A magnetically modulated integrated conveyor belt roller detection system energy harvester

Abstract

The application discloses a kind of integrated conveyor belt roller detection system energy collector of magnetic force modulation, including outer rotor assembly, intermediate magnetic conduction module assembly, inner rotor assembly and stator assembly, the outer rotor assembly includes cylindrical outer rotor shell, and a circle of outer annular staggered magnetic pole permanent magnet is fixed on inner wall;The intermediate magnetic conduction module assembly includes cylindrical magnetic conduction block fixed shell, is set in the inside of outer rotor shell;The inner rotor assembly is set to the inside of cylindrical magnetic conduction block fixed shell, including inner rotor shell, and inner wall ring has inner annular staggered magnetic pole permanent magnet.Said stator assembly includes annular stator shell, and its outer wall is sleeved with power generation coil.The rectification sensing component is electrically connected with power generation coil in a closed loop.The application is adapted to wider working condition, movement is frictionless, no lubrication, adopts integrated structure, overall package, installation is easy to disassemble, isolate coal dust particles in external environment, so that temperature monitoring is more stable, reliable.

Description

Technical Field

[0001] This invention relates to a roller conveyor for underground coal mining, and more particularly to an energy harvester for an integrated conveyor belt roller detection system that can be magnetically modulated. Background Technology

[0002] With the improvement of mechanization, the degree of coal body fragmentation has also increased significantly. The amount of dust generated when fully mechanized mining (tunneling) machines cut the coal body will also increase significantly. This will lead to the use of idler rollers (such as...) underground. Figure 11 As shown, the existing idler roller 6 structure has a rotating bearing installed at the left end of the idler roller shaft 61, and a fixed bushing 64 is fitted and fixed on the rotating bearing. The outer ring of the fixed bushing 64 is fixed on the inner wall of the idler roller 6. An idler roller cover 62 is fitted on the shaft 61 outside the fixed bushing 64, and the right end face of the idler roller cover 62 is clearance-fitted with the left end face of the bearing fixed bushing 64. An installation groove 631 is formed between the idler roller cover 62 and the idler roller cylinder 63. (The idler roller cylinder is connected to the conveyor belt and drives the idler roller cylinder to rotate during use.) When transporting coal, this dust will bring various safety hazards. However, when using ordinary modules with batteries to detect the movement status of the idler roller, due to the limitation of the battery's own lifespan, the idler roller needs to be disassembled and the battery replaced after the module's power supply battery is exhausted. It is impossible to monitor the rotational working status of the idler roller under the conveyor belt for a long time. On the other hand, ordinary detection modules are exposed to the outside world and are easy to be exposed to coal dust, which will also affect their lifespan. Moreover, in the event of damage, it is inconvenient to repair, disassemble, and replace them, requiring complete disassembly and reassembly, which reduces production efficiency. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of existing technology and provide an energy harvester for an integrated conveyor belt idler detection system with modulated magnetic force. This device has a long service life, is easier to install and maintain, has a wide applicable speed range, and is more efficient.

