Tension monitoring system and method for flight conveyor chain

Abstract

A kind of tension monitoring system and method of scraper conveyor chain, the system includes micro magnetic sensor, micro magnetic sensor positioning plate, micro magnetic sensor cover plate, proximity sensor, proximity sensor positioning plate and control processing module;Micro magnetic sensor and micro magnetic sensor cover plate are fixedly installed on micro magnetic sensor positioning plate, and micro magnetic sensor is sealed in the inside of cover plate, micro magnetic sensor positioning plate is inserted into the first plugboard of middle groove;Proximity sensor is fixedly installed on proximity sensor positioning plate, and proximity sensor positioning plate is inserted into the second plugboard of middle groove;Wherein when scraper passes through proximity sensor, micro magnetic sensor can just be opposite chain;Control processing module is connected with micro magnetic sensor and proximity sensor respectively by cable, to determine the tension data of chain according to the data collected by micro magnetic sensor and proximity sensor.This scheme can more directly obtain the data of chain tension, improve the measurement precision of chain tension data.

Description

Technical Field

[0001] This invention relates to the field of scraper conveyor technology, and in particular to a tension monitoring system and method for scraper conveyor chains. Background Technology

[0002] Scraper conveyors are crucial equipment in coal mining faces. They transport mined raw coal away from the face and support the coal mining machine and hydraulic supports. The scraper chain is the main working component of the scraper conveyor, primarily composed of a circular link chain and scrapers. It moves the raw coal continuously to the head position by circulating up and down between the head and tail positions. Because the scraper chain is an elastic body, its elongation and tension will vary depending on the resistance from the raw coal. An overly tight chain will accelerate wear and increase the risk of chain breakage; an overly loose chain will cause chain stacking and skipping, affecting the normal operation of the equipment. To maintain the chain tension within a reasonable range, the current main practice is to add a telescopic hydraulic cylinder at the tail position. By extending or retracting the cylinder, the length of the scraper conveyor is changed, thereby adjusting the chain tension.

[0003] To accurately adjust the chain tension, the most important thing is to accurately obtain the chain tension data. Currently, the commonly used methods for monitoring chain tension are: (1) installing strain gauges on the flat ring corresponding to the scraper; (2) measuring the amount of chain sag at the lower chain track position of the machine head, and inferring the chain tension based on this; (3) measuring the pressure value of the chain on the arc-shaped pressure plate at the tail of the machine, and reflecting the chain tension; (4) monitoring the pressure value of the hydraulic cylinder, and inferring the chain tension based on this. However, all of the above methods estimate the chain tension by estimation, and cannot obtain the chain tension data intuitively and accurately. Summary of the Invention

[0004] In view of this, and to address the above shortcomings, it is necessary to propose a tension monitoring system and method for scraper conveyor chains, which can obtain chain tension data more directly and improve the measurement accuracy of chain tension data.

[0005] In a first aspect, embodiments of the present invention provide a tension monitoring system for a scraper conveyor chain, comprising: a micro magnetic sensor, a micro magnetic sensor positioning plate, a micro magnetic sensor cover plate, a proximity sensor based on the Hall effect principle, a proximity sensor positioning plate, and a control processing module;

[0006] The micro-magnetic sensor is fixedly mounted on the micro-magnetic sensor positioning plate, and the micro-magnetic sensor cover plate is fixedly mounted on the micro-magnetic sensor positioning plate, sealing the micro-magnetic sensor inside the cover plate. The assembled micro-magnetic sensor positioning plate is inserted into the first mounting slot pre-opened in the first insert plate of the middle trough of the scraper conveyor. The proximity sensor is fixedly mounted on the proximity sensor positioning plate, and the assembled proximity sensor positioning plate is inserted into the second mounting slot pre-opened in the second insert plate of the middle trough of the scraper conveyor. The first insert plate and the second insert plate are two insert plates at different positions. The installation positions of the micro-magnetic sensor and the proximity sensor satisfy the following condition: when the scraper of the scraper conveyor passes the proximity sensor, the micro-magnetic sensor is directly opposite the chain of the scraper conveyor.

[0007] The control processing module is located at the head or tail of the scraper conveyor and is connected to the micro magnetic sensor and the proximity sensor via cables to determine the tension data of the scraper conveyor chain based on the data collected by the micro magnetic sensor and the proximity sensor.

