Mining excavator track roller device and method with real-time online detection function for bushing wear

Abstract

This invention discloses a track roller device and method for mining excavators with real-time online detection of bushing wear. The track roller device includes a track roller, a track roller shaft, two bushings, a sensor assembly, and a control device. The shaft hole of the track roller protrudes outward at its center to form an annular track roller detection boss. The sensor assembly is mounted in the track roller shaft and includes an inductive distance sensor, the detection head of which faces the annular track roller detection boss. The control device is used to determine whether the bushing wear is within a preset wear range and, based on the determination result, decides whether to stop the machine for maintenance. Therefore, this invention can achieve real-time online detection of the bushing wear state during excavator operation, solving the problems of unknowable bushing wear state, unpredictable equipment failures and damage, low operating efficiency, and high maintenance costs associated with existing excavator track rollers.

Description

TECHNICAL FIELD

[0001] The present application relates to a mine excavator support wheel device with a shaft sleeve wear real-time online detection function and a method thereof. BACKGROUND

[0002] The mine excavator support wheel is a key load-bearing component in the lower vehicle track device, which supports the entire excavator. Generally, the automatic lubrication system of the excavator injects lubricating grease into the copper sleeve part at regular intervals to reduce the wear of the parts. Under normal circumstances, the maintenance of the support wheel assembly only needs to replace the copper sleeve. However, since the copper sleeve, gasket and other parts in the support wheel assembly are installed inside the track frame, the on-site maintenance personnel can only rely on experience to judge the wear degree of the copper sleeve and other parts without disassembly.

[0003] Especially during the movement of the on-site mine excavator, in order to prevent insufficient lubrication from causing rapid wear of the copper sleeve, the oil injection frequency of the lubrication system is often increased, and the temperature of the support wheel part needs to be observed at all times through hand touch, infrared temperature measurement and other methods to indirectly judge whether the copper sleeve has hidden dangers of rapid wear. Not only does this cause waste of lubricating grease, but it also often leads to excessive wear of the copper sleeve, and even the copper sleeve is worn out, causing the support wheel shaft to come into contact with the support wheel, resulting in serious equipment failure and high maintenance costs. SUMMARY

[0004] The present application provides a mine excavator support wheel device with a shaft sleeve wear real-time online detection function and a method thereof. By embedding a sensor assembly in the support wheel shaft, real-time online detection of the wear state of the copper sleeve during the operation of the excavator can be achieved, solving the problems of unknown wear state of the copper sleeve during the use of the existing excavator support wheel, easy to cause unpredictable equipment failure and damage, low operation efficiency and high maintenance cost.

[0005] To achieve the above technical purposes, the present application will adopt the following technical solutions:

[0006] A mine excavator support wheel device with a shaft sleeve wear real-time online detection function, comprising a support wheel, a support wheel shaft and two shaft sleeves, the support wheel is sleeved on the outside of the support wheel shaft, and the two shaft sleeves are installed in the shaft holes of the support wheel from both sides of the support wheel; further comprising a sensor assembly and a control device, wherein:

[0007] The shaft hole of the support wheel is formed into a ring-shaped support wheel detection boss at the middle position; the L-shaped hole is provided in the support wheel shaft; the L-shaped hole comprises a threading hole and a sensor mounting hole, the threading hole is arranged along the axial direction of the support wheel shaft, and the sensor mounting hole is arranged along the radial direction of the support wheel shaft, one end of the threading hole is provided through the shaft end of the support wheel shaft, the other end is in communication with one end of the sensor mounting hole, and the other end of the sensor mounting hole is provided through the surface of the shaft body of the support wheel shaft;

[0008] The sensor assembly comprises an electric distance sensor, which is installed in the sensor mounting hole and has a detection head opposite the annular bolster detection boss; the electric distance sensor detects distance information relative to the annular bolster detection boss through the detection head and transmits the detected distance information to the control device through a signal transmission line according to a data detection period; the signal transmission line is arranged along the threading hole;

[0009] The control device calculates the bushing wear amount according to the distance information fed back by the electric distance sensor according to the data detection period, and then judges whether the calculated bushing wear amount is within a preset wear amount threshold range; when the judgment result shows that the bushing wear amount exceeds the preset wear amount threshold range, the machine is stopped for maintenance.

[0010] Preferably, the surface of the bolster shaft is provided with an annular embedding groove at a position corresponding to the annular bolster detection boss.

[0011] Preferably, the sensor assembly further comprises a mounting plate and a locking nut.

[0012] The sensor mounting hole is a stepped hole comprising two sections, i.e., first and second mounting hole sections; the threading hole is in communication with the first and second mounting hole sections, and the hole diameter of the first mounting hole section is smaller than that of the second mounting hole section.

[0013] The mounting plate is placed on the stepped surface between the first and second mounting hole sections, and the electric distance sensor is placed through a hole in the middle of the mounting plate and locked by the locking nut.

[0014] Preferably, a hole stop ring is arranged on the outside of the mounting plate.

[0015] Preferably, the control device comprises a calculation module, a judgment module, and an execution module.

[0016] The calculation module is used to calculate the bushing wear amount, and the calculation formula is:

[0017] W t = |D t -D0|;

[0018] In the formula, D0 represents the data detected by the electric distance sensor for the first time after the new bushing is installed; D t represents the distance detected by the electric distance sensor relative to the annular bolster boss at any time t, and W t represents the bushing wear amount at time t.

