0076] Figure 5 The left side embedded plate structure diagram of the split type scraper of the present application Figure 1 (the upper drawing is the perspective view, and the lower drawing is the front view).

[0077] Figure 6 The right side embedded plate structure diagram of the split type scraper of the present application Figure 1 (the upper drawing is the perspective view, and the lower drawing is the front view).

[0078] Figure 7 The pressing plate structure diagram of the split type scraper of the present application.

[0079] Figure 8 The coupling sleeve and the coupling sleeve application diagram of the present application.

[0080] Figure 9 The strain diagram of the meshing position when the scraper chain fault occurs in the present application.

[0081] Figure 10 The image monitoring module structure diagram of the present application.

[0082] Figure 11 The installation diagram of the signal acquisition equipment of the present application.

[0083] Figure 12 The position change diagram of the split type scraper under the fault working condition of the present application.

[0084] Figure 13 The double chain buffer device structure diagram of the present application.

[0085] Figure 14 Schematic diagram of the buffer support structure of the present application.

[0086] In the figure: 1, drive sprocket, 2, scraper, 3, round link chain, 4, middle groove, 5, coupling collar, 51, lug, 52, strain weak coupling contact point, 53, lead hole, 54, output line, 55, strain gauge, 6, split scraper, 61, cover plate, 611, rotating hinge, 612, sealing plate, 613, sealing hole, 6141, lead slot, 6142, lead slot, 6143, lead slot, 615, mounting hole, 616, cover plate groove, 617, round link chain groove, 618, coupling groove, 62, embedded plate, 621, bearing support, 622, running wheel shaft, 623, power generation device, 624, rubber wheel, 625, lead, 63, pressing plate, 64, micro battery, 65, strain acquisition instrument, 7, chain link calibration module, 71, RFID reader and writer, 72, passive electronic tag, 8, image monitoring module, 81, high-power industrial network camera, 82, fixing sleeve, 83, side plate, 84, support plate, 9, wireless transmission AP, 10, double-chain buffer device, 101, buffer support, 1011, fixed support plate, 1012, open link ring, 1013, connecting shaft, 1014, sliding sleeve, 1015, buffer spring, 102, connecting edge chain, 11, protocol conversion module.

[0087] It should be noted that these drawings and written descriptions are not intended to limit the scope of the concept of the present application in any way, but to illustrate the concept of the present application to those skilled in the art by referring to specific embodiments. DETAILED DESCRIPTION

[0088] In order to make the purpose, technical scheme and advantages of the embodiments of the present application more clear, the technical scheme in the embodiments will be described clearly and completely below in conjunction with the drawings of the embodiments of the present application. The following embodiments are used to illustrate the present application, but not to limit the scope of the present application.

[0089] In the description of the present application, it should be noted that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "inner", "outer" and the like indicate the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0090] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "mounting", "connection", "linking" should be understood broadly, for example, it can be fixed connection, or detachable connection, or integrally connected; it can be mechanical connection, or electrical connection; it can be directly connected, or indirectly connected through intermediate medium. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0091] As shown in Figure 2 A scraper chain service state intelligent monitoring management system, comprising a scraper chain service state intelligent monitoring device and an intelligent management platform for information storage processing and overall management scheduling. Among them, the scraper chain service state intelligent monitoring device comprises a scraper chain transmission device, a stress detection device, an image monitoring module 8, a chain link calibration module 7, and a wireless communication module.

[0092] The scraper chain transmission device is mainly composed of a driving sprocket 1, a scraper 2, a round link chain 3 and a middle trough 4. The driving sprocket 1 and the round link chain 3 are engaged to transmit motion and power, and the scraper 2 is used to transport materials along the middle trough 4. The middle trough 4 is arranged in parallel and divided into equal blocks for unified numbering.

[0093] The stress detection device is installed on two parallel arranged round link chains 3 and can move with the round link chains 3 to detect the stress change at the same coupling position of the double chains to determine whether a fault occurs.