[0008] Preferably, both the micro-magnetic sensor positioning plate and the proximity sensor positioning plate are provided with wiring grooves for laying cables connected to the control processing module.

[0009] Preferably, the micro-magnetic sensor positioning plate is equipped with two micro-magnetic sensors, and the installation positions of the two micro-magnetic sensors correspond to the two chains of the lower chain track of the scraper conveyor; correspondingly, the proximity sensor positioning plate is equipped with two proximity sensors, and the installation positions of the two proximity sensors correspond to the two chains of the lower chain track of the scraper conveyor.

[0010] Preferably, the first insert plate and the second insert plate are insert plates of two non-adjacent central slots, and the first insert plate and the second insert plate are two adjacent insert plates.

[0011] Preferably, the installation positions of the micro magnetic sensor and the proximity sensor satisfy the following condition: when the scraper of the scraper conveyor passes the proximity sensor, the micro magnetic sensor is directly opposite the vertical ring of the scraper conveyor chain.

[0012] Preferably, the control processing module includes a storage unit, a control unit, and a processing unit;

[0013] The storage unit is used to pre-store the standard magnetic signal value of the chain under non-stress conditions, as well as the correspondence between the change in magnetic signal and the tension value of the chain.

[0014] The control unit is used to monitor the data collected by the proximity sensor, and when the scraper of the scraper conveyor passes the proximity sensor, it captures the real-time magnetic signal data collected by the micro-magnetic sensor within a preset time period.

[0015] The processing unit is used to determine the current magnetic signal change corresponding to the current chain tension state based on the real-time magnetic signal data and the standard magnetic signal value, and to determine the tension data of the current chain tension state based on the correspondence between the magnetic signal change and the chain tension value.

[0016] Preferably, the control processing module further includes a first transformer and a second transformer;

[0017] The first transformer is used to convert the incoming 127V AC voltage into a 12V DC voltage to power the proximity sensor;

[0018] The second transformer is used to convert the 12V DC voltage to a 9V DC voltage to power the micro magnetic sensor.

[0019] Preferably, both the first mounting groove and the second mounting groove are T-shaped grooves.

[0020] Secondly, embodiments of the present invention provide a method for monitoring the tension of a scraper conveyor chain, the method comprising the following steps:

[0021] Step 101: Store in advance the standard magnetic signal value of the scraper conveyor chain in the unloaded state, as well as the correspondence between the change in magnetic signal and the tension value of the chain in the storage unit of the control processing module;

[0022] Step 102: Install the tension monitoring system of the scraper conveyor chain as described in the first aspect on the first and second insert plates of the scraper conveyor;

[0023] Step 103: During the operation of the scraper conveyor, the control unit of the control processing module receives data collected in real time from the proximity sensor and the micro-magnetic sensor based on the Hall principle.

[0024] Step 104: When the control unit determines that the scraper of the scraper conveyor passes the proximity sensor based on the data collected by the proximity sensor, it extracts the real-time magnetic signal data collected by the micro-magnetic sensor within a preset time period.

[0025] Step 105: The processing unit of the control processing module determines the current magnetic signal change corresponding to the current chain tension state based on the real-time magnetic signal data and the standard magnetic signal value;

[0026] Step 106: The processing unit determines the tension data corresponding to the current change in magnetic signal based on the correspondence between the change in magnetic signal and the tension value of the chain.

[0027] Preferably, in step 104, the step of intercepting the real-time magnetic signal data collected by the micro-magnetic sensor within a preset time period includes:

[0028] The real-time magnetic signal data collected by the micro-magnetic sensor is captured within P ms before and after the moment when the scraper of the scraper conveyor passes the proximity sensor.

