Dynamic wear monitoring and early warning device and method for support and guide system of coal mining machine

Abstract

The application discloses a kind of dynamic wear monitoring and early warning device and method of coal winning machine support guiding system, which uses several sensors (dynamic wear monitoring device) arranged dispersedly to dynamically monitor the wear condition of key parts of coal winning machine support guiding system, makes full use of the different position structures of guiding shoe and smooth shoe, creates reasonable space by segmentation, optimizes sensor configuration point, and implements effective protection.In addition, the application also uses dynamic wear early warning device to centrally control the wear condition of key parts of coal winning machine support guiding system, which is beneficial to gather the four-point support of coal winning machine support guiding system, the different optimized sensor configuration points of structure dispersed guiding shoe and smooth shoe in the most shortcut, economical and reasonable way, and implement centralized control of each sensor configuration point, which is convenient to improve control accuracy, reduce measurement error and reduce cost.

Description

Technical Field

[0001] This invention relates to a dynamic wear monitoring and early warning device and method for a coal mining machine support and guidance system, which is applied to the coal mining machine support and guidance system and relates to the fields of coal mining machinery and automatic control. Background Technology

[0002] Currently, coal mining machines employ guide shoes and smooth shoes support mechanisms. During underground coal mining, the guide shoes on the goaf side support the guide groove, providing vertical, horizontal, and lateral support, guidance, and limiting on the conveyor pin row. They support the coal mining machine's own weight, guide and limit its movement, and also bear the traction reaction force generated by the torque transmitted by the sprocket and the lateral forces generated during the machine's operation. The smooth shoes on the coal face are supported on the conveyor shovel, supporting the coal mining machine's own weight and also bearing part of the cutting reaction force generated by the coal cutting drum and the frictional resistance generated during the machine's operation.

[0003] The clearance G between the guide shoe and the conveyor pin row (vertical Y = 8~10mm and horizontal X = 5~6mm) should be able to ensure that the coal mining machine can pass smoothly when the vertical undulation of the conveyor is ±3° and the horizontal bending is ±1°. When the clearance G is reasonable, it ensures that the coal mining machine sprocket and the conveyor pin row mesh normally, the force is reasonable, and the operation is stable. When the clearance G is too large, the guide slipper cannot properly support, guide, and limit the movement. The sprocket of the coal mining machine and the pin row of the conveyor may not mesh properly, and the sprocket teeth may even be subjected to lateral forces on both sides, causing rapid pitting, sharp wear, or even tooth breakage. At the same time, it will cause large impact vibration noise, and sometimes the coal mining machine will experience slipper derailment. When the clearance G is too small, the guide slipper cannot properly adapt to the vertical undulation ±3° and horizontal bending ±1° of the conveyor. There will be rigid impact, jamming, and interference with the pin row of the conveyor. The support, guidance, and limiting functions will be abnormal, and sometimes accidents such as the guide slipper support lug tearing, guide groove breakage, and guide groove short baffle breaking will occur. Losing the normal support, guidance, and limiting functions of the guide slipper will cause the sprocket teeth to be subjected to lateral forces on both sides, causing huge impact vibration noise, often causing frequent damage to the coal mining machine sprocket, affecting underground safe production.

[0004] Because the surface hardness and wear resistance of the conveyor pins are stronger than the support, guidance, and limiting surfaces of the mining machine guides and smooth shoes, and because the conveyor pins are arranged along the entire working surface, the contact wear area of ​​the conveyor pins participating in support, guidance, and limiting is much larger than that of the mining machine guide shoes and smooth shoes themselves. Therefore, the following analysis is based on the assumption that the wear of the conveyor pins has met the requirements for normal use, except in cases where the conveyor pins are severely worn and must be replaced.

[0005] Currently, the mainstream equipment and testing methods for detecting the mechanical wear of guide shoes and smooth shoes of coal mining machines, both domestically and internationally, are represented by the following two:

[0006] 1. Use a shoe-shaped caliper to check the wear of the horizontal surface of the guiding slide shoe and the smooth shoe; detect the wear of the vertical surface (both guiding and limiting surfaces on both sides) of the guiding groove of the guiding slide shoe, and detect it according to the wear tolerance range specified by the dimensions at each location; generally check once a week. The defects of this detection method are: pure mechanical measurement, with primitive and backward concepts; special measuring tools for slide shoes need to be customized, and most of the special measuring tools for different series and specifications of slide shoes are different, with poor versatility; the auxiliary workload is very large, time-consuming and laborious, with low efficiency, and the actual operability underground is not good; the operator has to stay at the work site for a long time, posing safety risks.

[0007] 2. Use a JXCLGJ special measuring tool to measure the clearance between the guiding slide shoe of the coal mining machine and the pin row, and thus calculate the wear of the guiding slide shoe. The defects of this detection method are: it is only a mechanical state detection, rather than real-time dynamic monitoring; pure manual measurement, with low efficiency, which is not conducive to safe production. Summary of the Invention

[0008] The purpose of the present invention is to provide a dynamic wear monitoring and warning device and method for the support and guiding system of a coal mining machine, so as to solve the problems that it is difficult to detect the mechanical wear of the support and guiding system underground in existing coal mining machines, it is not easy to operate, the concept is backward, the auxiliary workload is large, the efficiency is low, and there are safety risks.

[0009] To achieve the above technical purpose, the present invention will adopt the following technical solutions:

[0010] A dynamic wear monitoring and warning device for the support and guiding system of a coal mining machine is used to dynamically monitor the wear of the support and guiding system of the coal mining machine and give warnings; the support and guiding system of the coal mining machine includes a guiding slide shoe support mechanism and a smooth shoe support mechanism; the guiding slide shoe support mechanism includes a guiding slide shoe and a conveyor pin row supporting the guiding slide shoe; the smooth shoe support mechanism includes a smooth shoe and a transport scraper plate supporting the smooth shoe, and the guiding slide shoe and the smooth shoe are respectively arranged on the coal mining machine body; the dynamic wear monitoring and warning device includes a dynamic wear monitoring device and a dynamic wear warning device; among them:

[0011] The dynamic wear monitoring device includes a first and a second dynamic wear monitoring group;

[0012] The first dynamic wear monitoring group is installed on the smooth shoe and is used to monitor the wear amount A of the characteristic wear area of the bottom plane of the smooth shoe, and can transmit the monitored wear amount A to the dynamic wear warning device;

[0013] The second dynamic wear monitoring group is installed on the guiding slide shoe and is used to monitor the wear amount B of the characteristic wear area of the guiding slide shoe, and can transmit the monitored wear amount B to the dynamic wear warning device;

[0014] The dynamic wear warning device determines whether the wear of the smooth boot sole surface exceeds the limit based on the received wear amount A. If the determination result shows that the wear of the smooth boot sole surface exceeds the limit, the first warning prompt is output.

[0015] The dynamic wear warning device determines whether the wear of the guide shoe exceeds the limit based on the received wear amount B. If the determination result shows that the wear of the guide shoe exceeds the limit, a second warning prompt is output.

[0016] Preferably, the smooth boot sole plane has two feature points, each of which is located on the longitudinal center line of the double ears of the smooth boot, and the distance between each feature point and the adjacent end of the smooth boot sole plane is L / 8, where L is the distance between the two lateral ends of the smooth boot sole plane; the feature wear area of ​​the smooth boot sole plane is the area between the two feature points.

[0017] Preferably, the first dynamic wear monitoring group includes two sensors A, namely the first sensor A and the second sensor A; the first sensor A and the second sensor A are respectively installed at two feature points set on the smooth boot sole plane.

[0018] Preferably, the characteristic wear area of ​​the guide shoe includes the characteristic wear area of ​​the support upper surface that contacts the guide groove of the guide shoe and the upper surface of the conveyor pin row, as well as the characteristic wear area of ​​the left side of the guide limit and the characteristic wear area of ​​the right side of the guide limit that correspondingly contacts the left and right sides of the guide groove of the guide shoe and the conveyor pin row.

[0019] The second dynamic wear monitoring group includes sensor B, sensor C, and sensor D; wherein:

[0020] Sensor B is used to sense the wear amount of the characteristic wear area of ​​the support upper plane that contacts the guide shoe guide groove and the upper plane of the conveyor pin row, which is recorded as the first wear amount B1; and can transmit the sensed first wear amount B1 to the dynamic wear warning device.

