Scraper conveyor chain monitoring device and method based on Hall principle

Abstract

The invention discloses a scraper conveyor chain monitoring device and method based on the Hall principle. The device comprises a full-open skylight plugboard 1, a sensor positioning plate 2, a sensor module 3, a signal processing module 4 and a monitoring substation 5, the full-open skylight inserting plate 1 is arranged at a middle groove of the scraper conveyor; a sensor positioning plate 2 is arranged on the face, facing a scraper conveyor chain, of the fully-open skylight inserting plate 1. The sensor module 3 is mounted on the sensor positioning plate 2 at a position corresponding to the chain; the signal processing module 4 is used for receiving detection data of the sensor module 3 and calculating to obtain real-time chain pitch data; and the monitoring substation 5 is used for monitoring the real-time running speed data of the scraper chain and determining the health state of the chain according to the real-time pitch length data of the chain. The sensor module and the full-open skylight inserting plate are combined and installed, and the scraper conveyor does not occupy too much space; in addition, after being installed, the sensor can be prevented from being damaged, and meanwhile chain data can be effectively obtained.

Description

Technical Field

[0001] The present application relates to the technical field of mining scraper conveyor equipment, and in particular to a scraper conveyor chain monitoring device and method based on the Hall principle. Background Art

[0002] Scraper conveyor is an important equipment for coal mine transportation. Whether it can operate reliably is directly related to the safe and efficient production of the mine. The working surface of the scraper conveyor fluctuates when it is working. In actual production underground, the amount of coal changes with the changes in the conditions of the coal mining working surface, which makes the load of the conveyor complex and variable.

[0003] Since the scraper chain is an elastic body, its length will expand or contract accordingly when the tension acting on it changes. When the scraper chain is too loose, the meshing force between the chain and the sprocket is small, which is easy to cause the chain to fall off and the sprocket to be damaged. When the too loose chain circulates at the bottom of the middle groove, the friction with the bottom plate is large, which is easy to get stuck and the chain is seriously worn. When the scraper chain is too tight, the contact force between the chain and the sprocket increases, the equipment operation resistance and energy consumption increase, the wear of parts such as the sprocket increases, and the service life is reduced.

[0004] The current chain monitoring devices have great limitations in use. They are too large and inconvenient to install. In addition, the sensors are exposed and lack protection, making them easily damaged. Summary of the invention

[0005] In view of this, it is necessary to provide a scraper conveyor chain monitoring device and method based on the Hall principle to solve the problems of large size, inconvenient installation and easy damage of sensors in the chain pitch measurement scheme in the prior art.

[0006] A scraper conveyor chain monitoring device based on the Hall principle, comprising a fully-opening skylight plug plate 1, a sensor positioning plate 2, a sensor module 3, a signal processing module 4 and a monitoring substation 5;

[0007] The fully-open skylight plug plate 1 is arranged at the middle groove of the scraper conveyor; the fully-open skylight plug plate 1 is provided with a sensor positioning plate 2 on the side facing the scraper conveyor chain; the sensor module 3 is installed on the sensor positioning plate 2 at a position corresponding to the chain;

[0008] The signal processing module 4 is used to receive the detection data of the sensor module 3 and calculate the real-time chain pitch data; the monitoring substation 5 is used to monitor the real-time running speed data of the scraper chain, and determine the health status of the chain according to the real-time chain pitch length data of the signal processing module 4.

[0009] Preferably, a sensor installation groove 21 is provided at a position corresponding to the sensor positioning plate 2 and the chain; and the sensor module 3 is detachably installed in the sensor installation groove 21 by means of bolts.

[0010] Preferably, a protective cover 22 is further provided at the sensor mounting groove 21 on the sensor positioning plate 2 .

[0011] Preferably, the protective cover 22 is movably connected to the sensor positioning plate 2 , and the protective cover 22 is used to cover the sensor installation groove 21 .

[0012] Preferably, it also includes a power module 6 ; the power module 6 is used to supply power to the sensor module 3 , the signal processing module 4 and the monitoring substation 5 .

[0013] Preferably, it also includes an alarm module 7, which is used to issue an alarm prompt when the monitoring substation 5 determines that the health status of the chain is abnormal.

[0014] A scraper conveyor chain monitoring method based on the Hall principle, comprising:

[0015] The time interval between adjacent links of the chain is obtained by receiving the sensor module through the monitoring substation;

[0016] Obtain the real-time running speed of the chain through monitoring substations;

[0017] The monitoring substation obtains an average chain link length according to the time interval and the real-time running speed;

[0018] The monitoring substation compares the average link length to the initial link length and determines the health of the chain.

[0019] Preferably, the monitoring substation compares the average link length with the initial link length and determines the health of the chain, including:

[0020] The monitoring substation calculates the elongation of the chain according to the average chain link length and the initial chain link length;

[0021] If the elongation exceeds a preset threshold, it is determined that the health status of the chain is abnormal.

[0022] Compared with the prior art, the beneficial effects of the present application are: by installing the sensor module in combination with the fully open skylight plug plate, the scraper conveyor does not have too much sensor space; and the sensor can be effectively protected from damage after installation, and the installation position of the sensor can effectively obtain chain data. Therefore, the solution provided by the present application has the advantages of small size, easy installation, good sensor protection, etc., making it more reliable and efficient in practical applications. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 A is a structural schematic diagram of a scraper conveyor chain monitoring device based on the Hall principle provided in an embodiment of the present application.

[0024] Figure 2 A structural schematic diagram B of a scraper conveyor chain monitoring device based on the Hall principle provided in an embodiment of the present application.