[0029] As described above, the tension monitoring system for the scraper conveyor chain provided by this solution includes a micro-magnetic sensor, a micro-magnetic sensor positioning plate, a micro-magnetic sensor cover plate, a proximity sensor, a proximity sensor positioning plate, and a control processing module. The micro-magnetic sensor and its cover plate are assembled on the micro-magnetic sensor positioning plate, and the proximity sensor is assembled on the proximity sensor positioning plate. The assembled micro-magnetic sensor positioning plate and proximity sensor positioning plate are respectively inserted into the insert plates in the middle troughs of the two scraper conveyors. Thus, the control processing module can determine the tension data of the scraper conveyor chain based on the data collected by the micro-magnetic sensor and the proximity sensor. Therefore, this solution can directly determine the chain tension data based on the change in the magnetic signal in the micro-magnetic sensor. Moreover, the micro-magnetic sensor has high monitoring accuracy, resulting in higher accuracy of the monitored tension data. Furthermore, this solution rationally sets the positional relationship between the proximity sensor and the micro-magnetic sensor so that the micro-magnetic sensor is directly opposite the chain when the scraper passes by the proximity sensor. This ensures that the data monitored by the micro-magnetic sensor is always data corresponding to the chain, avoiding the influence of data collected from other locations on the chain tension monitoring. Attached Figure Description

[0030] Figure 1 An exploded view of a tension monitoring system for a scraper conveyor chain provided by the present invention.

[0031] Figure 2 This is a schematic diagram of the middle trough of a scraper conveyor provided by the present invention.

[0032] Figure 3 An assembly diagram of a tension monitoring system for a scraper conveyor chain provided by the present invention.

[0033] Figure 4 This is a schematic diagram of a micro magnetic sensor positioning plate provided by the present invention.

[0034] Figure 5 A flowchart of a method for monitoring the tension of a scraper conveyor chain provided by the present invention.

[0035] In the diagram: 1. Micro magnetic sensor; 2. Micro magnetic sensor positioning plate; 3. Micro magnetic sensor cover plate; 4. Proximity sensor; 5. Proximity sensor positioning plate; 6. Control processing module; 7. Central groove; 8. First insert plate; 9. First mounting groove; 10. Second insert plate; 11. Second mounting groove; 12. Scraper; 13. Chain; 131. Flat ring; 132. Vertical ring; 14. Cable; 15. Wiring groove; 16. Mounting hole. Detailed Implementation

[0036] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0037] A micromagnetic sensor is a vector sensor that operates based on the giant magnetoresistance effect and axial acquisition principle. The giant magnetoresistance effect refers to the phenomenon where the impedance of a sensitive material changes significantly with changes in an external magnetic field when excited by a high-frequency current. Furthermore, micromagnetic sensors can monitor magnetic fields with nanotesla-level accuracy, allowing for the detection of even weak magnetic field variations. When using a micromagnetic sensor to monitor chain tension, if the chain is not under tension, the sensor will acquire a distinct magnetic signal, which will be used as a reference value. When the chain is under tension, the reference value of the magnetic signal acquired by the sensor will change significantly. Therefore, this solution considers monitoring chain tension data based on the change in the magnetic signal caused by chain tension.

[0038] See Figure 1-4 This invention provides a tension monitoring system for a scraper conveyor chain, comprising: a micro magnetic sensor 1, a micro magnetic sensor positioning plate 2, a micro magnetic sensor cover plate 3, a proximity sensor based on the Hall effect principle 4, a proximity sensor positioning plate 5, and a control processing module 6.

[0039] The micro-magnetic sensor 1 is fixedly installed on the micro-magnetic sensor positioning plate 2, and the micro-magnetic sensor cover plate 3 is fixedly installed on the micro-magnetic sensor positioning plate 2, sealing the micro-magnetic sensor 1 inside the cover plate. The assembled micro-magnetic sensor positioning plate 2 is inserted into the first mounting slot 9 pre-opened on the first insert plate 8 of the middle trough 7 of the scraper conveyor. The proximity sensor 4 is fixedly installed on the proximity sensor positioning plate 5, and the assembled proximity sensor positioning plate 5 is inserted into the second mounting slot 11 pre-opened on the second insert plate 10 of the middle trough 7 of the scraper conveyor. The first insert plate 8 and the second insert plate 10 are two insert plates at different positions. The installation positions of the micro-magnetic sensor 1 and the proximity sensor 4 satisfy the following condition: when the scraper 12 of the scraper conveyor passes the proximity sensor 4, the micro-magnetic sensor 1 is exactly facing the chain 13 of the scraper conveyor.

[0040] The control processing module 6 is located at the head or tail of the scraper conveyor and is connected to the micro magnetic sensor 1 and the proximity sensor 4 via cable 14 to determine the tension data of the scraper conveyor chain based on the data collected by the micro magnetic sensor 1 and the proximity sensor 4.