[0021] Sensor C is used to sense the wear amount of the characteristic wear area on the left side of the guide limiter where the guide shoe guide groove and the conveyor pin row are in lateral contact, which is recorded as the second wear amount B2; and can transmit the sensed second wear amount B2 to the dynamic wear warning device.

[0022] Sensor D is used to sense the wear amount of the characteristic wear area on the right side of the guide limiter where the guide shoe guide groove and the conveyor pin row are in lateral contact, which is recorded as the third wear amount B3; and can transmit the sensed third wear amount B3 to the dynamic wear warning device.

[0023] The dynamic wear warning device determines whether the wear condition of the characteristic wear area of ​​the upper support surface of the guide shoe guide groove exceeds the limit based on the received first wear amount B1. If the determination result shows that the wear condition of the characteristic wear area of ​​the upper support surface of the guide shoe guide groove exceeds the limit, a second warning prompt is output.

[0024] The dynamic wear warning device determines whether the wear condition of the characteristic wear area on the left side of the guide limit of the guide shoe guide groove exceeds the limit based on the received second wear amount B2. If the determination result shows that the wear condition of the characteristic wear area on the left side of the guide limit of the guide shoe guide groove exceeds the limit, the device outputs a second warning prompt.

[0025] The dynamic wear warning device determines whether the wear condition of the characteristic wear area on the right side of the guide limit of the guide shoe guide groove exceeds the limit based on the received third wear amount B3. If the determination result shows that the wear condition of the characteristic wear area on the right side of the guide limit of the guide shoe guide groove exceeds the limit, a second warning prompt is output.

[0026] Preferably, the characteristic wear area of ​​the upper support surface is a strip area with a thickness of B±(δ1+δ2) near the geometric center point of the four force-bearing surfaces formed when the upper support surface contacts the pin row of the conveyor; where: B is the length of the short side of the quadrilateral formed by the geometric center point of the four force-bearing surfaces, δ1 is the design clearance setting value that meets the requirements, and δ2 is the maximum wear amount of the left / right side of the guide limit.

[0027] The sensor B includes two sensors, namely the first sensor and the second sensor B; the first sensor B and the second sensor B are respectively installed at the locations of two feature points set on the upper plane of the support; the two feature points set on the upper plane of the support are two of the geometric center points of the four force-bearing facets that are diagonally distributed.

[0028] Preferably, the characteristic wear area on the left side of the guide limit is a strip area containing two characteristic points set on the left side of the guide limit, with the horizontal left-side characteristic line floating upward σ1 and downward σ2. σ1 is the maximum upward floating amount of the horizontal left-side characteristic line when the upper support plane of the guide shoe has the maximum wear; σ2 is the maximum downward floating amount of the horizontal left-side characteristic line caused by the guide shoe clearance deflection angle; the horizontal left-side characteristic line is the intersection line of the pitch circle of the coal mining machine sprocket, the horizontal plane of the conveyor pin row, and the left side of the guide limit.

[0029] The sensor C includes two sensors, namely the first sensor C and the second sensor C; the first sensor C and the second sensor C are respectively installed at the positions of the two feature points set on the left side of the guide limiter.

[0030] The two feature points set on the left side of the guiding and limiting member are the intersections of the horizontally leftward feature line and the geometric vertical centerlines of the two small force-bearing surfaces on the left side; the two small force-bearing surfaces on the left side are two discontinuous and separated small force-bearing surfaces formed by the contact between the left side of the guiding and limiting member and the left side of the conveyor pin row.

[0031] Preferably, the characteristic wear area on the right side of the guiding and limiting member is a strip area where the horizontally rightward feature line floats upward by σ3 and downward by σ4 and includes the two feature points set on the right side of the guiding and limiting member. σ3 is the maximum upward floating amount of the horizontally rightward feature line when the upper support plane of the guiding slider has the maximum wear amount; σ4 is the maximum downward floating amount of the horizontally rightward feature line caused by the clearance deflection angle of the guiding slider; the horizontally rightward feature line is the intersection line of the pitch circle of the coal mining machine sprocket, the horizontal plane of the conveyor pin row, and the right side of the guiding and limiting member.

[0032] There are two sensors D, namely the first and second sensors D; the first and second sensors D are respectively installed at the positions of the two feature points set on the right side of the guiding and limiting member.

[0033] The two feature points set on the right side of the guiding and limiting member are the intersections of the horizontally rightward feature line and the geometric vertical centerlines of the two small force-bearing surfaces on the right side; the two small force-bearing surfaces on the right side are two discontinuous and separated small force-bearing surfaces formed by the contact between the right side of the guiding and limiting member and the right side of the conveyor pin row.

[0034] Preferably, for the dynamic wear warning device, a first maximum wear amount Bmax1 is preset for the upper support plane, a second maximum wear amount Bmax2 is preset for the left side of the guiding and limiting member, and a third maximum wear amount Bmax3 is preset for the right side of the guiding and limiting member.

[0035] The dynamic wear warning device determines whether the wear condition of the upper support plane is over-limit by comparing whether the first wear amount B1 is within the allowable range of the first maximum wear amount Bmax1. If the judgment result shows that |B1 - Bmax1| < a1, it indicates that the wear condition of the upper support plane is not over-limit; otherwise, it indicates that the wear condition of the upper support plane is over-limit, and a second warning prompt is output; a1 is a constant.

[0036] The dynamic wear warning device determines whether the wear condition of the left side of the guiding and limiting member is over-limit by comparing whether the second wear amount B2 is within the allowable range of the second maximum wear amount Bmax2. If the judgment result shows that |B2 - Bmax2| < a2, it indicates that the wear condition of the left side of the guiding and limiting member is not over-limit; otherwise, it indicates that the wear condition of the left side of the guiding and limiting member is over-limit, and a second warning prompt is output; a2 is a constant.

[0037] The dynamic wear warning device determines whether the wear condition of the right side of the guiding limit is excessive by comparing whether the third wear amount B3 is within the allowable range of the first maximum wear amount Bmax3. If the judgment result shows that |B3 - Bmax3| < a3, it indicates that the wear condition of the right side of the guiding limit is not excessive; otherwise, it indicates that the wear condition of the right side of the guiding limit is excessive, and a second warning prompt is output; a3 is a constant.

[0038] Preferably, sensors A to D are displacement sensors or stroke sensors; and sensors A to D have the same structure, including a sensor body, a cable, and a contact head. The sensor body is integrally columnar, and one end of the sensor body is provided with a mounting head, and the other end is provided with a contact head. There is a lead hole inside the sensor body, one end of the cable is led out from the lead hole, and the other end is connected to the contact head.

[0039] Another technical object of the present invention is to provide a method for dynamically monitoring and warning the wear of a coal mining machine support and guiding system, including the following steps:

[0040] Step 1. Design a special sensor:

[0041] According to the actual working environment requirements of the coal mining machine support and guiding system, design a special sensor;

[0042] The special sensor is a displacement sensor or a stroke sensor, including a sensor body, a cable, and a contact head. The sensor body is integrally columnar, and one end of the sensor body is provided with a mounting head, and the other end is provided with a contact head. There is a lead hole inside the sensor body, one end of the cable is led out from the lead hole, and the other end is connected to the contact head;

[0043] Step 2. Determine the installation position of the dynamic wear monitoring device:

[0044] Step 2.1. Consider each plane of the guiding shoe guiding groove and the multi-surface contact with the conveyor pin row as a single-surface contact:

[0045] In the contacts between the supporting upper plane, the left side of the guiding limit, and the right side of the guiding limit of the guiding shoe guiding groove and the conveyor pin row respectively, the multi-surface contacts of the supporting upper plane, the left side of the guiding limit, the right side of the guiding limit and the conveyor pin row are all separated and intermittent multi-small-force-surface contacts. These separated and intermittent multi-small-force-surfaces are processed by a single cut during the processing, so the multi-surface contacts of the supporting upper plane, the left side of the guiding limit, the right side of the guiding limit and the conveyor pin row can be regarded as single-surface contacts;

[0046] Step 2.2. Select the characteristic wear areas of the supporting upper plane, the left side of the guiding limit, and the right side of the guiding limit:

[0047] The characteristic wear area of ​​the upper support plane is selected as follows: The strip area with a thickness of B±(δ1+δ2) near the geometric center point of the four force-bearing surfaces formed by the contact between the upper support plane and the conveyor pin row is selected as the characteristic wear area of ​​the upper support plane, where: B is the length of the short side of the quadrilateral formed by the geometric center point of the four force-bearing surfaces, δ1 is the design clearance setting value that meets the requirements, and δ2 is the maximum wear amount of the left / right side of the guide limit.