[0094] The image monitoring module 8 is installed on the top of the coal baffle of the middle trough 4 to obtain the real-time image features of the scraper 2 and the round link chain 3 in a specific area.

[0095] The chain link calibration module 7 is installed on the top of the coal baffle of the middle trough 4 and the surface of the split scraper 6 to obtain the fault position of the scraper chain in different service states in real time.

[0096] The double chain buffer device 10 is used for safety protection when the scraper chain fails.

[0097] The strain, image and position label signals are transmitted to the intelligent management platform through the wireless communication module.

[0098] The following gives a preferred embodiment of the stress detection device of the above embodiment:

[0099] As shown in Figure 3 The stress detection device is composed of a split scraper 6, a strain gauge 55, a coupling sleeve 5 and a strain acquisition instrument 65.

[0100] The split blade includes a cover plate 61, two embedded plates 62 and a pressing plate 63. The cover plate 61 is provided with a cover plate groove 616 in the middle of the top surface. The two embedded plates 62 are symmetrically installed on the two sides of the cover plate 61, and the embedded plates 62 are provided with walking parts. The pressing plate 63 is installed on the bottom surface of the cover plate 61, and a containing cavity for assembling the circular ring chain 3 and its stress monitoring parts is arranged between the cover plate 61 and the pressing plate 63.

[0101] The following gives a preferred embodiment of the cover plate of the above embodiment:

[0102] As shown in Figure 4 , Figure 7 , the two ends of the cover plate 61 are each provided with a symmetrically arranged embedding groove, the inner wall profile of the embedding groove is matched with the outer wall profile of the embedded plate 62, so that the embedded plate 62 can be completely embedded and fixed in the embedding groove. The bottom surface of the cover plate 61 is of a concave structure for assembling the pressing plate 63. The horizontal inner wall of the bottom surface groove of the cover plate 61 is provided with two pairs of circular ring chain grooves I (i.e. left and right engaging circular ring chain grooves I in the figure) arranged at intervals, parallel to each other and perpendicular to the horizontal inner wall long side. The top surface of the pressing plate 63 is provided with circular ring chain grooves II (i.e. left and right engaging circular ring chain grooves II in the figure) which are the same in number as the circular ring chain grooves I and correspond one by one in position. The middle part of each of the circular ring chain grooves I and the circular ring chain grooves II is provided with an inwardly extending coupling groove 618. The cover plate 61 in the two coupling grooves 618 and between the two coupling grooves 618 is provided with a lead groove 6141 and a lead groove 6142 which communicate with each other, for completing the electrical connection between the strain gauge 55 and the strain acquisition instrument 65.

[0103] Further scheme: The opening surface of the cover plate groove 616 is provided with a sealing plate 612 connected by a rotating hinge 611, and the sealing plate 612 is provided with a plurality of signal overflow outlets filled with ceramic materials, which can greatly reduce the overflow attenuation in the signal transmission process.

[0104] It should be noted that the top surface of the cover plate 61 is provided with an installation hole 615 on each side, which is fixed together with the pressing plate 63 by bolts. The side surface of the cover plate 61 and the side surface of the embedded plate 62 are each provided with a sealing hole 613 for fixing the two together by bolts.

[0105] The following gives a preferred embodiment of the embedded plate of the above embodiment:

[0106] As shown in Figure 5 , Figure 6As shown, the part of the embedded plate 62 close to the outer side is provided with a downwardly open mounting groove, and a walking component is assembled in the mounting groove, the walking component being a walking wheel composed of a bearing, a bearing support 621, a walking wheel shaft 622 and a rubber wheel 624. The part of the embedded plate 62 close to the outer side is provided with an inwardly open mounting groove, and a power generation device 623 is assembled in the mounting groove, the power generation device 623 being coaxially installed with the walking wheel shaft 622, and the power generation device 623 is connected with the micro battery 4 through a lead 625 along a lead groove 6143.