[0041] Due to the structure and usage characteristics of the micro magnetic sensor 1, it is considered that after the micro magnetic sensor 1 is installed on the micro magnetic sensor positioning plate 2, a micro magnetic sensor cover plate 3 is added on top to seal the micro magnetic sensor 1 inside the cover plate, thereby protecting the micro magnetic sensor 1.

[0042] The first mounting slot 9 on the first insert plate 8 and the second mounting slot 11 on the second insert plate 10 are both T-shaped slots. This allows the assembled micro-magnetic sensor positioning plate 2 and proximity sensor positioning plate 5 to be directly inserted into the mounting slots without additional fixing. Furthermore, the bottom of the T-shaped slot is open, allowing the micro-magnetic sensor 1 to directly face the scraper conveyor chain 13 through the opening below the T-shaped slot. This structure does not affect signal monitoring and improves the accuracy of signal acquisition.

[0043] In one embodiment, both the micro-magnetic sensor positioning plate 2 and the proximity sensor positioning plate 5 are provided with wiring grooves 15 for laying cables 14 connected to the control processing module 6. In this embodiment, the micro-magnetic sensor positioning plate 2 is provided with mounting holes 16 for the micro-magnetic sensor 1 and wiring grooves 15 for wiring. The micro-magnetic sensor 1 is fixedly mounted on the micro-magnetic sensor positioning plate 2 through the mounting holes, and the cable is laid in the wiring grooves 15, thereby enabling power supply to the micro-magnetic sensor 1 and real-time transmission of the signal from the micro-magnetic sensor 1. At the same time, placing the cable in the wiring grooves 15 not only facilitates assembly but also provides a certain degree of protection for the cable. Similarly, the proximity sensor positioning plate 5 is also provided with mounting holes and wiring grooves for mounting the proximity sensor 4 and laying the cable connected to the proximity sensor 4, so as to power the proximity sensor 4 and transmit the data collected by the proximity sensor 4.

[0044] Since the scraper conveyor consists of two chains, to ensure comprehensive and accurate monitoring, two micro-magnetic sensors 1 and two proximity sensors 4 can be installed on the corresponding plates. For example, two micro-magnetic sensors 1 are installed on the micro-magnetic sensor positioning plate 2, and the installation positions of these two micro-magnetic sensors 1 correspond to the two chains of the lower track of the scraper conveyor; correspondingly, two proximity sensors 4 are installed on the proximity sensor positioning plate 5, and the installation positions of these two proximity sensors 4 correspond to the two chains of the lower track of the scraper conveyor.

[0045] Furthermore, it should be noted that since the scraper is connected to two chains simultaneously, meaning the scraper will inevitably pass through two proximity sensors 4 at the same time, if there are two micro-magnetic sensors 1, only one proximity sensor 4 can be set. Of course, setting two proximity sensors 4 can improve the reliability of the system; if one proximity sensor 4 fails, the other proximity sensor 4 can still work normally.

[0046] The installation distance between the micro-magnetic sensor 1 and the Hall effect proximity sensor 4 cannot be too close, lest the magnetic field inside the Hall effect proximity sensor 4 affect the measurement accuracy of the micro-magnetic sensor 1. At the same time, the installation distance cannot be too far, lest stretching and wear cause an increase in the chain link pitch, preventing the scraper chain from being perfectly aligned with the micro-magnetic sensor 1 when the scraper passes the proximity sensor 4. In actual scraper conveyors, not every middle trough has an insert plate; typically, insert plates are placed on the middle trough every 1-3 troughs. Therefore, it is considered that the first insert plate 8 and the second insert plate 10 are insert plates for two non-adjacent middle troughs, and that the first insert plate 8 and the second insert plate 10 are two adjacent insert plates. This satisfies the requirement that the distance between the proximity sensor 4 and the micro-magnetic sensor 1 is neither too far nor too close, while also adapting to the existing structural design of the scraper conveyor.