[0004] This invention is achieved through the following technical solution: The present invention discloses an energy harvester for an integrated conveyor belt idler detection system with magnetic modulator, comprising an outer rotor assembly, an intermediate magnetic conductive module assembly, an inner rotor assembly, and a stator assembly; The stator assembly includes an annular stator housing, with a generator coil sleeved on the outer circumferential wall of the stator housing. The intermediate magnetic guide module assembly includes a cylindrical magnetic guide block fixing housing, with multiple slots circumferentially formed on the annular outer wall of the cylindrical magnetic guide block fixing housing. A magnetic guide block is installed in each slot. The magnetic guide block fixing housing is spaced around the stator housing. The left wall of the stator housing is glued to the left bottom wall of the magnetic guide block fixing housing. The magnetic guide block fixing housing and the stator housing are connected to form a U-shaped annular groove structure. The central opening on the bottom wall of the magnetic guide block fixing housing passes through the shaft of the idler roller, and the inner wall of the stator housing is ring-fixed to the idler roller shaft cover. The inner rotor assembly includes an inner rotor housing, which is a stepped ring-shaped structure composed of a large-diameter ring platform and a small-diameter ring platform coaxially. An inner annular staggered permanent magnet is ring-mounted on the annular outer wall of the large-diameter ring platform. The large-diameter ring platform is inserted into a U-shaped annular groove between the generator coil and the magnetic block fixing housing. The inner rotor housing can rotate within the U-shaped annular groove. A bearing is disposed within the annular hole of the small-diameter ring platform, and the inner ring of the bearing is fixed to the shaft and located on the left side of the idler roller shaft cover. The outer rotor assembly includes a cylindrical outer rotor housing. An outer annular staggered permanent magnet is fixed on the inner wall of the annular cylinder of the outer rotor housing. The outer rotor housing passes through a central hole on the left side of the cylinder bottom, through which the shaft passes and is embedded in an installation groove formed between the idler roller shaft cover and the idler roller cylinder. The outer wall of the outer rotor housing is press-fitted with the inner wall of the idler roller cylinder. The permanent magnet spacer rings are set outside the cylindrical magnetic block fixing housing. The outer ring staggered permanent magnet and the inner ring staggered permanent magnet are concentric ring permanent magnets. The rectifier sensor assembly is glued to the bottom left side of the magnetic block fixing housing. The circuit board of the rectifier sensor assembly is made of copper-clad epoxy paper laminate and includes a rectifier module, a voltage regulator module and a storage module. Two enameled wires, positive and negative, are led out from the generator coil, pass through the opening on the annular stator housing and face upwards, and are connected to the positive and negative poles of the rectifier module at the input end of the circuit board, respectively. Two wires are then led out from the positive and negative poles of the rectifier module at the output end and connected to the positive and negative poles of the voltage regulator module at the input end. Two wires are then led out from the positive and negative poles of the voltage regulator module at the output end and connected to the positive and negative poles of the temperature sensor mounted on the circuit board, respectively, to form a closed loop. The storage module is connected in parallel to the positive and negative poles of the voltage regulator module at the output end through the two enameled wires.

[0005] The present invention has the following beneficial effects: (1) In this invention, on the one hand, electricity is generated by the principle of magnetoelectricity, without the need for friction, thus making the lifespan of the collector longer; (2) The present invention adopts an integrated structure, and all working conditions are integrated into one structure and encapsulated as a whole. Even if there is a large amount of coal dust in the well, it will not affect the normal operation of the structure and thus affect its lifespan. In contrast, the existing technology will be affected by external dust and thus affect the lifespan of the collector. (2) In this invention, embedded installation is adopted. During assembly, it can work normally as long as it is correctly embedded into the side of the idler mechanism without changing the original idler structure. It makes reasonable use of space and is more convenient to disassemble and maintain. In contrast, existing technologies often modify the original structure of the idler, making installation and disassembly inconvenient and costly. (3) This invention has a magnetic modulation function, which enables coaxial reversal. It uses permanent magnets with different numbers of inner and outer magnetic poles, so that when the outer rotor assembly rotates, the inner rotor assembly rotates faster, thereby expanding the cutting of magnetic field lines and providing a wider speed range. It can still operate normally under low-speed conditions. (4) The present invention transmits torque through magnetic force, which does not require lubrication and is superior to current mechanical gears. It has lower requirements for the application environment and its quality and function can be maintained even in harsh environments. (5) The present invention can effectively avoid the impact of vibration when the idler roller rotates. There is an air gap between the stator assembly and the rotor assembly. The air gap has a buffering function, so there is no need to worry about the safety problem that the collector may fall off due to the vibration of the idler roller.

[0006] (5) Compared with the prior art, the present invention is easier and faster to assemble, and has a lower cost; it is battery-free and more environmentally friendly. (6) The present invention can achieve self-powered power supply to power the sensor components and detect the shaft temperature of the idler roller system in real time. Compared with the prior art, it reduces the losses caused by mechanical damage and improves work efficiency. Attached Figure Description

[0007] Figure 1 This is a perspective view of an energy harvester for an integrated conveyor belt idler detection system with magnetic modulator according to the present invention. Figure 2 This is the present invention. Figure 1 The diagram shown is a three-dimensional exploded view of the structure. Figure 3 This is the invention Figure 1 A partial three-dimensional exploded view of the structure shown; Figure 4 yes Figure 2 The diagram shows a three-dimensional structure of the external rotor assembly of the energy harvester. Figure 5 yes Figure 2 The diagram shows a three-dimensional structure of the rotor assembly inside the energy harvester. Figure 6 yes Figure 2 A schematic diagram of the three-dimensional structure of the intermediate magnetic conductive module shown in the diagram; Figure 7 This is a schematic diagram of the three-dimensional structure of the energy harvester stator assembly and intermediate magnetic conductive module combined. Figure 8 This is a schematic diagram of the arrangement of the Hellbeck array permanent magnet group in the existing energy harvester design; Figure 9 This is a three-dimensional view of the energy harvester without an outer rotor housing, viewed from the left. Figure 10 This is a top-view 3D schematic diagram of the energy harvester without an external rotor housing. Figure 11 This is a schematic diagram of the structure of the idler roller used in the installation and application of the present invention. Detailed Implementation

[0008] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. The specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of protection of the present invention.