[0048] The characteristic wear area on the left side of the guide limiter is selected as follows: The strip area containing the two characteristic points set on the left side of the guide limiter, with the horizontal left-side characteristic line floating upward by σ1 and downward by σ2, is selected as the characteristic wear area on the left side of the guide limiter. Where: σ1 is the maximum upward floating amount of the horizontal left-side characteristic line when the upper surface of the guide shoe support is at its maximum wear; σ2 is the maximum downward floating amount of the horizontal left-side characteristic line caused by the guide shoe clearance deflection angle; the horizontal left-side characteristic line is the intersection line of the coal mining machine sprocket pitch circle, the horizontal plane of the conveyor pin row, and the left side of the guide limiter.

[0049] The characteristic wear area of ​​the right side of the guide limit is selected as follows: The characteristic wear area of ​​the right side of the guide limit is the strip area where the horizontal rightward characteristic line floats upward by σ3 and downward by σ4, and includes the two characteristic points set on the right side of the guide limit. Wherein: σ3 is the maximum upward floating amount of the horizontal leftward characteristic line when the upper surface of the guide shoe support is at its maximum wear; σ4 is the maximum downward floating amount of the horizontal leftward characteristic line caused by the clearance deflection angle of the guide shoe; the horizontal rightward characteristic line is the intersection line of the pitch circle of the coal mining machine sprocket, the horizontal plane of the conveyor pin row, and the right side of the guide limit.

[0050] Step 2.3: Selection of mounting sites for each dedicated sensor:

[0051] In the characteristic wear area of ​​the upper support plane, one set of geometric center points that are diagonally distributed among the four force-bearing small surfaces formed by the contact between the upper support plane and the conveyor pin row are selected as the characteristic points of the upper support plane.

[0052] In the characteristic wear area on the left side of the guide limit, the intersection of the horizontal left-side characteristic line and the geometric vertical center line of the two force-bearing surfaces on the left is selected as the characteristic point of the left side of the guide limit. The two force-bearing surfaces on the left are two discontinuous force-bearing surfaces formed by the contact between the left side of the guide limit and the left side of the conveyor pin row.

[0053] In the characteristic wear area of ​​the right side of the guide limit, the intersection of the horizontal right-side characteristic line and the geometric vertical center line of the two force-bearing surfaces on the right side is selected as the characteristic point of the right side of the guide limit. The two force-bearing surfaces on the right side are two discontinuous force-bearing surfaces formed by the contact between the right side of the guide limit and the right side of the conveyor pin row.

[0054] On the smooth boot sole plane, two points with a distance of L / 8 from the longitudinal center line of the smooth boot's two ears and the adjacent ends of the smooth boot at the lateral ends are selected as feature points on the smooth boot sole plane.

[0055] The feature points on the upper support plane, the left side of the guide limit, the right side of the guide limit, and the smooth boot sole plane obtained above are the installation positions of the dynamic wear monitoring device.

[0056] Step 3: Install the dynamic wear monitoring device.

[0057] Based on the installation location of the dynamic wear monitoring device determined in step two, install the special sensor designed in step one at each feature point location, and connect the cables of each special sensor to the coal mining machine electrical control box.

[0058] Step 4: Dynamic monitoring for wear and tear early warning:

[0059] The electrical control box of the coal mining machine is equipped with a dynamic wear early warning device. The dynamic wear early warning device dynamically monitors the wear condition of the area around the installation position of each dedicated sensor based on the data monitored by each dedicated sensor. When the wear condition of the area around the installation position of each dedicated sensor exceeds the limit, a corresponding early warning is issued, thus realizing dynamic monitoring of wear early warning.

[0060] Based on the above-mentioned technical objectives, the present invention has the following advantages compared with the prior art:

[0061] 1. The dynamic wear monitoring and early warning device for the coal mining machine support and guidance system described in this invention employs several dispersed sensors (dynamic wear monitoring devices) to dynamically monitor the wear of key components of the coal mining machine support and guidance system. It fully utilizes the different positional structures of the guide shoes and smooth shoes, creating a reasonable spatial arrangement, optimizing sensor placement points, and implementing effective protection. Furthermore, this invention uses dynamic wear early warning devices to centrally manage the wear of key components of the coal mining machine support and guidance system. This facilitates the efficient, economical, and rational aggregation of the optimized sensor placement points of the four-point support of the coal mining machine support and guidance mechanism, the dispersed guide shoes, and smooth shoes, allowing for centralized management of each sensor placement point. This improves control accuracy, reduces measurement errors, and lowers costs.

[0062] In practical use, operators can monitor the dynamic wear information of the coal mining machine's support and guidance system in real time simply by clicking the keyboard, operating buttons, and looking at the display screen at the underground roadway control station (or even the surface central control room). There is no need to stay at the work site for a long time for preparation and inspection operations, which reduces safety risks. The entire process is electrically automatic, which enables the detection of wear of the coal mining machine's guide shoes and smooth shoes to be carried out with fewer people, or even unmanned, improving work efficiency.

[0063] 2. When determining the installation positions of each sensor, this invention summarizes the "method of recognizing the multi-faceted contact between the guide shoe groove of the coal mining machine and the pin row of the conveyor as a single-faceted contact"; this simplifies the sensor layout, while still being universal, distortion-free, and maintaining the sensor detection accuracy.

[0064] Meanwhile, this invention establishes a "preferred rule for the characteristic wear area of ​​the plane contact between the guide shoe groove of the coal mining machine and the pin row of the conveyor, the smooth shoe and the coal shovel plate of the conveyor," pointing out that there is a characteristic wear area in the plane contact between the guide shoe groove of the coal mining machine and the pin row of the conveyor. By optimizing the characteristic wear area, the wear condition of the upper plane of the contact support and the guide limiting surfaces on both sides can be basically reflected. At the same time, it has certain guiding significance for the structural design, process treatment, production and manufacturing, use and maintenance of the coal mining machine and the smooth shoe. The bottom plane of the contact between the smooth shoe of the coal mining machine and the shovel plate of the conveyor is approximately the characteristic wear area, and generally does not need to be further subdivided.

[0065] 3. This invention develops a dedicated sensor specifically for the structure of the coal mining machine's support and guidance system and its actual operating environment. This dedicated sensor has high adaptability; it can work reliably for extended periods under conditions of harmful gases and dust, and has strong anti-vibration, waterproof, dustproof, and corrosion-resistant functions.

[0066] This specialized sensor is a displacement or stroke sensor that is both explosion-proof and intrinsically safe. It has a compact structure and a moderate price. The structural dimensions are generally 10-15mm in diameter and ≤25-35mm in length, with a weight of 0.1kg / piece. Each coal mining machine typically uses a maximum of 16 pieces, and the weight of the protective structure and electrical control components generally does not exceed 2.5kg, which is only half the weight of foreign coal mining machine-specific measuring tools (approximately 5kg).

[0067] This dedicated sensor boasts high data acquisition accuracy; its measurement accuracy is no less than 0.2mm, which is at least 5-10 times that of the original domestic slipper wear detection equipment; the sensor has high structural rigidity and strength, is easy to protect, and is generally used in combination. It is buried at selected characteristic points on the guide slipper and smooth slipper of the coal mining machine, making it safe and convenient to use.

[0068] 4. Multiple dedicated sensors can be placed in the characteristic wear areas of the guide shoes and smooth shoes of the coal mining machine support mechanism. If the placement density is too high or the number of sensors is too large, it will result in redundant information, complex structure, and increased costs. If the placement density is too low or the number of sensors is too small, information loss and fragmentation will occur, leading to distorted and inaccurate measurement information. Poor placement will prevent effective and accurate information collection, which is undoubtedly another unreasonable design. Therefore, obtaining the optimal number and placement points is crucial.