[0019] The judgment module is used to judge whether the bushing wear amount exceeds the preset wear amount threshold, and when the judgment result shows that |Wt -W max When W≤ΔW, it indicates that the wear amount W of the shaft sleeve t Exceeding the preset wear amount threshold W max of the allowable range ΔW, the execution module is triggered to issue an execution command to control the mine excavator to stop for maintenance.

[0020] Another technical purpose of the present application is to provide a mine excavator bogie wheel device with real-time online detection function of shaft sleeve wear, which comprises a bogie wheel, a bogie shaft and two shaft sleeves, the bogie wheel is sleeved on the bogie shaft, and the two shaft sleeves are installed in the shaft holes of the bogie wheel from both sides of the bogie wheel; it also comprises a sensor assembly and a control device.

[0021] The shaft hole of the bogie wheel is outwardly convex at the middle position to form a ring-shaped bogie wheel detection boss; the bogie shaft is provided with an L-shaped hole; the L-shaped hole comprises a threading hole and a sensor mounting hole, the threading hole is arranged along the axial direction of the bogie shaft, and the sensor mounting hole is arranged along the radial direction of the bogie shaft, one end of the threading hole is provided through the shaft end of the bogie shaft, and the other end is in communication with one end of the sensor mounting hole, and the other end of the sensor mounting hole is provided through the surface of the shaft body of the bogie shaft;

[0022] The sensor assembly comprises a contact limit switch; the contact limit switch is installed in the sensor mounting hole, and the contact of the contact limit switch is opposite to the ring-shaped bogie wheel detection boss; the contact limit switch is connected with the control device through a signal transmission line, and is provided with two outputs, which are high-level output and low-level output; when the output of the contact limit switch is low-level output, it indicates that the contact of the contact limit switch is triggered by the ring-shaped bogie wheel detection boss or the contact limit switch fails, otherwise, the output of the contact limit switch is high-level output.

[0023] The signal transmission line is arranged along the threading hole;

[0024] The control device outputs corresponding control signals according to the information transmitted by the contact limit switch; when the information transmitted by the contact limit switch received by the control device is high-level output, the control device outputs a first control signal to control the mine excavator to work normally; when the information transmitted by the contact limit switch received by the control device is low-level output, the control device outputs a second control signal to control the mine excavator to stop for maintenance.

[0025] Preferably, the surface of the bogie shaft is provided with a ring-shaped embedding groove at the position corresponding to the ring-shaped bogie wheel detection boss.

[0026] Preferably, the sensor assembly further comprises a mounting plate and a locking nut.

[0027] The sensor mounting hole is a stepped hole, including two sections, corresponding to the first and second mounting hole sections; the threading hole is in communication with the first and second mounting hole sections, and the hole diameter of the first mounting hole section is smaller than that of the second mounting hole section;

[0028] The mounting plate is arranged on the stepped surface between the first and second mounting hole sections, the contact type limit switch is arranged through the hole in the middle position of the mounting plate and locked by the locking nut, and the outer side of the mounting plate is provided with a hole stop ring.

[0029] The third technical purpose of the present application is to provide a copper bush wear real-time online detection method for a mining excavator support wheel device, which is realized based on the above-mentioned mining excavator support wheel device with the shaft bush wear real-time online detection function, and includes the following steps:

[0030] Step one, assemble the support wheel device:

[0031] The assembly of the support wheel device on the track frame is completed, and specifically includes the following steps:

[0032] Step 1.1, two shaft bushes are respectively assembled from both ends of the support wheel;

[0033] Step 1.2, install the sensor assembly on the support wheel shaft, specifically including the following steps:

[0034] Step 1.2.1, the cable of the inductive distance sensor is inserted into the sensor mounting hole and then pulled out from the threading hole to expose the end surface of the support wheel shaft;

[0035] Step 1.2.2, the sensor assembly is placed in the sensor mounting hole, and the sensor assembly is formed by rotating the inductive distance sensor through two locking nuts and a mounting plate;

[0036] Step 1.2.3, adjust the exposed height of the inductive distance sensor, which requires:

[0037] 1) The detection head end of the inductive distance sensor exposes the groove bottom surface of the annular groove provided on the support wheel shaft;

[0038] 2) The detection head end of the inductive distance sensor is lower than the surface of the support wheel shaft body;

[0039] Step 1.2.4, after the sensor assembly is taken out, the two locking nuts are tightened;

[0040] Step 1.2.5, the sensor assembly is placed in the sensor mounting hole, and the mounting plate is fixed on the support wheel shaft by using the hole stop ring;

[0041] Step 1.3, assemble the support wheel to the support wheel shaft;

[0042] Step 1.4, the assembly of the supporting wheel shaft on the track frame is completed, and the assembly of the supporting wheel device on the track frame is completed;

[0043] Step two, the distance D0 at the initial moment relative to the supporting wheel annular boss is measured by the inductive distance sensor;

[0044] Step three, during the operation of the mining excavator, the distance value relative to the supporting wheel annular boss is measured in real time by the inductive distance sensor, and is recorded as D t , and the shaft sleeve wear amount is calculated by the following formula:

[0045] W t = |D t -D0|;

[0046] In the formula, D0 represents the data detected by the inductive distance sensor for the first time after the new shaft sleeve is installed; D t represents the distance detected by the inductive distance sensor relative to the supporting wheel annular boss at any time t, and W t represents the shaft sleeve wear amount at time t.

[0047] Step four, the shaft sleeve wear amount W t is compared with the size of the preset wear threshold W max , if the shaft sleeve wear amount W t exceeds the preset wear threshold W max , an alarm signal of "supporting wheel shaft sleeve wear exceeds the limit" is sent, and the on-site maintenance personnel immediately stop and repair according to the alarm information.