[0047] The chain 13 of the scraper conveyor is composed of alternating flat rings 131 and vertical rings 132. To further improve the sensitivity and accuracy of the signal collected by the micro-magnetic sensor 1, it is considered that the micro-magnetic sensor 1 collects the signal from the vertical ring 132 of the chain. This means that the installation positions of the micro-magnetic sensor 1 and the proximity sensor 4 are such that when the scraper 12 of the scraper conveyor passes the proximity sensor 4, the micro-magnetic sensor 1 is directly opposite the vertical ring 132 of the scraper conveyor chain. Because the vertical ring 132 is closer to the micro-magnetic sensor 1, the sensitivity is higher, the collected signal is stronger, and the obtained data is more accurate. Moreover, this setting ensures that the control processing module 6 only intercepts the data from the vertical ring 132, reducing the amount of data processing and improving processing efficiency.

[0048] It should be noted that the scraper is used as the reference for the signal feedback of the proximity sensor 4 because the scraper can generate a more significant signal on the proximity sensor 4, so that it can be fed back to the control processing module 6 in a timely and accurate manner, and the control processing module 6 can perform the corresponding processing operation.

[0049] In one embodiment, the control processing module 6 includes a storage unit, a control unit, and a processing unit;

[0050] The storage unit is used to pre-store the standard magnetic signal value of the chain under non-stress conditions, as well as the correspondence between the change in magnetic signal and the tension value of the chain;

[0051] The control unit is used to monitor the data collected by the proximity sensor 4, and when the scraper 12 of the scraper conveyor passes the proximity sensor 4, it intercepts the real-time magnetic signal data collected by the micro magnetic sensor 1 within a preset time period.

[0052] The processing unit is used to determine the change in the current magnetic signal corresponding to the current chain tension state based on the real-time magnetic signal data and the standard magnetic signal value, and to determine the tension data of the current chain tension state based on the correspondence between the change in the magnetic signal and the chain tension value.

[0053] In this embodiment, the standard magnetic signal value is the magnetic signal curve of the chain under no force. The correspondence between the change in magnetic signal and the chain tension can be obtained in advance based on experiments and tests. For example, 8 nT (nanotesla) corresponds to a tension of 1 kg.

[0054] The control processing module 6 may also include a first transformer and a second transformer; the first transformer is used to convert the input 127V AC voltage into 12V DC voltage to power the proximity sensor 4; the second transformer is used to convert the 12V DC voltage into 9V DC voltage to power the micro magnetic sensor 1.

[0055] Since the proximity sensor 4 operates at 12V DC and the micro-magnetic sensor 1 operates at 9V DC, in this embodiment, the control processing module 6 is connected to both the micro-magnetic sensor 1 and the Hall effect proximity sensor 4 via cable 14. It is responsible for powering both the micro-magnetic sensor 1 and the Hall effect proximity sensor 4 and processing their transmitted signals. The control processing module 6 is connected to a 127V AC power supply and internally includes a 127V AC to 12V DC power transformer. The 12V power supply powers the Hall effect proximity sensor 4, and the 12V DC power supply is simultaneously connected to a 12V DC to 9V DC power transformer, which powers the micro-magnetic sensor 1.

[0056] In addition, such as Figure 5 As shown in the figure, this embodiment of the invention also provides a method for monitoring the tension of a scraper conveyor chain, the method comprising the following steps:

[0057] Step 101: Store in advance the standard magnetic signal value of the scraper conveyor chain in the unloaded state, as well as the correspondence between the change in magnetic signal and the tension value of the chain in the storage unit of the control processing module;

[0058] Step 102: Install the tension monitoring system of the scraper conveyor chain of the above embodiments on the first and second insert plates of the scraper conveyor;

[0059] Step 103: During the operation of the scraper conveyor, the control unit of the control processing module receives data collected in real time from the proximity sensor and the micro-magnetic sensor based on the Hall principle.

[0060] Step 104: When the control unit determines that the scraper of the scraper conveyor passes the proximity sensor based on the data collected by the proximity sensor, it intercepts the real-time magnetic signal data collected by the micro magnetic sensor within a preset time period.

[0061] Step 105: The processing unit of the control processing module determines the change in the current magnetic signal corresponding to the current chain tension state based on the real-time magnetic signal data and the standard magnetic signal value;

[0062] Step 106: The processing unit determines the tension data corresponding to the current change in magnetic signal based on the correspondence between the change in magnetic signal and the tension value of the chain.