[0069] In this invention, each sensing location (smooth shoe sole plane, guide shoe guide groove support upper plane, guide limit left side, guide limit right side) has two or four feature points in its characteristic wear area (two feature points in the characteristic wear areas of the smooth shoe sole plane, guide limit left side, and guide limit right side; four feature points in the characteristic wear area of ​​the guide shoe guide groove support upper plane). This invention uses the principle of two points on a line to approximate three points on a plane when arranging dedicated sensors; two points refer to two feature points. Therefore, for characteristic wear areas with only two feature points, dedicated sensors only need to be placed at the locations of the feature points to achieve wear monitoring of the corresponding characteristic wear area. For characteristic wear areas with four feature points, dedicated sensors need to be placed at the locations of a set of feature points distributed diagonally to achieve wear monitoring of this type of characteristic wear area. Thus, this invention arranges dedicated sensors on preferred feature points, resulting in the simplest and most representative arrangement; this rule reduces the number of sensors required and lowers usage costs; it is both economical and convenient. Attached Figure Description

[0070] Figure 1 This is an automatic control block diagram of the dynamic wear monitoring and early warning device for the coal mining machine support and guidance system described in this invention;

[0071] Figure 2 This is a schematic diagram of the dynamic wear monitoring and early warning device for the coal mining machine support and guidance system described in this invention;

[0072] Figure 3 yes Figure 2 A schematic diagram of the arrangement of the corresponding sensors on the left smooth shoe; in the figure: (a) is the front view of the arrangement of the corresponding sensors on the left smooth shoe, and (b) is the A-direction view of (a);

[0073] Figure 4 yes Figure 2 A schematic diagram of the arrangement of the corresponding sensors on the left guide shoe; in the figure: (a) is the front view of the arrangement of the corresponding sensors on the left guide shoe, (b) is the top view of (a); (c) is the left view of (a), and (d) is the B-direction view of (a);

[0074] Figure 5 This is a schematic diagram of the structure of the sensor described in this invention;

[0075] In the diagram: 1. Guide shoe; 2. Sprocket; 3. Coal mining machine body; 4. Smooth shoe; 5. Conveyor pin row; 611. First sensor A; 612. Second sensor A; 621. First sensor B; 622. Second sensor B; 631. First sensor C; 632. Second sensor C; 641. First sensor D; 642. Second sensor D; 601. Cable; 602. Flange; 603. Mounting thread; 604. Sensor body; 605. Contact. Detailed Implementation

[0076] 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.

[0077] 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).

[0078] Example 1

[0079] like Figure 1-5As shown, the present invention discloses a dynamic wear monitoring and early warning device for a coal mining machine support and guidance system, used for dynamically monitoring the wear of the coal mining machine support and guidance system and providing early warning; the coal mining machine support and guidance system includes a guide shoe support mechanism and a smooth shoe support mechanism; the guide shoe support mechanism includes a guide shoe 1 and a conveyor pin row 5 matched with the guide shoe 1; the smooth shoe support mechanism includes a smooth shoe 4 and a conveyor shovel plate matched with the smooth shoe 4, and the guide shoe 1 and smooth shoe 4 are respectively installed on the coal mining machine body 3; the dynamic wear monitoring and early warning device includes a dynamic wear monitoring device and a dynamic wear early warning device; wherein: the dynamic wear monitoring device includes a first dynamic wear monitoring group and a second dynamic wear monitoring group; the first dynamic wear monitoring group is installed on the smooth shoe 4 and is used to monitor the wear amount A of the characteristic wear area on the bottom plane of the smooth shoe 4, and can transmit the monitored wear amount A to the dynamic wear early warning device; the first dynamic wear monitoring group includes two sensors A, corresponding to the first sensor A611 and the second sensor A612; the first sensor A611 and the second sensor A612 are respectively installed at two characteristic points set on the bottom plane of the smooth shoe. The second dynamic wear monitoring group is installed on the guide shoe 1 to monitor the wear amount B of the characteristic wear area of ​​the guide shoe 1 and can transmit the monitored wear amount B to the dynamic wear early warning device. The dynamic wear early warning device determines whether the wear condition of the bottom surface of the smooth shoe 4 exceeds the limit based on the received wear amount A. If the determination result indicates that the wear condition of the bottom surface of the smooth shoe 4 exceeds the limit, a first early warning message is output. Similarly, the dynamic wear early warning device determines whether the wear condition of the guide shoe 1 exceeds the limit based on the received wear amount B. If the determination result indicates that the wear condition of the guide shoe 1 exceeds the limit, a second early warning message is output.

[0080] Since the guide groove of the guide shoe 1 has three surfaces (support upper surface, guide limit left surface, and guide limit right surface) in contact with the conveyor pin row 5, these three surfaces will inevitably experience wear. Therefore, the second dynamic wear monitoring group described in this invention includes sensor B, sensor C, and sensor D. Sensor B is used to sense the wear amount of the characteristic wear area of ​​the support upper surface in contact with the guide groove of the guide shoe 1 and the upper surface of the conveyor pin row 5, denoted as the first wear amount B1; and can transmit the sensed first wear amount B1 to the dynamic wear warning device. Sensor C is used to sense the wear amount of the characteristic wear area of ​​the guide limit left surface in lateral contact with the guide groove of the guide shoe 1 and the conveyor pin row 5, denoted as the second wear amount B2; and can transmit the sensed second wear amount B2 to the dynamic wear warning device. Sensor D is used to sense the wear amount of the characteristic wear area of ​​the guide limit right surface in lateral contact with the guide groove of the guide shoe 1 and the conveyor pin row 5, denoted as the third wear amount B3; and can transmit the sensed third wear amount B3 to the dynamic wear warning device. It can be seen that the characteristic wear area of ​​the guide shoe 1 includes the characteristic wear area of ​​the upper support surface where the guide groove of the guide shoe 1 and the upper surface of the transport pin row 5 are in contact, as well as the characteristic wear area of ​​the left side of the guide limit and the characteristic wear area of ​​the right side of the guide limit where the guide groove of the guide shoe 1 and the left and right sides of the transport pin row 5 are in contact.

[0081] The dynamic wear warning device determines whether the wear condition of the upper support surface of the guide groove of the guide shoe 1 exceeds the limit based on the received first wear amount B1. If the determination result shows that the wear condition of the upper support surface of the guide groove of the guide shoe 1 exceeds the limit, a second warning prompt is output. The dynamic wear warning device determines whether the wear condition of the left guide limit surface of the guide groove of the guide shoe 1 exceeds the limit based on the received second wear amount B2. If the determination result shows that the wear condition of the left guide limit surface of the guide groove of the guide shoe 1 exceeds the limit, a second warning prompt is output. The dynamic wear warning device determines whether the wear condition of the right guide limit surface of the guide groove of the guide shoe 1 exceeds the limit based on the received third wear amount B3. If the determination result shows that the wear condition of the right guide limit surface of the guide groove of the guide shoe 1 exceeds the limit, a second warning prompt is output.

[0082] In order to more accurately monitor the wear of each contact surface (upper support surface, left guide limit surface, right guide limit surface, and bottom surface of smooth shoe 4), and to reduce the number of sensors used and the data processing load of the subsequent dynamic wear warning device, the selection of characteristic wear areas, especially the characteristic points of the characteristic wear areas, is particularly important.

[0083] In this invention: the characteristic wear area of ​​the upper support surface is a strip area with a thickness of B ± (δ1 + δ2) near the geometric center point of the four force-bearing surfaces formed when the upper support surface contacts the conveyor pin 5; where: B is the length of the short side of the quadrilateral formed by the geometric center points of the four force-bearing surfaces, δ1 is the design clearance setting value that meets the requirements, and δ2 is the maximum wear amount of the left / right side of the guide limit. The sensor B includes two sensors, corresponding to a first sensor B621 and a second sensor B622; the first sensor B621 and the second sensor B622 are respectively installed at the locations of two characteristic points set on the upper support surface; the two characteristic points set on the upper support surface are two of the geometric center points of the four force-bearing surfaces that are diagonally distributed.