[0048] The fourth technical purpose of the present application is to provide a copper sleeve wear real-time online detection method for a supporting wheel device of a mining excavator, which is realized based on the above-mentioned supporting wheel device of the mining excavator with the shaft sleeve wear real-time online detection function, and includes the following steps:

[0049] Step one, assembling the supporting wheel device:

[0050] The assembly of the supporting wheel device on the track frame is completed, and specifically includes the following steps:

[0051] Step 1.1, two shaft sleeves are respectively assembled from both ends of the supporting wheel;

[0052] Step 1.2, installing a sensor assembly on the supporting wheel shaft, specifically including the following steps:

[0053] Step 1.2.1, the cable of the contact type limit switch is inserted into the sensor installation hole and then inserted out of the threading hole to expose the end surface of the supporting wheel shaft;

[0054] Step 1.2.2, the sensor assembly is put into the sensor mounting hole as a whole, and the sensor assembly is screwed on the contact limit switch through two locking nuts and the mounting plate to form;

[0055] Step 1.2.3, adjust the exposed height of the contact limit switch, as follows:

[0056] 1) The contact of the contact limit switch is exposed above the groove bottom surface of the annular embedding groove provided on the support wheel shaft;

[0057] 2) The contact of the contact limit switch is below the surface of the support wheel shaft body;

[0058] Step 1.2.4, after the sensor assembly is taken out as a whole, the two locking nuts are tightened;

[0059] Step 1.2.5, the sensor assembly is put into the sensor mounting hole as a whole, and the mounting plate is fixed on the support wheel shaft by using the hole stop ring;

[0060] Step 1.3, assemble the support wheel to the support wheel shaft;

[0061] Step 1.4, assemble the support wheel shaft to the track frame, and the assembly of the support wheel device on the track frame is completed;

[0062] Step 2, after the initial installation is completed, the output of the contact limit switch is high level output;

[0063] Step 3, as the shaft sleeve wears out, the distance between the contact of the contact limit switch and the annular boss of the support wheel gradually decreases, until the contact of the contact limit switch contacts the annular boss of the support wheel, triggering the output of the contact limit switch to be low level output;

[0064] Step 4, the control device sends an alarm signal of "support wheel shaft sleeve wear exceeds limit", and the on-site maintenance personnel immediately stop and repair according to the alarm information.

[0065] Based on the above technical purpose, compared with the prior art, the present application has the following advantages:

[0066] 1. The copper sleeve wear detection method of the mine excavator support wheel proposed in the present application is a real-time online detection method, which solves the problem that the wear state of the mine excavator support wheel cannot be detected during work, and avoids the major equipment loss caused by the direct contact and wear between the support wheel shaft and the support wheel due to excessive wear of the copper sleeve.

[0067] 2. In the present application, the wear detection sensor is installed on the relatively static support wheel shaft, fully considering the dynamic rotation of the copper sleeve during work and the uneven wall thickness wear, and the maximum wear value of the copper sleeve in the circumferential direction can be detected in real time.

[0068] 3. In the application, by adding an annular groove on the outer surface of the support wheel shaft, the installation height of the detection sensor on the support wheel shaft is ensured to be lower than the outer surface of the shaft, avoiding the sensor from being damaged by collision during the disassembly and assembly of the support wheel shaft.

[0069] 4. In the application, by adding an annular boss on the inner surface of the support wheel shaft hole, on the one hand, the requirement for the sensor detection distance is reduced, and the procurement cost of the sensor is reduced; on the other hand, in the application example of the limit switch, the height of the annular boss determines the maximum wear limit value of the copper sleeve. BRIEF DESCRIPTION OF DRAWINGS

[0070] Figure 1 is a structural schematic diagram of the mine excavator support wheel device (assembled to the track frame) with the shaft sleeve wear real-time online detection function described in embodiment 1 of the application;

[0071] Figure 2 is a partial enlarged schematic diagram of the sensor assembly installation position in Figure 1 ;

[0072] Figure 3 is a structural schematic diagram of the mine excavator support wheel device with the shaft sleeve wear real-time online detection function described in embodiment 1 of the application;

[0073] Figure 4 is a partial enlarged schematic diagram of the sensor assembly installation position in Figure 3 ;

[0074] Figure 5 is a structural schematic diagram of the mine excavator support wheel device with the shaft sleeve wear real-time online detection function described in embodiment 2 of the application;

[0075] Figure 6 is a partial enlarged schematic diagram of the sensor assembly installation position in Figure 5 ;

[0076] Figure 7 is a flowchart of the copper sleeve wear real-time online detection method of the mine excavator support wheel device described in embodiment 3 of the application;

[0077] Figure 8 is a flowchart of the copper sleeve wear real-time online detection method of the mine excavator support wheel device described in embodiment 4 of the application;

[0078] In the figure: 1, sealing element; 2, support wheel; 3, shaft sleeve; 4, gasket; 5, support wheel shaft; 6, retaining ring; 7, track frame; 8, retaining pin; 9, split pin; 10, sensor cable; 11, threading hole; 12, contact limit switch; 13, sensor mounting hole; 14, support wheel detection boss; 15, oil storage groove; 16, lubricating oil hole; 17, retaining pin hole; 18, inductive distance sensor; 19, mounting plate; 20, hole retaining ring; 21, locking nut. Detailed Implementation

[0079] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention. Unless otherwise specifically stated, the relative arrangement, expressions, and values ​​of components and steps set forth in these embodiments do not limit the scope of the present invention. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values.