[0107] With reference to the above embodiment, a preferred embodiment of the double-chain buffer device is given as follows: Figure 3 As shown, two coupling collars 5 are symmetrically installed in the round-link chain groove 617 of the split blade 6, and the annular inner wall of the coupling collar 5 is provided with one strain groove weak coupling contact point 52 upwardly and downwardly; a strain gauge 55 is pasted on the strain groove weak coupling contact point 52, used for obtaining the strain of the corresponding round-link chain 3, and the installation position of the strain gauge 55 is the same in any split blade 6; a strain acquisition instrument 65 and a micro battery 64 are installed in the cover plate groove 616, and the strain acquisition instrument 65 is connected with the strain gauge 55 through a lead.

[0108] As shown in the above embodiment, a preferred embodiment of the coupling collar is given as follows: Figure 8 As shown, the coupling collar 5 is composed of two semicircular arcs, and the free end of the same side of the two semicircular arcs is provided with a lug 51 extending horizontally outwardly and having a mounting hole, wherein the upper semicircular arc is fixed on the cover plate 61 through a fastener, and the lower semicircular arc is fixed on the pressing plate 63 through a fastener; the semicircular arc is provided with a lead hole 53 at the strain groove weak coupling contact point 52, used for outputting the output line 54 of the strain gauge 55.

[0109] With reference to the above embodiment, a preferred embodiment of the double-chain buffer device is given as follows:

[0110] As shown in the above embodiment, a preferred embodiment of the coupling collar is given as follows: Figure 12 , Figure 13 As shown, the double-chain buffer device 10 includes buffer supports 101 installed on the split blade 6 and connecting edge chains 102; one split blade 6 is provided with four buffer supports 101, two of which are symmetrically installed on the two side faces of one end of the split blade 6, and the other two are symmetrically installed on the two side faces of the other end of the split blade 6; two connecting edge chains 102 are installed on adjacent two split blades 6, and the free end of the connecting edge chain 102 is connected with the corresponding buffer support 101.

[0111] With reference to the above embodiment, a preferred embodiment of the buffer support is given as follows:

[0112] As shown in the above embodiment, a preferred embodiment of the coupling collar is given as follows: Figure 2As shown, the buffer support 101 comprises a fixed support plate 1011, a connecting shaft 1013, an open link ring 1012 and a pair of buffer springs 1015; the fixed support plate 1011 is used for fixed connection with the split blade 6; one end of the connecting shaft 1013 is provided with a thread, which is installed on the fixed support plate 1011 in a threaded manner, and the other end is provided with a flange structure; one end of the open link ring 1012 is sleeved on the connecting shaft 1013 and can move parallel to the connecting shaft 1013, and the other end is connected with the connecting edge chain 102; the pair of buffer springs 1015 are sleeved on the connecting shaft 1013, one of which is installed between the fixed support plate 1011 and the open link ring 1012, and the other is installed between the flange structure and the open link ring 1012.

[0113] Further scheme: the open link ring 1012 is welded by two symmetrically arranged connecting plates and a U-shaped column or integrally cast into shape; each of the two connecting plates is provided with a coaxially arranged assembly hole for the connecting shaft 1013 to pass through.

[0114] Further scheme: a sliding sleeve 1014 capable of moving parallel to the connecting shaft 1013 is also sleeved on the connecting shaft 1013 between the two connecting plates.

[0115] Further scheme: the top of the fixed support plate 1011 is provided with a threaded hole for connection with the connecting shaft 1013, and the middle and bottom of the fixed support plate 1011 are both provided with a sealing hole 613 connected with the split blade 6.

[0116] Further scheme: the two connecting shafts 1013 for connection with the connecting edge chain 102 between the two adjacent split blades 6 are on the same horizontal line.

[0117] Further scheme: a plurality of fixed blades 2 are arranged between the two adjacent split blades 6, and the connecting edge chain 102 is placed on the fixed blade 2.