[0084] In this invention: the characteristic wear area on the left side of the guide limit is a strip area containing two characteristic points set on the left side of the guide limit, with the horizontal left-side characteristic line floating upward σ1 and downward σ2. σ1 is the maximum upward floating amount of the horizontal left-side characteristic line when the upper surface of the guide shoe support has the maximum wear; σ2 is the maximum downward floating amount of the horizontal left-side characteristic line caused by the guide shoe clearance deflection angle; the horizontal left-side characteristic line is the intersection line of the coal mining machine sprocket pitch circle, the horizontal plane of the conveyor pin row 5, and the left side of the guide limit; the sensor C includes two, corresponding to the first sensor C631 and the second sensor C632; the first sensor C631 and the second sensor C632 are respectively installed at the positions of the two characteristic points set on the left side of the guide limit; the two characteristic points set on the left side of the guide limit are the intersection points of the horizontal left-side characteristic line and the geometric vertical center lines of the two force-bearing surfaces on the left; the two force-bearing surfaces on the left are the two discontinuous force-bearing surfaces formed by the contact between the left side of the guide limit and the left side of the conveyor pin row 5.

[0085] In this invention: the characteristic wear area on the right side of the guide limit is a strip area containing two characteristic points set on the right side of the guide limit, with the horizontal right-side characteristic line floating upward σ3 and downward σ4. σ3 is the maximum upward floating amount of the horizontal right-side characteristic line when the upper support plane of the guide shoe 1 has the maximum wear amount; σ4 is the maximum downward floating amount of the horizontal right-side characteristic line generated by the clearance deflection angle of the guide shoe 1; the horizontal right-side characteristic line is the intersection line of the pitch circle of the coal mining machine sprocket, the horizontal plane of the conveyor pin row 5, and the right side of the guide limit; the sensor D includes two, corresponding to the first sensor D641 and the second sensor D642; the first sensor D641 and the second sensor D642 are respectively installed at the positions of the two characteristic points set on the right side of the guide limit; the two characteristic points set on the right side of the guide limit are the intersection points of the horizontal right-side characteristic line and the geometric vertical center lines of the two force-bearing surfaces on the right; the two force-bearing surfaces on the right are the two discontinuous force-bearing surfaces formed by the contact between the right side of the guide limit and the right side of the conveyor pin row 5.

[0086] For the dynamic wear warning device, a first maximum wear amount Bmax1 is preset for the support upper plane, a second maximum wear amount Bmax2 is preset for the left side of the guiding and limiting part, and a third maximum wear amount Bmax3 is preset for the right side of the guiding and limiting part. The dynamic wear warning device determines whether the wear condition of the support upper plane exceeds the limit by comparing whether the first wear amount B1 is within the allowable range of the first maximum wear amount Bmax1. If the judgment result shows that |B1 - Bmax1| < a1, it indicates that the wear condition of the support upper plane does not exceed the limit; otherwise, it indicates that the wear condition of the support upper plane exceeds the limit, and a second warning prompt is output; a1 is a constant. The dynamic wear warning device determines whether the wear condition of the left side of the guiding and limiting part exceeds the limit by comparing whether the second wear amount B2 is within the allowable range of the second maximum wear amount Bmax2. If the judgment result shows that |B2 - Bmax2| < a2, it indicates that the wear condition of the left side of the guiding and limiting part does not exceed the limit; otherwise, it indicates that the wear condition of the left side of the guiding and limiting part exceeds the limit, and a second warning prompt is output; a2 is a constant. The dynamic wear warning device determines whether the wear condition of the right side of the guiding and limiting part exceeds the limit by comparing whether the third wear amount B3 is within the allowable range of the third maximum wear amount Bmax3. If the judgment result shows that |B3 - Bmax3| < a3, it indicates that the wear condition of the right side of the guiding and limiting part does not exceed the limit; otherwise, it indicates that the wear condition of the right side of the guiding and limiting part exceeds the limit, and a second warning prompt is output; a3 is a constant.

[0087] In the present invention, sensors A to D are displacement sensors or stroke sensors; and the structures of sensors A to D are the same, including a sensor main body 604, a cable 601, and a contact 605. The sensor main body 604 is integrally arranged in a columnar shape, and one end of the sensor main body 604 is provided with a mounting head, and the other end is provided with a contact 605. The mounting head is provided with a mounting thread 603 and a flange 602. The mounting thread 603 is used to install the sensor main body 604 into the target mounting hole by means of threaded connection. The flange 602 is used to achieve the axial limit of the sensor main body 604 in the target mounting hole. A lead hole is provided inside the sensor main body 604, and one end of the cable 601 is led out from the lead hole, and the other end is connected to the contact 605.

[0088] Embodiment 2

[0089] A method for dynamically monitoring and warning the wear of a coal mining machine support and guiding system in this embodiment includes the following steps:

[0090] Step 1: Design a special sensor:

[0091] To meet the actual operating environment requirements of the coal mining machine support and guidance system, a special sensor was designed. It has the advantages of high adaptability and high precision, and can meet the usage requirements of the coal mining machine support and guidance system.

[0092] like Figure 5 As shown, the dedicated sensor is a displacement sensor or a stroke sensor, including a sensor body 604, a cable 601, and a contact 605. The sensor body 604 is generally cylindrical, with a mounting head at one end and a contact 605 at the other end. A lead-in hole is provided inside the sensor body 604, through which one end of the cable 601 extends, and the other end connects to the contact 605. Alternatively, the dedicated sensor described in this invention can also be wireless. Its structural dimensions are generally a diameter of 10–15 mm, a length of ≤25–35 mm, a measuring range of 0–20 mm, and a measurement accuracy of ≤0.2 mm. It has the advantages of high data acquisition accuracy and reliability, and also possesses strong shock resistance, waterproofing, dustproofing, and corrosion resistance, making it suitable for long-term reliable operation under conditions of harmful gases and dust.

[0093] Step 2: Determining the installation location of the dynamic wear monitoring device:

[0094] When assembling a dynamic wear monitoring and early warning device in the coal mining machine support and guidance system, on the one hand, a "distributed layout" should be adopted, adapting to local conditions and making full use of the different positions and structures of the guide shoes 1 and smooth shoes 4 to create reasonable space, optimize sensor configuration points, and implement effective protection. On the other hand, a "centralized management and control" approach should be adopted, which is conducive to bringing together the optimized sensor configuration points of the four-point support and structurally dispersed guide shoes 1 and smooth shoes 4 in the most efficient, real-time, economical, and reasonable way, and implementing centralized management and control of each sensor configuration point, thereby improving control accuracy, reducing measurement errors, and lowering costs.

[0095] Based on the principle of "decentralized deployment and centralized control", sensors at various points on the guide shoes 1 and smooth shoes 4 of the coal mining machine support and guiding mechanism collect data in real time using the piezoelectric ranging principle of displacement sensors. The measured data values ​​are transmitted (or wirelessly) to the control center of the coal mining machine electrical control box via cable 601 for data processing. The controller compares the processed data with the wear warning calibration value in the control center database. The controller issues a warning command to remind the coal mining machine driver that the wear of guide shoes 1 and smooth shoes 4 has reached the warning value or to remind them to replace them.

[0096] To determine the selection of the placement points of the guide shoe 1 and smooth shoe 4 of the coal mining machine support and guiding mechanism, the present invention will adopt the following method:

[0097] Each plane of the guide shoe 1 guide groove and the multi-faceted contact between the guide shoe 1 and the conveyor pin row 5 are considered as single-faceted contact:

[0098] In the contact between the guide shoe 1 guide groove and the conveyor pin row 5, the multi-face contact of the guide shoe 1 guide groove support upper plane, guide limit left side, guide limit right side and conveyor pin row 5 is a separated and intermittent multi-force small-face contact. These separated and intermittent multi-force small faces are processed in one cut during the processing. Therefore, the multi-face contact of the support upper plane, guide limit left side, guide limit right side and conveyor pin row 5 can be regarded as a single-face contact.

[0099] Selection of mounting sites for each dedicated sensor:

[0100] During underground coal mining, when the guide shoe 1 guides the groove, and during the support and guidance limiting process of the conveyor pin 5, smooth shoe 4, and conveyor shovel plate, based on the working principle, contact characteristics, and force characteristics of the related parts, there are selectable feature points on the upper support plane of the guide shoe 1 guide groove, the left side of the guide limiting, the right side of the guide limiting, and the bottom plane of the smooth shoe 4. Specifically:

[0101] The method for selecting feature points supporting the upper plane is as follows:

[0102] Although the upper support plane is a separation of two discontinuous force-bearing surfaces, it can still be regarded as a single plane since it was machined in one cut.