[0009] like Figures 1-7 As shown, the energy harvester of the integrated conveyor belt idler detection system of the present invention, which is magnetically modulated, includes an outer rotor assembly 4, an intermediate magnetic conductive module assembly 3, an inner rotor assembly 2, and a stator assembly 1.

[0010] The stator assembly 1 includes an annular stator housing 11, with a generator coil 13 fitted onto the outer circumferential wall of the stator housing. The intermediate magnetic conductive module assembly 3 includes a cylindrical magnetic conductive block fixing housing 31, with multiple slots circumferentially formed on the annular outer wall of the cylindrical magnetic conductive block fixing housing 31, and a magnetic conductive block 32 installed in each slot. The magnetic conductive block fixing housing is spaced around the stator housing, and the left wall of the stator housing is glued to the left bottom wall 34 of the magnetic conductive block fixing housing. The connection between the magnetic conductive block fixing housing and the stator housing forms a U-shaped annular groove structure 33. The central opening on the bottom wall of the magnetic conductive block fixing housing passes through the shaft 61 of the idler roller, and the inner wall of the stator housing is ring-fixed to the idler roller shaft cover 62. The two are fixed by an interference fit.

[0011] The inner rotor assembly 2 includes an inner rotor housing 21, which is a stepped ring-shaped structure composed of a large-diameter ring platform and a small-diameter ring platform coaxially. An inner annular staggered permanent magnet 23 is ring-mounted on the annular outer wall of the large-diameter ring platform. The large-diameter ring platform 212 is inserted into a U-shaped annular groove between the generator coil 13 and the magnetic block fixing housing. The inner rotor housing 21 can rotate within the U-shaped annular groove. A bearing 22 is disposed within the annular hole of the small-diameter ring platform 211, and the inner ring of the bearing is fixed to the shaft 61 and located on the left side of the idler roller cover 62.

[0012] The outer rotor assembly 4 includes a cylindrical outer rotor housing 41. A ring of outer annular interlaced permanent magnets 42 is fixed on the inner wall of the annular cylindrical body 412 of the outer rotor housing. The outer rotor housing 41 passes through a central hole on the left side bottom 411 of the outer rotor housing, through a shaft 61, and is embedded in a mounting groove 631 formed between the roller shaft cover 62 and the roller cylinder 63. The outer wall of the outer rotor housing 41 is press-fitted with the inner wall of the roller cylinder 63 to achieve fixation and synchronous rotation. The outer annular interlaced permanent magnets 42 are spaced apart and arranged outside the cylindrical magnetic block fixing housing 31, so they do not interfere with each other during movement. The outer annular interlaced permanent magnets and the inner annular interlaced permanent magnets are concentric annular permanent magnets.

[0013] Preferably, the outer annular staggered permanent magnet consists of multiple groups (such as...) Figure 11 The inner annular staggered permanent magnet consists of multiple groups of magnetized permanent magnets arranged in alternating circumferential and radial directions, forming a ring-shaped permanent magnet inside the outer rotor housing. This results in more uniform and denser magnetic field lines and a larger magnetic flux modulus. Figure 4 (A group of) Permanent magnets with opposite magnetic poles in adjacent positions cooperate to form a ring-shaped permanent magnet, which is set on the outside of the inner rotor housing.

[0014] The rectifier sensor assembly 5 is glued to the left bottom wall 34 of the magnetic block fixing housing. The circuit board of the rectifier sensor assembly is made of copper-clad epoxy paper laminate and includes a rectifier module, a voltage regulator module, and a storage module. The rectifier module, voltage regulator module, and storage module are all surface-mount electronic components. The generator coil 13 leads out two enameled wires, which pass through the opening on the annular stator housing 11 and are connected upwards to the positive and negative poles of the rectifier module at the input end of the circuit board, respectively. Then, two wires are led out from the positive and negative poles of the rectifier module at the output end and connected to the positive and negative poles of the voltage regulator module at the input end. Then, two wires are led out from the positive and negative poles of the voltage regulator module at the output end and connected to the positive and negative poles of the temperature sensor mounted on the circuit board, respectively, to form a closed loop. The storage module can be connected by connecting the positive and negative enameled wires in parallel to the positive and negative poles of the voltage regulator module at the output end.