[0118] The following gives a preferred embodiment of the image monitoring module of the above embodiment:

[0119] As Figure 10As shown in 11, the image monitoring module 8 is used to obtain the real-time working state of the scraper 2 and the circular chain 3, and is installed at the same position and equidistantly on the baffle side of the corresponding middle trough 4. One split scraper 6 is arranged in every four adjacent scrapers 2 in the middle trough 4. The clear image of one split scraper can be obtained simultaneously in the field of view of any camera. The image monitoring module 8 comprises a bottom plate for being fixed on the baffle side of the coal baffle 5, a pair of side plates 83 which are symmetrically arranged on the bottom plate and are installed in a mutually perpendicular manner, a pair of supporting plates 84 and a high-power industrial network camera 81. The pair of supporting plates 84 are symmetrically arranged in the two side plates 83, and the supporting plates 84 are connected together with the adjacent side plates 83. A plurality of fixing sleeves 82 are installed between the two supporting plates 84. The high-power industrial network camera 81 is installed between the two supporting plates 84.

[0120] Further scheme: a plurality of first connecting holes are spaced in an up-down manner on the side plate 83. The second connecting hole coaxial with the first connecting hole is arranged on the supporting plate 84. The second connecting hole is connected with the first connecting holes at different positions by bolts to realize the height adjustment function of the supporting plate 84 on the side plate 83.

[0121] The following gives a preferred embodiment of the chain link calibration module of the above embodiment:

[0122] As shown in Figure 11 , the chain link calibration module 7 comprises an RFID reader 71 and a passive electronic tag 72. The RFID reader 71 is installed on the baffle side of the middle trough 4 in parallel with the image monitoring module 8 and has the same number. Any passive electronic tag 72 has a unique ID number and is arranged on the upper surface of the split scraper 6 to run synchronously with the scraper, which is used to obtain the position signal of the moving scraper.

[0123] The following gives a preferred embodiment of the wireless communication module of the above embodiment:

[0124] As shown in Figure 2 , the wireless communication module mainly comprises a wireless transmission AP 9 and a protocol conversion module 11. The wireless transmission AP 9 is arranged side by side with the high-power industrial camera 81 and has the same number as the split scraper 6. The RFID reader 71, the high-power industrial network camera 81 and the wireless transmission AP 9 are connected with the protocol conversion module 11 through the RS232 / RS485 terminal interface. The connection communication of strain measurement, image acquisition and tag positioning can be uniformly converted into PI protocol for wireless transmission. The communication with the communication server of the intelligent management platform is realized through remote wireless mode, which is used for remote transmission of multi-state parameter data signals.

[0125] The following gives a preferred embodiment of the intelligent management platform of the above embodiment:

[0126] The intelligent management platform is composed of a communication server, a network cloud platform and a computer processing terminal. The communication server is used for acquiring strain, image and position information of the scraper chain during service, the network cloud platform is used for downloading, storing and interacting performance index parameters and characteristic variables, and the computer processing terminal is used for data processing of the performance index parameters and the characteristic variables, service state evaluation and equipment management.

[0127] As can be seen from the above, the present application divides the scraper chain transmission device block, takes the strain characteristic parameter at the weakly coupled contact position of the double chain as the judgment standard, and evaluates the working state of the scraper chain in combination with the monitored image and the calibrated position information. Compared with the prior art, the monitoring device, system and method can realize real-time and reliable monitoring of the service state of the scraper chain and accurate fault positioning, thereby intelligently realizing segmented monitoring and unified management and scheduling of the scraper chain transmission system, providing an effective basis for intelligent management and maintenance of the equipment, avoiding major safety production accidents, greatly shortening the maintenance and repair cycle, improving the production efficiency of the equipment, and having a wide application prospect.