[0103] When the coal mining machine and the conveyor are used together, the upper surface of the support and the pin row 5 of the conveyor can contact each other to form four force-bearing surfaces (because there are gaps at the pin column of the pin row). The geometric center points of the four force-bearing surfaces are denoted as a, b, c, and d. Among them, geometric center points a and d are on the same side of the longitudinal geometric center line, while geometric center points b and c are on the same side of the longitudinal geometric center line.

[0104] Since the geometric center points a, b, c, and d are relatively close to each other, and the coal mining machine operates with bidirectional traction, the probability of contact between the four geometric center points is approximately equal. Clearly, at least one geometric center point on each side of the two force-bearing faces will be in contact with the force along the longitudinal geometric center line.

[0105] Based on the property that the contact probability of the four geometric center points a, b, c, and d is approximately equal, these four geometric center points a, b, c, and d can form a relatively regular quadrilateral abcd. This regular quadrilateral abcd contains at least one plane (such as abc, adc, etc.). According to the axiom that three points not on a straight line determine a plane, two of the three geometric center points that make up this plane must appear at opposite corners of the regular quadrilateral. We can further divide the four geometric center points a, b, c, and d arranged around the perimeter into two groups, each containing two geometric center points arranged diagonally, corresponding to geometric center points a and c and geometric center points b and d. Two geometric center points a and c or b and d from one group can approximately replace the geometric center points a, b, c, and d arranged around the perimeter; this simplifies the structure, reduces the number of sensors, and lowers costs.

[0106] In other words, in this embodiment, one set of geometric center points that are diagonally distributed among the four force-bearing surfaces formed by the contact between the upper support plane and the transport pin row 5 is selected as the feature points of the upper support plane.

[0107] Feature point selection method on the left side of the guide limit:

[0108] First, the intersection line of the pitch circle of the coal mining machine sprocket, the horizontal plane of the conveyor pin row 5, and the left side of the guide limit is called the horizontal leftward feature line. Then, the two discontinuous force-bearing surfaces formed by the contact between the left side of the guide limit and the left side of the conveyor pin row 5 are called the two force-bearing surfaces on the left. The intersection point of the horizontal leftward feature line and the geometric vertical center line of the two force-bearing surfaces on the left is the feature point of the left side of the guide limit.

[0109] The method for selecting the feature point on the right side of the guide limit is as follows: First, the intersection line of the pitch circle of the coal mining machine sprocket, the horizontal plane of the conveyor pin row 5, and the right side of the guide limit is called the horizontal rightward feature line. Then, the two discontinuous force-bearing surfaces formed by the contact between the right side of the guide limit and the right side of the conveyor pin row 5 are called the two force-bearing surfaces on the right side. The intersection point of the horizontal rightward feature line and the geometric vertical center line of the two force-bearing surfaces on the right side is the feature point on the right side of the guide limit.

[0110] The bottom plane of the smooth shoe 4 is a complete plane. Based on the operating mechanism, contact characteristics, and force characteristics of the smooth shoe 4 during the operation of the coal mining machine, and considering the preferred installation position of the special sensor, the preferred position of the wear area is generally set within L / 8 of each end of the bottom plane of the smooth shoe 4. The intersection of the longitudinal double-ear center line of the smooth shoe 4 of the coal mining machine and the straight line L / 8 of each end of the bottom plane of the smooth shoe 4 is called the characteristic point of the contact support surface between the smooth shoe 4 of the coal mining machine and the conveyor shovel plate.

[0111] In other words, in this invention, the feature points on the bottom plane of the smooth boot 4 are arranged on the longitudinal double-ear center line of the smooth boot 4, and the distance between the feature points on the bottom plane of the smooth boot 4 and the adjacent ends of the smooth boot 4 at the two ends in the lateral direction is L / 8.

[0112] The guide groove of the coal mining machine guide shoe 1 and the plane of the conveyor pin row 5 have a characteristic wear area; the characteristic wear area can basically reflect the wear of the upper plane of the contact support and the guide limiting surfaces on both sides; the bottom plane of the coal mining machine smooth shoe 4 and the conveyor shovel plate is approximately the characteristic wear area, and generally does not need to be further subdivided.

[0113] The design clearance setting values ​​for the guide shoe 1 guide groove and the conveyor pin row 5 contact guide limit left and right sides are 5-6mm respectively; at the same time, the maximum wear of the guide limit left and right sides is 5mm respectively; and there is a gap 13-3 in the middle area of ​​the contact support surface between the guide shoe 1 guide groove and the conveyor pin row 5, which does not participate in the contact support, etc.

[0114] During the contact support, guidance, and limiting process between the guide shoe 1 guide groove and the conveyor pin row 5, four strip areas (excluding empty spaces) with a width approximately equal to the short side B ± (δ1 + δ2) mm are formed along the long side A of the four force-bearing surfaces. These are called the characteristic wear areas on the upper surface of the contact support between the guide shoe 1 guide groove and the conveyor pin row 5. Where: B is the short side dimension of the four force-bearing surfaces; δ1 is the design clearance setting value to meet the requirements, which can be 5–6 mm; and δ2 is the maximum wear amount on the left / right side of the guide limiting surface, which can be 5 mm.

[0115] During the operation of the coal mining machine, when the machine body is in a horizontal state, the two intersecting lines formed by the intersection of the sprocket pitch circle, the horizontal plane of the conveyor pin row 5, and the left and right side faces of the guide limit are called the left and right characteristic lines; the vertical distance between the upper plane of the lower hook of the coal mining machine guide shoe 1 and the lower plane of the left end of the conveyor pin row 5 is defined as X (generally X = 8~10mm).

[0116] Generally, coal mining machines can adapt to pitch mining conditions of ±5°. Due to the structural characteristics of the rocker arm and cantilevered drum of the conventional coal mining machine's cutting mechanism, the center of gravity of the coal mining machine is almost always biased towards the coal wall during underground operation, and there is a possibility of it briefly tilting towards the coal wall. Taking the intersection point s of the vertical center line of the coal mining machine's smooth shoe 4 and the upper surface of the conveyor shovel as the fulcrum, rotate counterclockwise 0.3° towards the coal wall (the maximum gap angle generated by the gap X = 8~10mm). At this time, the position lines of the left and right characteristic lines mapped on the left and right sides of the guide limit will be moved down by about 10mm from the original initial position (Y≈10mm, approximate value).

[0117] For the upper support plane, the maximum wear is designed to be 10mm. At this time, the position lines of the left and right feature lines mapped on the left and right sides of the guide limit will be moved up by 10mm compared with the original initial position.

[0118] The left and right characteristic lines formed by the intersection of the sprocket pitch circle, the horizontal plane of the conveyor pin row 5, and the left and right side faces of the guide limiter have a floating range of approximately ±10mm along the vertical direction of the conveyor pin row 5. This ±10mm floating area along the vertical direction of the left and right characteristic lines of the conveyor pin row 5 is called the characteristic wear area (excluding the empty space). Therefore, the guide limiter wear on the left and right side faces of the guide limiter generally occurs mainly within a ±10mm floating range above and below these two characteristic lines.

[0119] Therefore, the strip area containing the two feature points set on the left side of the guide limit can be selected as the characteristic wear area of ​​the left side of the guide limit, where: σ1 is the maximum upward floating amount of the horizontal left-side feature line when the upper surface of the guide shoe support is at its maximum wear; σ2 is the maximum downward floating amount of the horizontal left-side feature line caused by the deflection angle of the guide shoe 1 gap, and the values ​​of σ1 and σ2 can be 10mm; the horizontal left-side feature line is the intersection line of the pitch circle of the coal mining machine sprocket, the horizontal plane of the conveyor pin row 5, and the left side of the guide limit. Similarly, the characteristic wear area on the right side of the guide limit can be selected as the strip area containing the two characteristic points set on the right side of the guide limit, with the horizontal rightward characteristic line floating upward σ3 and downward σ4. Wherein: σ3 is the maximum upward floating amount of the horizontal rightward characteristic line when the upper support plane of the guide shoe 1 has the maximum wear amount; σ4 is the maximum downward floating amount of the horizontal rightward characteristic line caused by the clearance deflection angle of the guide shoe 1, and the values ​​of σ3 and σ4 can be 10mm; the horizontal rightward characteristic line is the intersection line of the pitch circle of the coal mining machine sprocket, the horizontal plane of the conveyor pin row 5, and the right side of the guide limit.