[0080] For ease of description, spatial relative terms such as "above," "over," "on the upper surface of," "above," etc., are used here to describe the spatial positional relationship of a device or feature as shown in the figure with other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation besides the orientation of the device as described in the figure. For example, if the device in the figure is inverted, a device described as "above" or "above" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations).

[0081] Example 1

[0082] like Figures 1-3 As shown, the mining excavator track roller device with real-time online detection function for bushing wear according to the present invention includes a track roller, a track roller shaft, two bushings, a sensor assembly, and a control device. The track roller is sleeved on the outside of the track roller shaft, and the two bushings are inserted into the shaft holes of the track roller from both sides; both bushings are copper bushings, wherein:

[0083] The copper sleeve is installed in the center hole of the supporting wheel, the supporting wheel shaft is installed at the center of the copper sleeve and is in rolling cooperation with the copper sleeve, a gasket is arranged at each end of the supporting wheel to avoid direct contact and wear between the supporting wheel and the body of the track frame, the supporting wheel and the gasket are cooperatively provided with a sealing cavity, the sealing cavity is installed at the cavity body and cooperates with the surface of the track frame to form a sealing effect, so that foreign matters such as dust and sand outside are prevented from entering and polluting the lubricating grease, the retaining ring is welded to the outside of the track frame, and an oil injection hole and a retaining pin hole are arranged on the retaining ring, the retaining pin is provided with pin holes at both ends and passes through the retaining ring and the supporting wheel shaft to play the functions of axial positioning and anti-rotation of the supporting wheel shaft, so that the supporting wheel shaft and the track frame are kept stationary, and the open pin passes through the pin holes at both ends of the retaining pin to play the function of fixing the retaining pin and prevent the retaining pin from falling off.

[0084] The structural characteristics of each part are as follows:

[0085] The supporting wheel is provided with a stopper at both ends and cooperates with the copper sleeve, the gasket and the sealing to form a circular arc surface for contacting the track plate.

[0086] The supporting wheel shaft is a stepped shaft, one end of which is provided with a retaining pin hole and has a slightly larger diameter, the shaft is provided with a lubricating oil hole and an oil storage groove, and a threading hole for laying a sensor cable is arranged at the center of the shaft, the threading hole is not communicated with the lubricating oil hole to avoid damage of the lubricating grease to the cable and pollution of foreign matters to the lubricating grease, the shaft is further provided with a sensor mounting hole for mounting a sensor assembly and an annular groove is arranged around the center of the sensor, and the sensor mounting hole is communicated with the threading hole.

[0087] The copper sleeve has a T-shaped structure, one end of which is provided with a stepped stopper and cooperates with the stopper of the supporting wheel to form an oil storage and detection space between the two copper sleeves at the center of the supporting wheel after assembly.

[0088] Specifically, the shaft hole of the supporting wheel is outwardly protruded to form a ring-shaped supporting wheel detection boss at the middle position, the L-shaped hole is arranged in the supporting wheel shaft, the L-shaped hole includes a threading hole and a sensor mounting hole, the threading hole is arranged along the axial direction of the supporting wheel shaft, and in the drawings, the threading hole is arranged along the axial extension direction of the supporting wheel shaft, while the sensor mounting hole is arranged along the radial direction of the supporting wheel shaft, and in the drawings, the sensor mounting hole is arranged on the lower half shaft of the supporting wheel shaft, the purpose is that based on engineering practice, such a sensor arrangement can better realize the monitoring of the wear degree of the shaft sleeve, one end of the threading hole is arranged through the shaft end of the supporting wheel shaft, and the other end is communicated with one end of the sensor mounting hole, and the other end of the sensor mounting hole is arranged through the surface of the shaft body of the supporting wheel shaft. In addition, the L-shaped hole is arranged in the supporting wheel shaft to mount the sensor assembly, which is more conducive to the development of engineering practice.

[0089] The sensor assembly comprises a contact limit switch, a mounting plate and a locking nut; the contact limit switch is installed in the sensor mounting hole, and the contact of the contact limit switch is opposite to the annular bolster detection boss; the contact limit switch is connected with the control device through a signal transmission line, and is provided with two outputs corresponding to high level output and low level output; when the output of the contact limit switch is low level output, it indicates that the annular bolster detection boss triggers the contact of the contact limit switch or the contact limit switch fails, otherwise, the output of the contact limit switch is high level output. The signal transmission line is arranged along the threading hole. The sensor mounting hole is a stepped hole comprising two sections corresponding to the first and second mounting hole sections; the threading hole is communicated with the first and second mounting hole sections, and the aperture of the first mounting hole section is smaller than that of the second mounting hole section; the mounting plate is placed on the stepped surface between the first and second mounting hole sections, the contact limit switch is placed through the hole in the middle position of the mounting plate and is locked by the locking nut, and the outer side of the mounting plate is provided with a hole stop ring.

[0090] The control device outputs corresponding control signals according to the information transmitted by the contact limit switch; when the information transmitted by the contact limit switch received by the control device is high level output, the control device outputs a first control signal to control the normal operation of the mining excavator; when the information transmitted by the contact limit switch received by the control device is low level output, the control device outputs a second control signal to control the mining excavator to stop for maintenance.