[0015] The power generation coil is connected to the rectifier sensing component to form a closed loop, wherein the power generation coil provides alternating current, the rectifier sensing component integrates the current into direct current, and powers the temperature sensor contained therein to monitor the temperature of the idler roller in real time.

[0016] The rectifier module, voltage regulator module, and storage module are all commercially available. The rectifier module consists of diodes, specifically A7 diodes, to reduce output voltage drop and generate DC voltage. The voltage regulator module consists of Zener diodes, specifically MCC349B diodes. The storage module consists of capacitors with a capacitance of 100uF and a voltage limit of 5V. This combination of components ensures the stability and reliability of the output voltage.

[0017] The working process of the device of the present invention is as follows: When the idler roller 6 rotates, the roller cylinder 63 rotates, causing the cylindrical outer rotor housing 41 of the outer rotor assembly 4 and the outer annular interlaced permanent magnet 42 inside its annular housing to rotate. At this time, since the shaft 61 with the bearing ring is relatively stationary with respect to the ground, the magnetic field is adjusted by the intermediate magnetic guiding module assembly 3, which is relatively stationary with respect to the shaft, making the magnetic field more stable. This allows the inner annular interlaced permanent magnet 23 to accelerate relatively smoothly under the action of magnetic force. At the same time, the generator coil 13 on the stator assembly 1 continuously cuts the magnetic field lines. When the rotation speed of the idler roller 6 reaches a certain speed, the generator coil 13 generates alternating current due to cutting the magnetic field lines. This alternating current is converted into direct current by the rectifier module and then stabilized at 5V by the voltage regulator module, enabling the temperature sensor to work normally. The excess electricity is stored in the storage module for use by the temperature sensor in subsequent operations.

[0018] Example The test was conducted using a V-shaped idler roller transported by a coal conveyor belt. The structure includes an idler roller shaft 61 with a diameter of 45 mm, an idler roller shaft cover 62 with an outer diameter of 108 mm, and an idler roller cylinder 63 with a diameter of 200 mm and an inner wall thickness of 20 mm. There is a 20 mm gap between the idler roller cylinder 63 and the idler roller shaft cover 62. This gap is used to set up the device of the present invention.

[0019] The dimensions of the device of the present invention are set as follows: the outer diameter of the stator assembly 1 and the idler roller 6 is 200mm, the inner diameter is 151mm, the height is 530mm, and the diameter of the shaft 61 is 55mm.

[0020] The overall structure is arranged sequentially from the outside to the inside: Outer rotor assembly 4, including an outer rotor housing 41 with an outer diameter of 141mm, an inner diameter of 139mm, a height of 20mm, and an internal 55mm through hole; an outer annular interlaced permanent magnet 42 with an inner diameter of 135mm, an outer diameter of 139mm, and a height of 10mm; intermediate magnetic guiding module assembly 3, including a magnetic block fixing annular housing 31 with an inner diameter of 124mm, an outer diameter of 132mm, and a height of 11mm; a magnetic block 32 with a length of 5mm, a width of 9mm, a height of 5mm, and an inclination angle of 60°; and inner rotor assembly 2, including an inner annular interlaced permanent magnet 23 with an inner diameter of 117mm, an outer diameter of 121mm, and a height of 10mm. The inner rotor housing 21 has an inner diameter of 115mm, an outer diameter of 117mm, and a height of 10mm. The stator assembly 1 includes a stator housing 11 with an inner diameter of 108mm, an outer diameter of 109mm, and a height of 10mm. The generator coil 12 has an inner diameter of 109mm, an outer diameter of 113mm, and a height of 10mm. The stator housing 11 is coaxial with the outer rotor housing 41 and the inner rotor housing 21. During the rotation of the outer rotor assembly 4, the outer annular staggered permanent magnet 41 rotates with it. Under the action of magnetic force, the inner annular staggered permanent magnet 23 rotates in the opposite direction with accelerated rotation. The permanent magnets are arranged correspondingly to each other, and there is no friction between them.

[0021] The rectifier module consists of diodes, specifically type A7; the voltage regulator module consists of Zener diodes, specifically type MCC349B; and the storage module consists of capacitors, with a capacitance of 100uF and a voltage limit of 5V.

[0022] The outer rotor assembly 4 moves together with the rotation of the idler roller 63. Under the action of the magnetic field, the inner rotor assembly 2 is accelerated to rotate. When the speed of the idler roller 6 reaches a certain level, an induced current is generated inside the generator coil 13.