[0120] The feature points on the upper support plane, the left side of the guide limit, the right side of the guide limit, and the bottom plane of the smooth shoe 4 obtained above are the installation positions of the dynamic wear monitoring device.

[0121] Step 3: Install the dynamic wear monitoring device.

[0122] Based on the installation location of the dynamic wear monitoring device determined in step two, install the special sensor designed in step one at each feature point location, and connect the cable 601 of each special sensor to the coal mining machine electrical control box.

[0123] Step 4: Dynamic monitoring for wear and tear early warning:

[0124] The electrical control box of the coal mining machine is equipped with a dynamic wear early warning device. The dynamic wear early warning device dynamically monitors the wear condition of the area around the installation position of each dedicated sensor based on the data monitored by each dedicated sensor. When the wear condition of the area around the installation position of each dedicated sensor exceeds the limit, a corresponding early warning is issued, thus realizing dynamic monitoring of wear early warning.

Claims

1. A dynamic wear monitoring and warning device for a support and guiding system of a coal mining machine, which is used for dynamically monitoring the wear of the support and guiding system of the coal mining machine and giving warnings; the support and guiding system of the coal mining machine includes a guiding sliding shoe support mechanism and a smooth shoe support mechanism; the guiding sliding shoe support mechanism includes a guiding sliding shoe and a conveyor pin row matching with the guiding sliding shoe; the smooth shoe support mechanism includes a smooth shoe and a transportation scraper plate matching with the smooth shoe, and the guiding sliding shoe and the smooth shoe are respectively arranged on the coal mining machine body; it is characterized in that, The dynamic wear monitoring and early warning device includes a dynamic wear monitoring device and a dynamic wear early warning device; wherein: The dynamic wear monitoring device includes a first dynamic wear monitoring group and a second dynamic wear monitoring group; The first dynamic wear monitoring group is installed on the smooth boot and is used to monitor the wear amount A of the characteristic wear area on the sole plane of the smooth boot, and can transmit the monitored wear amount A to the dynamic wear early warning device. The second dynamic wear monitoring group is installed on the guide shoe to monitor the wear amount B of the characteristic wear area of ​​the guide shoe and can transmit the monitored wear amount B to the dynamic wear early warning device. The dynamic wear warning device determines whether the wear of the smooth boot sole surface exceeds the limit based on the received wear amount A. If the determination result shows that the wear of the smooth boot sole surface exceeds the limit, the first warning prompt is output. The dynamic wear warning device determines whether the wear of the guide shoe exceeds the limit based on the received wear amount B. If the determination result shows that the wear of the guide shoe exceeds the limit, a second warning prompt is output. The smooth boot sole plane has two feature points. Each feature point is located on the longitudinal center line of the double lugs of the smooth boot, and the distance between each feature point and the adjacent end of the smooth boot sole plane is L / 8, where L is the distance between the two ends of the smooth boot sole plane in the lateral direction. The feature wear area of ​​the smooth boot sole plane is the area between the two feature points. The first dynamic wear monitoring group includes two sensors A, namely the first sensor A and the second sensor A; the first sensor A and the second sensor A are respectively installed at two feature points set on the smooth boot sole plane; The characteristic wear areas of the guide shoe include the characteristic wear area of ​​the support upper plane that contacts the guide groove of the guide shoe and the upper plane of the transport pin row, as well as the characteristic wear areas of the left side of the guide limit and the right side of the guide limit that correspond to the left and right sides of the guide groove of the guide shoe and the transport pin row. The second dynamic wear monitoring group includes sensor B, sensor C, and sensor D; wherein: Sensor B is used to sense the wear amount of the characteristic wear area of ​​the support upper plane that contacts the guide shoe guide groove and the upper plane of the conveyor pin row, which is recorded as the first wear amount B1; and can transmit the sensed first wear amount B1 to the dynamic wear warning device. Sensor C is used to sense the wear amount of the characteristic wear area on the left side of the guide limiter where the guide shoe guide groove and the conveyor pin row are in lateral contact, which is recorded as the second wear amount B2; and can transmit the sensed second wear amount B2 to the dynamic wear warning device. Sensor D is used to sense the wear amount of the characteristic wear area on the right side of the guide limiter where the guide shoe guide groove and the conveyor pin row are in lateral contact, which is recorded as the third wear amount B3; and can transmit the sensed third wear amount B3 to the dynamic wear warning device. The dynamic wear warning device determines whether the wear condition of the characteristic wear area of ​​the upper support surface of the guide shoe guide groove exceeds the limit based on the received first wear amount B1. If the determination result shows that the wear condition of the characteristic wear area of ​​the upper support surface of the guide shoe guide groove exceeds the limit, a second warning prompt is output. The dynamic wear warning device determines whether the wear condition of the characteristic wear area on the left side of the guide limit of the guide shoe guide groove exceeds the limit based on the received second wear amount B2. If the determination result shows that the wear condition of the characteristic wear area on the left side of the guide limit of the guide shoe guide groove exceeds the limit, the device outputs a second warning prompt. The dynamic wear warning device determines whether the wear condition of the characteristic wear area on the right side of the guide limit of the guide shoe guide groove exceeds the limit based on the received third wear amount B3. If the determination result shows that the wear condition of the characteristic wear area on the right side of the guide limit of the guide shoe guide groove exceeds the limit, a second warning prompt is output.

2. The dynamic wear monitoring and early warning device for the coal mining machine support and guidance system according to claim 1, characterized in that: The characteristic wear area of ​​the support upper plane is a strip area with a thickness of B±(δ1+δ2) near the geometric center point of the four force-bearing small surfaces formed when the support upper plane contacts the pin row of the conveyor; where: B is the length of the short side of the quadrilateral formed by the geometric center point of the four force-bearing small surfaces, δ1 is the design clearance setting value that meets the requirements, and δ2 is the maximum wear amount of the left / right side of the guide limit. The sensor B includes two sensors, namely the first sensor and the second sensor B; the first sensor B and the second sensor B are respectively installed at the locations of two feature points set on the upper plane of the support; the two feature points set on the upper plane of the support are two of the geometric center points of the four force-bearing facets that are diagonally distributed.

3. The dynamic wear monitoring and early warning device for the coal mining machine support and guidance system according to claim 1, characterized in that: The characteristic wear area on the left side of the guide limit is a strip area containing two characteristic points set on the left side of the guide limit, with the horizontal left-side characteristic line floating upward by σ1 and downward by σ2. σ1 is the maximum upward floating amount of the horizontal left-side characteristic line when the upper surface of the guide shoe support has the maximum wear; σ2 is the maximum downward floating amount of the horizontal left-side characteristic line caused by the guide shoe clearance deflection angle; the horizontal left-side characteristic line is the intersection line of the coal mining machine sprocket pitch circle, the horizontal plane of the conveyor pin row, and the left side of the guide limit. The sensor C includes two sensors, namely the first sensor C and the second sensor C; the first sensor C and the second sensor C are respectively installed at the positions of the two feature points set on the left side of the guide limiter. The two feature points set on the left side of the guide limit are the intersection of the horizontal leftward feature line and the geometric vertical center line of the two force-bearing surfaces on the left; the two force-bearing surfaces on the left are two discontinuous force-bearing surfaces formed by the contact between the left side of the guide limit and the left side of the transport pin row.