[0091] Embodiment 2

[0092] As shown in Figures 4-5 , the difference between this embodiment and embodiment 1 is only that the sensor used in the sensor assembly is a contact limit switch, so that a different control mode is configured, and the same parts are not described again. Specifically:

[0093] In the embodiment, the sensor assembly comprises an electric distance sensor, a mounting plate, a locking nut and a hole stop ring. The electric distance sensor is mounted in the sensor mounting hole, and the detection head of the electric distance sensor is opposite to the annular bolster detection boss; the electric distance sensor detects the distance information relative to the annular bolster detection boss through the detection head, and can transmit the detected distance information to the control device through the signal transmission line according to the data detection period; the signal transmission line is arranged along the threading hole; the sensor mounting hole is a stepped hole comprising two sections, i.e., the first and second mounting hole sections; the threading hole is in communication with the first and second mounting hole sections, and the hole diameter of the first mounting hole section is smaller than that of the second mounting hole section; the mounting plate is arranged on the stepped surface between the first and second mounting hole sections, the electric distance sensor is placed through the hole in the middle position of the mounting plate and is locked by the locking nut, and the hole stop ring is arranged on the outer side of the mounting plate to axially limit the mounting plate. The mounting plate is provided with a threaded hole matched with the external thread of the electric distance sensor, so as to facilitate the adjustment of the exposed height of the electric distance sensor on the mounting plate; the bolster shaft is provided with a cooperating groove of the hole stop ring at the appropriate position of the mounting plate positioning hole (i.e., the second mounting hole section).

[0094] The control device calculates the shaft sleeve wear amount according to the distance information fed back by the electric distance sensor according to the data detection period, and then judges whether the calculated shaft sleeve wear amount is within the preset wear amount threshold range; when the judgment result shows that the shaft sleeve wear amount exceeds the preset wear amount threshold range, the machine is stopped for maintenance.

[0095] Specifically, the control device comprises a calculation module, a judgment module and an execution module.

[0096] The calculation module is used to calculate the shaft sleeve wear amount, and the calculation formula is:

[0097] W t = |D t -D0|;

[0098] In the formula, D0 represents the data detected by the electric distance sensor for the first time after the new shaft sleeve is installed; D t represents the distance detected by the electric distance sensor relative to the annular bolster boss at any time t, and W t represents the shaft sleeve wear amount at time t.

[0099] The judgment module is used to judge whether the shaft sleeve wear amount exceeds the preset wear amount threshold, and when the judgment result shows that |W t -W max |≤ΔW, it indicates that the shaft sleeve wear amount W t exceeds the preset wear amount threshold W maxThe allowable range ΔW of the weight of the driver is compared with the allowable range ΔW of the weight of the driver, a trigger execution module is triggered, an execution command is issued, and the mining excavator is controlled to stop for maintenance.

[0100] The mounting step of the sensor assembly on the carrier wheel shaft is as follows:

[0101] Step 1: After the cable of the inductive distance sensor is threaded into the sensor mounting hole from the threading hole, the cable is threaded out to expose the shaft end face.

[0102] Step 2: Two locking nuts and a mounting plate are screwed onto the inductive distance sensor, and after the sensor assembly is assembled, the whole is placed into the sensor mounting hole.

[0103] Step 3: The exposed height of the inductive distance sensor on the mounting plate is adjusted, and the requirements are as follows:

[0104] 1) The highest point of the inductive distance sensor is higher than the surface of the annular groove of the carrier wheel shaft; in this way, it can be ensured that the inductive distance sensor will not be damaged by colliding with the inner surface of the copper sleeve during the process of threading the copper sleeve after the sensor assembly is mounted and fixed on the carrier wheel shaft.

[0105] 2) The highest point of the inductive distance sensor is lower than the surface of the carrier wheel shaft (the mating surface of the inner hole of the copper sleeve); in this way, it can be ensured that the carrier wheel boss will not be directly contacted and worn by the surface of the carrier wheel shaft under the premise that the sensor detects the distance between the carrier wheel boss.

[0106] Step 4: After the sensor assembly is taken out as a whole, the two locking nuts are tightened.

[0107] Step 5: The sensor assembly is placed into the carrier wheel shaft mounting hole as a whole, and the mounting plate is fixed on the carrier wheel shaft by using a hole stop ring.

[0108] In addition, considering the working characteristics of the carrier wheel device of the mining excavator: when the mining excavator is normally loaded for operation, the running system is in a locked state, and the shaft sleeve (copper sleeve) and the carrier wheel shaft are in a relatively static state; when the mining excavator needs to move to a position, the running system works, and the carrier wheel copper sleeve and the carrier wheel shaft are in a relatively rotating and sliding state; especially when the working surface is replaced for a long distance, the carrier wheel copper sleeve will be worn to varying degrees.

[0109] According to such working characteristics, the carrier wheel copper sleeve wear detection system is associated with the running speed of the excavator, and is set to two modes of loading operation mode and running mode.

[0110] I. Loading operation mode

[0111] Function: Real-time detection of whether the carrier wheel copper sleeve will be worn under impact and vibration during the excavating operation;

[0112] Data acquisition of the inductive distance sensor: When the excavator is in loading operation, the data acquisition of the inductive distance sensor is in intermittent acquisition mode, for example, the acquisition cycle is set to once per minute.

[0113] Data processing: Processing is performed through the first calculation module and the first judgment module. That is:

[0114] The first calculation module is used to calculate the wear amount of the bushing, and the calculation formula is as follows: This represents the data fed back by the inductive distance sensor. D0 represents the data initially detected by the inductive distance sensor after the new bushing is installed, which is a preset constant.