[0128] As shown in Figure 1 , an intelligent monitoring and management method for a scraper chain service state comprises the following steps:

[0129] (1) initializing the intelligent monitoring and management system for the scraper chain service state, setting a strain change rate threshold W0(%) and frame image pixel difference thresholds Z l , Z h , and an edge standard line angle difference threshold ID of the positioning label; and sequentially numbering the middle troughs (4) arranged side by side along the working face as 1, 2, …1·i, 2·i, …1·(N-1), 2·N; the wireless communication module forms i number transmission nodes, each number transmission node can independently collect the strain of the scraper chain, the image of the middle trough and the position information of the electronic label, and can be remotely transmitted by a unified wireless PI protocol.

[0130] (2) signal monitoring: the stress detection device is synchronously operated with the chain system, the strain gauge 55 arranged at the weakly coupled contact point 52 of the coupling sleeve ring 5 acquires the strain at the left and right meshing circular chain trough 617 positions of the corresponding split scraper 6 and the circular ring chain 3; the image monitoring module 8 acquires the real-time image of the middle trough 4 in the equidistant section and matches the edge standard line of the moving split scraper 6; the chain link calibration module 7 acquires the ID number of the moving split scraper 6 to determine the position information of the corresponding scraper; the independently acquired signals are uniformly transmitted to the intelligent management platform by the wireless communication module, and data extraction, analysis processing and storage are performed.

[0131] (3) service state determination of the scraper chain: as shown in Figures 3-12, the strain values at the left and right meshing circular chain grooves 617 show similar change characteristics and both show periodic fluctuations. After the fault occurs, the strain values at the left and right meshing circular chain grooves 617 both change irregularly and disorderly. When the scraper chain transmission device is in the two states of shutdown and normal operation, the strain values of the strain weak coupling contact points 52 in the left and right meshing position circular chain grooves 617 obtained by the strain gauge 55 are respectively ε Y1 , ε Y2 and ε N1 , ε N2 , the strain values of the strain weak coupling contact points 52 in the real-time operation monitoring state are respectively ε X1 , ε X2 , the correction factor λ0=(ε Y1 ×ε Y2 ) / (ε N1 ×ε N2 ) is set to eliminate the influence of start-up and chain tension on strain measurement, and the real-time strain change rates of the left and right meshing position strain weak coupling contact points 52 are respectively:

[0132] W 1l =λ0×(|ε X1 -ε Y1 |) / ε Y1 and W 1r =λ0×(|ε X2 -ε Y2 |) / ε Y2 ; the single-frame image pixel difference obtained by the image monitoring module 8 at equal time intervals is set as Z1; the longitudinal horizontal and vertical center line AB of the split scraper 6 under normal operation of the chain transmission device is set as the reference standard line, and the longitudinal center line A'B' of the split scraper 6 obtained by the monitoring high-magnification industrial network camera 81 at any time is set as the edge standard line, and the angle between AB and A'B' is If the measured W 1l and W 1r are both greater than W0, Z1 is less than Z l , and , it can be determined that the scraper chain has a chain jamming fault, if the measured W 1l or W 1r is greater than W0, Z1 is greater than Z h , and , it can be determined that a chain breakage fault occurs, if the fault occurs, step (4) can be further executed, otherwise it can be determined that the fault is misjudged, the strain change is caused by unstable factors, and steps (1)-(3) are repeatedly executed.

[0133] (4) Fault location and action: under normal working conditions, the double-chain buffer device 10 is always in a relaxed state; when the round-link chain 3 has a chain jamming failure, the motor automatically stops at a stall state, and when a chain breaking failure occurs, the angles of AB and A'B' are At this time, the open link ring 1012 of the double-chain buffer device 10 can move in parallel along the connecting shaft 1013 under the traction of the connecting edge chain 102, and release the chain breaking tension impact under the action of the buffer spring 1015, so that the double-chain system of the scraper continues to run safely and stably, avoiding the chain breaking causing a chain jamming failure; at the same time of the failure, the corresponding RFID reader 71 arranged on the coal baffle groove side of the middle groove 4 can obtain the ID number of the passive electronic tag 72 on the upper surface of the split scraper 6, and the corresponding ith number transmission node position can be accurately determined in combination with the image information obtained by the image monitoring module 8, and the intelligent management platform remotely controls the emergency stop brake to complete the repair work.