[0063] In step 104, the real-time magnetic signal data collected by the micro-magnetic sensor within a preset time period is extracted, including:

[0064] The real-time magnetic signal data collected by the micro-magnetic sensor is captured within P ms before and after the moment when the scraper of the scraper conveyor passes the proximity sensor.

[0065] In this embodiment, after the monitoring system is installed and the relevant information of the control processing module is configured, the scraper conveyor begins operation. The micro-magnetic sensor and proximity sensor transmit the collected signals to the control processing module via cables. The proximity sensor can detect the signals of the scraper and chain passing by. When the proximity sensor detects the scraper passing by, the control processing module records that moment and simultaneously captures the signals collected by the micro-magnetic sensor within a certain period before and after that moment. Furthermore, the control processing module compares the collected signal values ​​with the magnetic signal values ​​generated by the scraper conveyor chain under non-stress conditions to obtain the amplitude of the signal change caused by the current tension force on the chain. Then, based on the correspondence between the magnetic signal change of the micro-magnetic sensor and the tension force value, the tension force data of the scraper conveyor chain can be determined.

[0066] Furthermore, the control processing module can transmit the obtained tension data to the monitoring substation of the scraper conveyor via cable. Based on the transmitted tension data, the monitoring substation of the scraper conveyor, combined with the extension and retraction of the tail cylinder, the working position and working status of the coal mining machine, etc., adjusts the extension of the tail cylinder accordingly to ensure that the chain tension is always within a reasonable range.

[0067] Furthermore, the method and device embodiments provided in this solution are based on the same inventive concept, and detailed descriptions can be found in the relevant content of the device embodiments.

[0068] In summary, the tension monitoring system and method for scraper conveyor chains provided in this solution can have at least the following beneficial effects:

[0069] (1) Using micro magnetic sensors to measure the tension of scraper conveyor chain. Innovatively, micro magnetic sensors are used to monitor the tension of scraper conveyor chain. Based on the high monitoring accuracy of micro magnetic sensors, more accurate tension monitoring data is obtained.

[0070] (2) Data is collected and analyzed by combining a micro-magnetic sensor and a Hall effect-based proximity sensor. The Hall effect-based proximity sensor is used as the start signal; when the scraper passes the Hall effect-based proximity sensor, the vertical ring of the chain passes directly below the micro-magnetic sensor. During tension analysis, only the micro-magnetic signal of the vertical ring is captured, reducing computational load, simplifying the calculation and analysis process, and lowering hardware requirements. Simultaneously, the position of the vertical ring is closer to the micro-magnetic sensor, resulting in more accurate data.

[0071] (3) Monitor the chain tension data of the lower chain path of the scraper conveyor. The lower chain path was chosen to be monitored because the working environment of the upper chain is more severe, and the installation method of the sensor is difficult to guarantee long-term reliable use.

[0072] (4) Install the micro magnetic sensor and the Hall effect proximity sensor inside the middle plate of the scraper conveyor. Installing the micro magnetic sensor and the Hall effect proximity sensor inside the middle plate of the scraper conveyor provides protection for the sensors, and the measurement position is close to the scraper and chain, resulting in more accurate measurement results.

[0073] The modules or units in the device of this invention can be merged, divided, and deleted according to actual needs. 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 processes of the above embodiments and making equivalent changes according to the claims of this invention still fall within the scope of the invention.

Claims

1. A tension monitoring system for a scraper conveyor chain, characterized in that, include: Micro magnetic sensor, micro magnetic sensor positioning plate, micro magnetic sensor cover plate, Hall effect proximity sensor, proximity sensor positioning plate and control processing module; The micro-magnetic sensor is fixedly mounted on the micro-magnetic sensor positioning plate, and the micro-magnetic sensor cover plate is fixedly mounted on the micro-magnetic sensor positioning plate, sealing the micro-magnetic sensor inside the cover plate. The assembled micro-magnetic sensor positioning plate is inserted into the first mounting slot pre-opened in the first insert plate of the middle trough of the scraper conveyor. The proximity sensor is fixedly mounted on the proximity sensor positioning plate, and the assembled proximity sensor positioning plate is inserted into the second mounting slot pre-opened in the second insert plate of the middle trough of the scraper conveyor. The first insert plate and the second insert plate are two insert plates at different positions. The installation positions of the micro-magnetic sensor and the proximity sensor satisfy the following condition: when the scraper of the scraper conveyor passes the proximity sensor, the micro-magnetic sensor is directly opposite the chain of the scraper conveyor. The control processing module is located at the head or tail of the scraper conveyor and is connected to the micro magnetic sensor and the proximity sensor respectively via cables to determine the tension data of the scraper conveyor chain based on the data collected by the micro magnetic sensor and the proximity sensor. The first insert plate and the second insert plate are insert plates for two non-adjacent central slots, and the first insert plate and the second insert plate are two adjacent insert plates; The installation positions of the micro magnetic sensor and the proximity sensor satisfy the following condition: when the scraper of the scraper conveyor passes the proximity sensor, the micro magnetic sensor is directly opposite the vertical ring of the scraper conveyor chain.