[0115] The first judgment module is used to judge the amount of bushing wear. Whether the wear exceeds the preset threshold, when the judgment result is... When, it indicates the amount of wear on the bushing. Exceeding the preset wear threshold W max Within the allowed range ΔW, the execution module is triggered to issue an execution command, controlling the mining excavator to stop for maintenance.

[0116] II. Walking Mode

[0117] Used for comprehensive detection of wear on the entire circumference of the support roller's copper bushing under rotating and sliding conditions.

[0118] Data acquisition of the inductive distance sensor: When the mining excavator is in the walking state, the data acquisition of the inductive distance sensor is in a high-frequency continuous acquisition mode; for example, the data acquisition cycle is set to 300 times per minute.

[0119] Data processing:

[0120] (1) Convert the collected data into bushing wear amount, and the calculation formula is: W t =|D t -D0|;

[0121] D0 represents the initial data detected by the inductive distance sensor after the new bushing is installed, which is a preset constant.

[0122] As the copper bushing slides periodically, in order to ensure that the calculated bushing wear amount W... t The numerical values ​​are simple and accurate, and the average bushing wear value can be obtained using the following algorithm. Replace the data D fed back by the inductive distance sensor in the above formula. t The advantage of doing this is that it avoids the computational complexity caused by high-frequency data acquisition and greatly reduces the frequency of real-time data calculation and monitoring.

[0123] Calculated value of average bushing wear The specific calculation is obtained through the following steps:

[0124] (1.1) Calculate the sliding period of the copper bushing in the circumferential direction based on the traveling speed of the mining excavator:

[0125] T t = 3.14 * d / V;

[0126] In the formula: T t d is the sliding period of the bushing in the circumferential direction; d is the diameter of the support roller; V is the travel speed of the excavator.

[0127] (1.2) Collected in the previous sliding period T j The data collected by the inductive ranging sensor inside is used to construct a dataset L. j ;

[0128] (1.3) The collected dataset L j After sorting the elements in the dataset in ascending order, a one-to-one correspondence is constructed to form the dataset L. j ′ L j ′ ={l 1j ,l 2j ,…l ij …l pj};

[0129] (1.4) Remove dataset L j ′ 5% of the elements at the beginning and end ij , and the remaining element l ij Construct a dataset A, A = {a1, a2, ..., a3} k …a q};

[0130] (1.5) Based on each element a in dataset A k Calculate the time after the previous sliding period T t Calculated value of average bushing wear

[0131]

[0132] The calculated average bushing wear value Replacement formula W t =|D t Data D in -D0| t This allows us to calculate the time elapsed after the previous sliding period T. j Wear on the rear axle bushing.

[0133] Example 3

[0134] like Figure 7As shown, the embodiment provides a real-time online detection method for copper bush wear of a mine excavator support wheel device, which is realized based on the mine excavator support wheel device with the real-time online detection function of shaft bush wear in embodiment 2, and includes the following steps:

[0135] Step one, assemble the support wheel device:

[0136] The assembly of the support wheel device on the track frame includes the following steps:

[0137] Step 1.1, install two shaft bushes from both ends of the support wheel respectively;

[0138] Step 1.2, install the sensor assembly on the support wheel shaft, which includes the following steps:

[0139] Step 1.2.1, pass the cable of the inductive distance sensor from the sensor installation hole and then pass it out from the threading hole to expose the end surface of the support wheel shaft;

[0140] Step 1.2.2, place the sensor assembly into the sensor installation hole, and the sensor assembly is formed by screwing the two locking nuts and the mounting plate on the inductive distance sensor;

[0141] Step 1.2.3, adjust the exposed height of the inductive distance sensor, which requires:

[0142] 1) The detection head end of the inductive distance sensor exposes the groove bottom surface of the annular groove provided on the support wheel shaft;

[0143] 2) The detection head end of the inductive distance sensor is lower than the surface of the support wheel shaft body;

[0144] Step 1.2.4, take out the sensor assembly as a whole, and tighten the two locking nuts;

[0145] Step 1.2.5, place the sensor assembly into the sensor installation hole, and use the hole stop ring to fix the mounting plate on the support wheel shaft;

[0146] Step 1.3, assemble the support wheel to the support wheel shaft;

[0147] Step 1.4, assemble the support wheel shaft to the track frame, and the assembly of the support wheel device on the track frame is completed;

[0148] Step two, measure the distance D0 relative to the annular boss of the support wheel at the initial time by the inductive distance sensor;

[0149] Step three, during the operation of the mine excavator, the distance value relative to the annular boss of the support wheel is measured in real time by the inductive distance sensor, denoted as D t , and the shaft bush wear amount is calculated by the following formula:

[0150] W t = |D t - D0|;

[0151] In the formula, D0 represents the data detected by the inductive distance sensor for the first time after the new bushing is installed; D t represents the distance detected by the inductive distance sensor at any time t relative to the annular boss of the wheel; W t represents the bushing wear amount at time t;

[0152] Step four, compare the bushing wear amount W t with the size of the preset wear threshold W max , if the bushing wear amount W t exceeds the preset wear threshold W max , an alarm signal of "wheel bushing wear exceeds limit" is sent, and the on-site maintenance personnel immediately stop and overhaul according to the alarm information.