[0134] (5) Repeat steps (1)-(4) to monitor the service state of the scraper chain in real time and perform intelligent management.

[0135] In the description provided herein, a large number of specific details are explained. However, it can be understood that the embodiments of the present application can be practiced without these specific details. In some examples, well-known methods, structures and techniques are not shown in detail in order not to obscure the understanding of the present description.

[0136] In addition, those skilled in the art can understand that although some embodiments described herein include certain features included in other embodiments but not others, combinations of features of different embodiments are also meant to be within the scope of the present application and form different embodiments. For example, in the above embodiments, those skilled in the art can use in a combined manner according to the known technical solutions and the technical problems to be solved by the present application.

[0137] The above is only the preferred embodiment of the present application, and is not intended to limit the present application in any form. Although the present application has been disclosed as above with the preferred embodiment, it is not intended to limit the present application, and any skilled person in the art can make some changes or modifications to the above-mentioned technical content without departing from the scope of the technical solutions of the present application, and any simple modification, equivalent change and modification of the above embodiments according to the technical essence of the present application are still within the scope of the present application.

Claims

1. A flight chain service state intelligent monitoring device, characterized in that, The application relates to a scraper chain service state intelligent monitoring device. The device comprises a scraper chain transmission device, a stress detection device, an image monitoring module, a chain link calibration module, a wireless communication module and a double-chain buffer device. The scraper chain transmission device comprises a driving sprocket, scrapers, a round link chain and a middle trough. The stress detection device is installed on two parallel arranged round link chains and can move with the round link chains to detect stress changes at the same coupling position of the double chains to determine whether a fault occurs. The image monitoring module is used for acquiring real-time image features of the scrapers and the round link chain in a specific area. The chain link calibration module is used for acquiring fault positions of the scraper chain in different service states in real time. The wireless communication module is used for remote transmission of stress, image and position tag state parameters. The double-chain buffer device is used for safety protection when a fault occurs in the scraper chain. The double-chain buffer device comprises buffer supports installed on split scrapers, two connecting edge chains installed between adjacent split scrapers, and a pair of buffer springs. The buffer support comprises a fixed support plate, a connecting shaft, an open link ring and the buffer springs. The stress detection device comprises split scrapers, a pair of coupling sleeve rings, strain gauges and a strain acquisition instrument and a micro battery. The image monitoring module comprises a bottom plate, a pair of side plates, a pair of support plates and a plurality of fixing sleeves.

3. The scraper chain service state intelligent monitoring device according to claim 1, wherein the image monitoring module comprises a bottom plate, a pair of side plates, a pair of support plates and a plurality of fixing sleeves. ​ ​ 2. The intelligent service state monitoring device for the scraper chain according to claim 1, characterized in that, ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ High-magnification industrial network camera, installed between two support plates; The chain link calibration module comprises: The RFID reader is installed on the coal baffle side of the middle groove in parallel with the image monitoring module and has the same number as the image monitoring module. The passive electronic tag has a unique ID number and is arranged on the upper surface of the split scraper to run synchronously with the scraper.