2. The tension monitoring system for scraper conveyor chains according to claim 1, characterized in that, Both the micro-magnetic sensor positioning plate and the proximity sensor positioning plate are provided with wiring grooves for laying cables connected to the control processing module.

3. The tension monitoring system for scraper conveyor chains according to claim 2, characterized in that, Two micro-magnetic sensors are installed on the micro-magnetic sensor positioning plate, and the installation positions of the two micro-magnetic sensors correspond to the two chains of the lower chain track of the scraper conveyor; correspondingly, two proximity sensors are installed on the proximity sensor positioning plate, and the installation positions of the two proximity sensors correspond to the two chains of the lower chain track of the scraper conveyor.

4. The tension monitoring system for scraper conveyor chains according to claim 1, characterized in that, The control processing module includes a storage unit, a control unit, and a processing unit; The storage unit is used to pre-store the standard magnetic signal value of the chain under non-stress conditions, as well as the correspondence between the change in magnetic signal and the tension value of the chain. The control unit is used to monitor the data collected by the proximity sensor, and when the scraper of the scraper conveyor passes the proximity sensor, it captures the real-time magnetic signal data collected by the micro-magnetic sensor within a preset time period. The processing unit is used to determine the current magnetic signal change corresponding to the current chain tension state based on the real-time magnetic signal data and the standard magnetic signal value, and to determine the tension data of the current chain tension state based on the correspondence between the magnetic signal change and the chain tension value.

5. The tension monitoring system for scraper conveyor chains according to claim 4, characterized in that, The control processing module also includes a first transformer and a second transformer; The first transformer is used to convert the incoming 127V AC voltage into a 12V DC voltage to power the proximity sensor; The second transformer is used to convert the 12V DC voltage to a 9V DC voltage to power the micro magnetic sensor.

6. The tension monitoring system for scraper conveyor chains according to any one of claims 1 to 5, characterized in that, Both the first mounting slot and the second mounting slot are T-shaped slots.

7. A method for monitoring the tension of a scraper conveyor chain, characterized in that, The control processing module includes a storage unit, a control unit, and a processing unit; the method includes the following steps: Step 101: Store in advance the standard magnetic signal value of the scraper conveyor chain in the unloaded state, as well as the correspondence between the change in magnetic signal and the tension value of the chain in the storage unit of the control processing module; Step 102: Install the tension monitoring system of the scraper conveyor chain as described in any one of claims 1-6 on the first and second insert plates of the scraper conveyor; Step 103: During the operation of the scraper conveyor, the control unit of the control processing module receives data collected in real time from the proximity sensor and the micro-magnetic sensor based on the Hall principle. Step 104: When the control unit determines that the scraper of the scraper conveyor passes the proximity sensor based on the data collected by the proximity sensor, it extracts the real-time magnetic signal data collected by the micro magnetic sensor within a preset time period. Step 105: The processing unit of the control processing module determines the current magnetic signal change corresponding to the current chain tension state based on the real-time magnetic signal data and the standard magnetic signal value; Step 106: The processing unit determines the tension data corresponding to the current change in magnetic signal based on the correspondence between the change in magnetic signal and the tension value of the chain.

8. The method for monitoring the tension of a scraper conveyor chain according to claim 7, characterized in that, In step 104, the step of intercepting the real-time magnetic signal data collected by the micro-magnetic sensor within a preset time period includes: The real-time magnetic signal data collected by the micro-magnetic sensor is captured within P ms before and after the moment when the scraper of the scraper conveyor passes the proximity sensor.

Images