[0153] Example 4

[0154] As shown in Figure 8 , the embodiment provides a real-time online detection method for copper bush wear of a mine excavator wheel device, which is realized based on the mine excavator wheel device with real-time online detection function of bush wear in Example 1, and includes the following steps:

[0155] Step one, assemble the wheel device:

[0156] Assemble the wheel device on the track frame, which includes the following steps:

[0157] Step 1.1, respectively install two bushings from both ends of the wheel;

[0158] Step 1.2, install the sensor assembly on the wheel shaft, which includes the following steps:

[0159] Step 1.2.1, pass the cable of the contact limit switch from the sensor installation hole into the hole, and then pass it out to the end surface of the wheel shaft;

[0160] Step 1.2.2, put the sensor assembly into the sensor installation hole, and the sensor assembly is formed by rotating the contact limit switch through two locking nuts and an installation plate;

[0161] Step 1.2.3, adjust the exposed height of the contact limit switch, which requires:

[0162] 1) The contact of the contact limit switch is exposed to the bottom surface of the annular groove provided on the wheel shaft;

[0163] 2) The contacts of the contact-type limit switch are lower than the surface of the support wheel shaft;

[0164] Step 1.2.4: After removing the sensor assembly as a whole, tighten the two locking nuts;

[0165] Step 1.2.5: Place the entire sensor assembly into the sensor mounting hole, and use the retaining ring to fix the mounting plate to the support shaft;

[0166] Step 1.3: Assemble the support rollers onto the support roller shaft;

[0167] Step 1.4: Assemble the track roller axle onto the track frame to complete the assembly of the track roller device onto the track frame;

[0168] Step 2: After the initial installation is completed, the output of the contact limit switch is a high-level output;

[0169] Step 3: As the bushing wears down, the distance between the contact of the limit switch and the annular boss of the support roller gradually decreases until the contact of the limit switch comes into contact with the annular boss of the support roller, triggering the output of the limit switch to a low level.

[0170] Step 4: The control device issues an alarm signal that the support roller bushing is worn beyond the limit. On-site maintenance personnel should immediately stop the machine for inspection and repair based on the alarm information.

[0171] Therefore, this invention solves the problem that the wear condition of the copper bushings of existing excavator support rollers is unknown during use, which can easily lead to unpredictable equipment failures and damages. It improves the intelligence level and operating efficiency of mining excavators, reduces equipment operation and maintenance costs, and reduces the workload of on-site maintenance personnel.

Claims

1. A method for real-time online detection of bushing wear of a mine excavator road wheel device, based on a mine excavator road wheel device with real-time online detection of bushing wear, characterized in that, The mine excavator bogie device with the shaft sleeve wear real-time online detection function comprises a bogie wheel, a bogie shaft, two shaft sleeves, a sensor assembly and a control device, the bogie wheel is sleeved on the bogie shaft, and the two shaft sleeves are installed in the shaft holes of the bogie wheel from both sides of the bogie wheel. The shaft hole of the bogie wheel is outwardly convex at the middle position to form a ring-shaped bogie wheel detection boss, an L-shaped hole is formed in the bogie shaft, the L-shaped hole comprises a threading hole and a sensor mounting hole, the threading hole is arranged along the axial direction of the bogie shaft, the sensor mounting hole is arranged along the radial direction of the bogie shaft, one end of the threading hole is arranged through the shaft end of the bogie shaft, the other end of the threading hole is communicated with one end of the sensor mounting hole, and the other end of the sensor mounting hole is arranged through the shaft body surface of the bogie shaft; The sensor assembly comprises an inductive distance sensor, the inductive distance sensor is installed in the sensor mounting hole, and the detection head of the inductive distance sensor is opposite to the ring-shaped bogie wheel detection boss; the inductive distance sensor detects the distance information relative to the ring-shaped bogie wheel detection boss through the detection head, and can transmit the detected distance information to the control device through the signal transmission line according to the data detection period; the signal transmission line is arranged along the threading hole; The control device calculates the shaft sleeve wear amount according to the distance information fed back by the inductive distance sensor according to the data detection period, and then judges whether the calculated shaft sleeve wear amount is within the preset wear amount threshold range; when the judgment result shows that the shaft sleeve wear amount exceeds the preset wear amount threshold range, the machine is stopped for maintenance; The surface of the bogie shaft is provided with an annular embedding groove at the position corresponding to the ring-shaped bogie wheel detection boss; The shaft sleeve wear real-time online detection method comprises the following steps: Step one, assemble the bogie device: Assemble the bogie device on the track frame, which comprises the following steps: Step 1.1, install the two shaft sleeves from both ends of the bogie wheel respectively; Step 1.2, install the sensor assembly on the bogie shaft, which comprises the following steps: Step 1.2.1, pass the cable of the inductive distance sensor into the sensor mounting hole, and then pass it out from the threading hole to expose the end surface of the bogie shaft; Step 1.2.2, put the sensor assembly into the sensor mounting hole, and form the sensor assembly by rotating the inductive distance sensor through the two locking nuts and the mounting plate; Step 1.2.3, adjust the exposed height of the inductive distance sensor, which requires: 1) the detection head end point of the inductive distance sensor exposes the groove bottom surface of the annular embedding groove provided on the bogie shaft; 2) the detection head end point of the inductive distance sensor is lower than the shaft body surface of the bogie shaft; Step 1.2.4, take out the sensor assembly as a whole, and tighten the two locking nuts; Step 1.2.5, put the sensor assembly into the sensor mounting hole, and fix the mounting plate on the bogie shaft by using the hole stop ring; Step 1.3, assemble the bogie wheel to the bogie shaft; Step 1.4, assemble the bogie shaft to the track frame, and complete the assembly of the bogie device on the track frame. Step two, measure the distance at the initial time from the load wheel ring boss by inductive distance sensor ; Step three, in the process of mining excavator operation, the distance value relative to the annular boss of the supporting wheel is measured in real time by inductive distance sensor, recorded as And the shaft sleeve wear is calculated by the following formula: ； In the formula, represents the data detected by the inductive distance sensor for the first time after the new bushing is installed; represents the distance detected by the inductive distance sensor at any time t relative to the annular boss of the wheel, represents the bushing wear at time t; Step four, compare the shaft sleeve wear amount with the preset wear amount threshold value , if the shaft sleeve wear amount exceeds the preset wear amount threshold value , an alarm signal of "the shaft sleeve wear of the wheel axle exceeds the limit" is sent, and the on-site maintenance personnel immediately stop the machine for maintenance according to the alarm information.