4. A flight chain service state intelligent monitoring management system, characterized in that, The intelligent management platform is used for information storage and processing and overall management and scheduling, and comprises: The communication server is used for obtaining strain, image and position information during service of the scraper chain; The network cloud platform is used for downloading, storing and interacting of performance index parameters and characteristic variables; The computer processing terminal is used for data processing of performance index parameters and characteristic variables, service state evaluation and equipment management. The management method comprises: (1) initializing parameter information of the intelligent monitoring and management system of the service state of the scraper chain; the parameter information comprises a strain change rate threshold, a frame image pixel difference threshold, an edge standard line angle difference threshold and a positioning tag ID; 5. A management method of the intelligent monitoring management system for the service state of the flight chain according to claim 4, characterized in that, (2) signal monitoring of the parameter information when the stress detection device and the chain system run synchronously; (3) judging the service state of the scraper chain according to the parameter information; (4) positioning and emergency treatment of the fault if the fault occurs; (5) repeating the above steps to monitor the service state of the scraper chain in real time and perform intelligent management. The signal monitoring of the parameter information when the stress detection device and the chain system run synchronously comprises: The stress detection device and the chain system run synchronously to obtain strain variables at positions corresponding to the split scraper and left and right engagement circular chain groove of the scraper chain; 6. The flight chain service condition intelligent monitoring management method according to claim 5, characterized in that, The image monitoring module is used to obtain real-time images of the middle groove in the equidistant section and match the edge standard line of the moving split scraper; The chain link calibration module is used to obtain the ID number of the moving split scraper to determine the position information of the corresponding scraper; The independently obtained signals are uniformly transmitted to the intelligent management platform by the wireless communication module for data extraction, analysis and storage. The judging of the service state of the scraper chain according to the parameter information comprises: ε 7. The flight chain service state intelligent monitoring management method according to claim 5, characterized in that, ε The strain values of the weak coupling contact points of the coupling rings in the left and right meshing position circular chain grooves obtained by the strain gauges are respectively ε Y1 、 ε Y2 and The real-time strain change rates of the weak coupling contact points of the left and right engagement position strain grooves are respectively: N1 、 λ N2 ; ε W 1l = ε 0×(| ε X1 - λ Y1 |) / ε Y1 and W 1r = ε 0×(| ε X2 - λ Y2 |) / λ Y2 ; wherein, ε 0 is a correction factor, the correction factor ε 0=( ε Y1 × ε Y2 ) / ( The real-time strain change rate, the image pixel difference and the angle between the longitudinal horizontal and vertical center lines AB and the longitudinal center line A'B' of the split scraper are used to judge whether a fault occurs, and the specific steps comprise: N1 × If a fault occurs, step (4) can be further performed, otherwise it can be determined that the fault is misjudged, the strain change is caused by unstable factors, and steps (1)-(3) are repeatedly performed. N2 ), to eliminate the influence of the start-up and chain tension on the strain measurement; The pixel difference of the single frame image acquired by setting the time interval of the image monitoring module is Z 1; The longitudinal horizontal vertical center line AB of the split blade of the scraper chain transmission device under normal operating conditions is set as the reference standard line, the longitudinal center line A'B' of the split blade obtained by the real-time monitoring camera at any time is the edge standard line, and the angle between AB and A'B' is ; The positioning and emergency treatment of the fault if the fault occurs comprise: If the measured W 1l And W 1r At the same time W 0, Z 1 Z l And < A scrapper chain jamming failure can be determined. If the measured W 1l or W 1r > W 0, Z 1> Z h and > a chain breakage fault can be determined to have occurred; When the fault occurs, each chain link calibration module arranged on the coal baffle side of the middle groove can obtain the electronic tag ID number on the upper surface of the unique split scraper, and the image information obtained by the image monitoring module can accurately determine the fault position, and the intelligent management platform remotely controls the emergency stop brake to complete the repair work.

8. The flight chain service state intelligent monitoring management method according to claim 5, characterized in that, ​ Under normal working condition, the double-chain buffer device is always in a relaxed state; when the scraper chain is stuck, the motor is automatically stopped at a stall state, and when the chain is broken, the angles of AB and A'B' are > At this time, the open link ring of the double-chain buffer device can move parallelly along the connecting shaft under the traction of the connecting edge chain, and release the impact of the broken chain tension under the action of the buffer spring, so that the double-chain system of the scraper continues to run safely and stably, avoiding the chain breakage causing the chain failure. ​

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