4. The dynamic wear monitoring and early warning device for the coal mining machine support and guidance system according to claim 1, characterized in that: The characteristic wear area on the right side of the guiding and limiting part is a strip area where the horizontal rightward characteristic line floats upward by σ3 and downward by σ4 and includes two characteristic points set on the right side of the guiding and limiting part. σ3 is the maximum upward floating amount of the horizontal rightward characteristic line when the upper plane of the support of the guiding slide shoe has the maximum wear amount; σ4 is the maximum downward floating amount of the horizontal rightward characteristic line caused by the clearance deflection angle of the guiding slide shoe; the horizontal rightward characteristic line is the intersection line of the pitch circle of the coal mining machine sprocket, the horizontal plane of the conveyor pin row and the right side of the guiding and limiting part. There are two sensors D, namely the first and second sensors D; the first and second sensors D are respectively installed at the positions of the two characteristic points set on the right side of the guiding and limiting part. The two characteristic points set on the right side of the guiding and limiting part are the intersections of the horizontal rightward characteristic line and the geometric vertical center lines of the two small force-bearing surfaces on the right side; the two small force-bearing surfaces on the right side are two discontinuous small force-bearing surfaces formed by the contact between the right side of the guiding and limiting part and the right side of the conveyor pin row.

5. The dynamic wear monitoring and early warning device for the coal mining machine support and guidance system according to claim 1, characterized in that: For the dynamic wear warning device, a first maximum wear amount Bmax1 is preset for the upper support plane, a second maximum wear amount Bmax2 is preset for the left side of the guiding and limiting part, and a third maximum wear amount Bmax3 is preset for the right side of the guiding and limiting part. The dynamic wear warning device judges whether the wear condition of the upper support plane exceeds the limit by comparing whether the first wear amount B1 is within the allowable range of the first maximum wear amount Bmax1. If the judgment result shows that |B1 - Bmax1| < a1, it indicates that the wear condition of the upper support plane does not exceed the limit; otherwise, it indicates that the wear condition of the upper support plane exceeds the limit, and a second warning prompt is output; a1 is a constant. The dynamic wear warning device judges whether the wear condition of the left side of the guiding and limiting part exceeds the limit by comparing whether the second wear amount B2 is within the allowable range of the second maximum wear amount Bmax2. If the judgment result shows that |B2 - Bmax2| < a2, it indicates that the wear condition of the left side of the guiding and limiting part does not exceed the limit; otherwise, it indicates that the wear condition of the left side of the guiding and limiting part exceeds the limit, and a second warning prompt is output; a2 is a constant. The dynamic wear warning device judges whether the wear condition of the right side of the guiding and limiting part exceeds the limit by comparing whether the third wear amount B3 is within the allowable range of the first maximum wear amount Bmax3. If the judgment result shows that |B3 - Bmax3| < a3, it indicates that the wear condition of the right side of the guiding and limiting part does not exceed the limit; otherwise, it indicates that the wear condition of the right side of the guiding and limiting part exceeds the limit, and a second warning prompt is output; a3 is a constant.

6. The dynamic wear monitoring and early warning device for the coal mining machine support and guidance system according to claim 1, characterized in that: Sensors A to D are displacement sensors or travel sensors; and sensors A to D have the same structure, including a sensor body, a cable and a contact head; the sensor body is integrally columnar, and one end of the sensor body is provided with a mounting head, the other end is provided with a contact head, and a lead hole is provided inside the sensor body. One end of the cable is led out from the lead hole, and the other end is connected to the contact head.

7. A method for dynamic wear monitoring and early warning of a coal mining machine support and guidance system, characterized in that, It includes the following steps: Step 1: Design a special sensor: According to the actual operating environment requirements of the coal mining machine support and guiding system, design a special sensor. The dedicated sensor is a displacement sensor or a stroke sensor, including a sensor body, a cable, and a contact. The sensor body is generally cylindrical, with a mounting head at one end and a contact at the other end. The sensor body also has a lead hole inside, with one end of the cable leading out from the lead hole and the other end connected to the contact. Step 2: Determining the installation location of the dynamic wear monitoring device: Step 2.1: Treat each plane of the guide shoe guide groove and the multi-faceted contact of the conveyor pin row as a single-faceted contact: In the contact between the upper support plane, the left side of the guide limit, the right side of the guide limit, and the transport pin row of the guide shoe guide groove, the multi-face contact between the upper support plane, the left side of the guide limit, the right side of the guide limit, and the transport pin row is a separated and discontinuous multi-force small-face contact. These separated and discontinuous multi-force small faces are machined in one cut during the processing. Therefore, the multi-face contact between the upper support plane, the left side of the guide limit, the right side of the guide limit, and the transport pin row can be regarded as a single-face contact. Step 2.2: Select the characteristic wear areas of the upper support plane, the left side of the guide limit, and the right side of the guide limit: The characteristic wear area of ​​the upper support plane is selected as follows: The strip area with a thickness of B±(δ1+δ2) near the geometric center point of the four force-bearing surfaces formed by the contact between the upper support plane and the conveyor pin row is selected as the characteristic wear area of ​​the upper support plane, where: B is the length of the short side of the quadrilateral formed by the geometric center point of the four force-bearing surfaces, δ1 is the design clearance setting value that meets the requirements, and δ2 is the maximum wear amount of the left / right side of the guide limit. The characteristic wear area on the left side of the guide limiter is selected as follows: The strip area containing the two characteristic points set on the left side of the guide limiter, with the horizontal left-side characteristic line floating upward by σ1 and downward by σ2, is selected as the characteristic wear area on the left side of the guide limiter. Where: σ1 is the maximum upward floating amount of the horizontal left-side characteristic line when the upper surface of the guide shoe support is at its maximum wear; σ2 is the maximum downward floating amount of the horizontal left-side characteristic line caused by the guide shoe clearance deflection angle; the horizontal left-side characteristic line is the intersection line of the coal mining machine sprocket pitch circle, the horizontal plane of the conveyor pin row, and the left side of the guide limiter. The characteristic wear area of ​​the right side of the guide limit is selected as follows: The characteristic wear area of ​​the right side of the guide limit is the strip area where the horizontal rightward characteristic line floats upward by σ3 and downward by σ4, and includes the two characteristic points set on the right side of the guide limit. Wherein: σ3 is the maximum upward floating amount of the horizontal rightward characteristic line when the upper plane of the guide shoe support has the maximum wear amount; σ4 is the maximum downward floating amount of the horizontal rightward characteristic line caused by the guide shoe clearance deflection angle; the horizontal rightward characteristic line is the intersection line of the pitch circle of the coal mining machine sprocket, the horizontal plane of the conveyor pin row, and the right side of the guide limit. Step 2.3: Selection of mounting sites for each dedicated sensor: In the characteristic wear area of ​​the upper support plane, one set of geometric center points that are diagonally distributed among the four force-bearing small surfaces formed by the contact between the upper support plane and the conveyor pin row are selected as the characteristic points of the upper support plane. In the characteristic wear area on the left side of the guide limit, the intersection of the horizontal left-side characteristic line and the geometric vertical center line of the two force-bearing surfaces on the left is selected as the characteristic point of the left side of the guide limit. The two force-bearing surfaces on the left are two discontinuous force-bearing surfaces formed by the contact between the left side of the guide limit and the left side of the conveyor pin row. In the characteristic wear area of ​​the right side of the guide limit, the intersection of the horizontal right-side characteristic line and the geometric vertical center line of the two force-bearing surfaces on the right side is selected as the characteristic point of the right side of the guide limit. The two force-bearing surfaces on the right side are two discontinuous force-bearing surfaces formed by the contact between the right side of the guide limit and the right side of the conveyor pin row. On the smooth boot sole plane, two points with a distance of L / 8 from the longitudinal center line of the smooth boot's two ears and the adjacent ends of the smooth boot at the lateral ends are selected as feature points on the smooth boot sole plane. The feature points on the upper support plane, the left side of the guide limit, the right side of the guide limit, and the smooth boot sole plane obtained above are the installation positions of the dynamic wear monitoring device. Step 3: Install the dynamic wear monitoring device. Based on the installation location of the dynamic wear monitoring device determined in step two, install the special sensor designed in step one at each feature point location, and connect the cables of each special sensor to the coal mining machine electrical control box. Step 4: Dynamic monitoring for wear and tear early warning: The electrical control box of the coal mining machine is equipped with a dynamic wear early warning device. The dynamic wear early warning device dynamically monitors the wear condition of the area around the installation position of each dedicated sensor based on the data monitored by each dedicated sensor. When the wear condition of the area around the installation position of each dedicated sensor exceeds the limit, a corresponding early warning is issued, thus realizing dynamic monitoring of wear early warning.

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