2. A method for real-time online detection of axle sleeve wear of a mine excavator road wheel device, based on a mine excavator road wheel device with real-time online detection function of axle sleeve wear, characterized in that, The mine excavator supporting wheel device with the shaft sleeve wear real-time online detection function comprises a supporting wheel, a supporting wheel shaft, two shaft sleeves, a sensor assembly and a control device, the supporting wheel is sleeved on the supporting wheel shaft, and the two shaft sleeves are respectively arranged in the shaft holes of the supporting wheel from both sides of the supporting wheel; The shaft hole of the supporting wheel is outwardly convex at the middle position to form a ring-shaped supporting wheel detection boss; the L-shaped hole is arranged on the supporting wheel shaft; the L-shaped hole comprises a threading hole and a sensor mounting hole, the threading hole is arranged along the axial direction of the supporting wheel shaft, and the sensor mounting hole is arranged along the radial direction of the supporting wheel shaft; one end of the threading hole is arranged through the shaft end of the supporting wheel shaft, and the other end is communicated with one end of the sensor mounting hole; the other end of the sensor mounting hole is arranged through the shaft body surface of the supporting wheel shaft; The sensor assembly comprises a contact limit switch; the contact limit switch is arranged in the sensor mounting hole, and the contact of the contact limit switch is opposite to the ring-shaped supporting wheel detection boss; the contact limit switch is connected with the control device through a signal transmission line, and is provided with two outputs, the two outputs correspond to a high-level output and a low-level output; when the output of the contact limit switch is the low-level output, it indicates that the ring-shaped supporting wheel detection boss triggers the contact of the contact limit switch or the contact limit switch fails; otherwise, the output of the contact limit switch is the high-level output; The signal transmission line is arranged along the threading hole; The control device outputs corresponding control signals according to the information transmitted by the contact limit switch; when the information transmitted by the contact limit switch received by the control device is the high-level output, the control device outputs the first control signal to control the mine excavator to work normally; when the information transmitted by the contact limit switch received by the control device is the low-level output, the control device outputs the second control signal to control the mine excavator to stop working for maintenance; The shaft sleeve wear real-time online detection method comprises the following steps: Step one, assemble the supporting wheel device: Assemble the supporting wheel device on the track frame, which comprises the following steps: Step 1.1, respectively assemble the two shaft sleeves from both ends of the supporting wheel; Step 1.2, install the sensor assembly on the supporting wheel shaft, which comprises the following steps: Step 1.2.1, pass the cable of the contact limit switch into the sensor mounting hole, and then pass it out from the threading hole to expose the end surface of the supporting wheel shaft; Step 1.2.2, put the sensor assembly into the sensor mounting hole as a whole, and form the sensor assembly by rotating the two locking nuts and the mounting plate on the contact limit switch; Step 1.2.3, adjust the exposed height of the contact limit switch, which requires: 1) the contact of the contact limit switch exposes the bottom surface of the ring-shaped groove provided on the supporting wheel shaft; 2) the contact of the contact limit switch is lower than the shaft body surface of the supporting wheel shaft; Step 1.2.4, take out the sensor assembly as a whole, and tighten the two locking nuts; Step 1.2.5, put the sensor assembly into the sensor mounting hole as a whole, and fix the mounting plate on the supporting wheel shaft by using the hole stop ring; Step 1.3, assemble the supporting wheel on the supporting wheel shaft; Step 1.4, the assembly of the supporting wheel shaft to the track frame is completed, and the assembly of the supporting wheel device to the track frame is completed; Step 2, after the initial installation is completed, the output of the contact limit switch is high level output; Step 3, as the shaft sleeve wears, the distance between the contact of the contact limit switch and the annular boss of the supporting wheel gradually decreases until the contact of the contact limit switch and the annular boss of the supporting wheel are in contact, triggering the output of the contact limit switch to be low level output; Step 4, the control device sends an alarm signal of "supporting wheel shaft sleeve wear limit", and the on-site maintenance personnel immediately stop and overhaul according to the alarm information.

3. The method for real-time online detection of the bushing wear of the mine excavator road wheel device according to claim 2, characterized in that, The surface of the supporting wheel shaft is provided with an annular embedding groove at a position corresponding to the annular supporting wheel detection boss.

4. The method for real-time online detection of the bushing wear of the mine excavator road wheel device according to claim 2, characterized in that, The sensor assembly further comprises a mounting plate and a locking nut. The sensor mounting hole is a stepped hole comprising two sections, corresponding to the first and second mounting hole sections; the threading hole is in communication with the first and second mounting hole sections, and the aperture of the first mounting hole section is smaller than that of the second mounting hole section. The mounting plate is placed on the stepped surface between the first and second mounting hole sections, the contact limit switch passes through the hole in the middle position of the mounting plate and is locked by the locking nut, and a hole stop ring is arranged on the outer side of the mounting plate.

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