[0023] Testing revealed that this invention employs an embedded installation method, requiring only correct insertion into the side of the idler roller mechanism for normal operation. During operation, the idler roller cylinder 63 rotates, causing relative movement between the inner and outer annular interlaced permanent magnets. This movement is frictionless and requires no lubrication. Through the principle of magnetoelectricity, the temperature sensor can operate continuously. The air gap between the stator and rotor assemblies provides a buffering effect during roller vibration, allowing the inner annular interlaced permanent magnets to more smoothly and rapidly cut magnetic field lines, adapting to a wider range of working conditions. The external rotor housing provides protection, isolating the invention from coal dust particles in the external environment, resulting in more stable and reliable operation. Disassembly is simple; the invention can be easily and quickly removed by correctly pulling it away from the side of the idler roller mechanism.

[0024] The embodiments described above are merely preferred embodiments of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. An energy harvester for an integrated conveyor belt idler detection system with magnetic modulatorable properties, characterized in that: It includes an outer rotor assembly (4), an intermediate magnetic conductive module assembly (3), an inner rotor assembly (2), and a stator assembly (1); The stator assembly includes an annular stator housing (11), and a generator coil (13) is sleeved on the outer circumferential wall of the stator housing. The intermediate magnetic guide module assembly includes a cylindrical magnetic guide block fixing housing (31), and multiple slots are opened along the circumferential direction on the annular outer wall of the cylindrical magnetic guide block fixing housing. A magnetic guide block (32) is installed in each slot. The magnetic guide block fixing housing is spaced around the stator housing. The left wall of the stator housing is glued to the left bottom wall (34) of the magnetic guide block fixing housing. The magnetic guide block fixing housing and the stator housing are connected to form a U-shaped annular groove structure (33). The middle opening on the bottom wall of the magnetic guide block fixing housing passes through the shaft (61) of the idler roller, and the inner wall of the stator housing is fixed to the idler roller shaft cover (62). The inner rotor assembly (2) includes an inner rotor housing (21), which is a stepped ring-shaped structure composed of a large-diameter ring platform and a small-diameter ring platform coaxially. An inner annular staggered permanent magnet (23) is installed on the annular outer wall of the large-diameter ring platform. The large-diameter ring platform (212) is inserted into the U-shaped annular groove between the generator coil (13) and the magnetic block fixing housing. The inner rotor housing (21) can rotate in the U-shaped annular groove. The bearing (22) is set in the annular hole of the small-diameter ring platform (211). The inner ring of the bearing is fixed on the shaft (61) and located on the left side of the roller shaft cover. The outer rotor assembly (4) includes a cylindrical outer rotor housing (41). A ring of outer annular interlaced permanent magnets (42) is fixed on the inner wall of the annular cylinder (412) of the outer rotor housing. The outer rotor housing passes through the shaft (61) through the middle hole on the bottom (411) of the outer rotor housing on the left side and is embedded in the mounting groove (631) formed between the idler roller cover and the idler roller cylinder. The outer wall of the outer rotor housing (41) is press-fitted with the inner wall of the idler roller cylinder (63). The outer annular interlaced permanent magnets (42) are spaced and arranged in a ring outside the cylindrical magnetic block fixing housing (31). The outer annular interlaced permanent magnets and the inner annular interlaced permanent magnets are concentric annular permanent magnets. Rectifier inductor assembly Component (5) is glued to the bottom left side of the magnetic block fixing housing. The circuit board of the rectifier sensor assembly is made of copper-clad epoxy paper laminate, including a rectifier module, a voltage regulator module and a storage module. Two enameled wires, positive and negative, are led out from the generator coil, pass through the opening on the annular stator housing and are connected to the positive and negative poles of the rectifier module at the input end of the circuit board, respectively. Two wires are led out from the positive and negative poles of the output end of the rectifier module and connected to the positive and negative poles of the input end of the voltage regulator module. Two wires are led out from the positive and negative poles of the output end of the voltage regulator module and connected to the positive and negative poles of the temperature sensor installed on the circuit board to form a closed loop. The storage module is connected in parallel to the positive and negative poles of the output end of the voltage regulator module through two enameled wires.

2. The energy harvester of the magnetically modulated integrated conveyor belt idler detection system according to claim 1, characterized in that: The outer annular staggered permanent magnet is formed by multiple sets of permanent magnets magnetized by alternating circumferential and radially arranged Halebeck arrays; the inner annular staggered permanent magnet is formed by multiple sets of adjacent permanent magnets with opposite magnetic poles.

3. The energy harvester of the magnetically modulated integrated conveyor belt idler detection system according to claim 1 or 2, characterized in that: The rectifier module, voltage regulator module and storage module are all surface-mount electronic components.

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