[0025] Figure 3 A schematic flow chart of a scraper conveyor chain monitoring method based on the Hall principle provided in an embodiment of the present application.

[0026] Figure 4 This is an example diagram of the appearance structure of the proximity sensor provided in an embodiment of the present application. DETAILED DESCRIPTION

[0027] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0028] Proximity sensors based on the Hall effect can be used to detect the presence or position change of metal objects (such as chains). When the chain links (whether flat or vertical) pass near the sensor, they change the magnetic field distribution around the sensor, causing a change in the output voltage of the Hall element. This change can be converted into an electrical signal for further processing.

[0029] See also Figure 1 to Figure 2 , Figure 1 Schematic diagram A of the structure of a scraper conveyor chain monitoring device based on the Hall principle provided in an embodiment of the present application; Figure 2 Schematic diagram B of the scraper conveyor chain monitoring device based on the Hall principle provided in the embodiment of the present application. The scraper conveyor 100, the middle trough 200 of the scraper conveyor, and the chain 300. The scraper conveyor chain monitoring device based on the Hall principle includes a full-opening skylight plug plate 1, a sensor positioning plate 2, a sensor module 3, a signal processing module 4 and a monitoring substation 5.

[0030] The fully open skylight plug plate 1 is arranged at the middle groove of the scraper conveyor; the fully open skylight plug plate 1 is provided with a sensor positioning plate 2 on the side facing the scraper conveyor chain; the sensor module 3 is installed on the sensor positioning plate 2 at the corresponding position of the chain. The signal processing module 4 is used to receive the detection data of the sensor module 3 and calculate the real-time chain pitch data; the monitoring substation 5 is used to monitor the real-time running speed data of the scraper chain, and determine the health status of the chain according to the real-time chain pitch length data.

[0031] The main function of the fully open skylight plug 1 is to pull out the plug during work and maintenance, check the operation and integrity of the scraper chain on the lower chain path, and repair the scraper chain. At the same time, the position of the fully open skylight plug 1 is close to the chain, and high-quality chain operation data can be obtained by setting a sensor. Therefore, the present application is provided with a sensor positioning plate 2 on the side of the fully open skylight plug 1 facing the scraper conveyor chain, and the sensor module 3 is installed on the sensor positioning plate 2 corresponding to the chain. Then the sensor module 3 can include at least 2 sensors, one corresponding to each chain.

[0032] Specifically, the sensor positioning plate 2 can be detachably fixed to the fully-opening sunroof plug plate 1 by means of bolts or the like. A sensor mounting groove 21 is provided on the sensor positioning plate 2 at a position corresponding to the chain; the sensor module 3 is detachably mounted in the sensor mounting groove 21 by bolts. The sensor mounting groove 21 can not only play a positioning role, so that the installation position of the sensor can be found quickly and accurately, but also avoid the installation position error caused by the movement of the sensor during installation. The sensor module is detachably mounted in the sensor mounting groove by bolts, and installation and disassembly are very convenient, without the need for complicated tools or steps. The detachable design allows the sensor module to be easily replaced and maintained, improving the flexibility and reliability of the system.

[0033] Furthermore, on the sensor positioning plate 2, a protective cover 22 is also provided at the sensor installation slot 21. The protective cover 22 is movably connected to the sensor positioning plate 2, and the protective cover 22 is used to cover the sensor installation slot 21. For example, the protective cover 22 is fixed to the sensor positioning plate 2 by a hinge, and when the sensor installation is completed, the full-open skylight plug plate 1 is inserted back into the middle slot of the scraper conveyor, and when the entire monitoring device is working, the protective cover 22 is turned over to cover the sensor, and then it can be fixed by means of buckles, bolts, etc.

[0034] By setting up a protective cover, the sensor can be effectively protected from the influence of the external environment, the service life of the sensor is extended, and failures caused by external factors are reduced.

[0035] The signal processing module 4 is used to receive the detection data of the sensor module 3 and calculate the real-time chain pitch data; the monitoring substation 5 is used to monitor the real-time running speed data of the scraper chain, and determine the health status of the chain according to the real-time chain pitch length data of the signal processing module 4. Further, it also includes: a power module 6; the power module 6 is used to supply power to the sensor module 3, the signal processing module 4 and the monitoring substation 5.

[0036] Furthermore, it also includes an alarm module 7, which is used to send out an alarm signal through the instructions of the monitoring substation when the monitoring substation 5 determines that the health status of the chain is abnormal, so as to promptly remind the operator to carry out inspection and maintenance, thereby realizing preventive maintenance, reducing the maintenance cost of sudden failures, and improving the reliability of the system.

[0037] In addition, the sensor positioning plate 2 is provided with a standardized interface for connecting with the sensor, which can realize fast and convenient installation and disassembly. The signal processing module 4, the monitoring substation 5, the power module 6 and the alarm module 7 can be integrated to form an integrated processing module through the CPU, the power management chip circuit, etc. During transportation, the integrated processing module can be removed to avoid damage from bumps and collisions, and the signal connection with the sensor is carried out through the standard version interface during operation. The integration and reliability of the entire monitoring device and the conveyor are further improved.

[0038] like Figure 3 As shown, based on the same inventive concept, the present application also provides a scraper conveyor chain monitoring method based on the Hall principle, comprising the following steps:

[0039] S301: receiving the time interval between adjacent links of the chain obtained by the sensor module at the monitoring substation;

[0040] S302: Obtain the real-time running speed of the chain through the monitoring substation;

[0041] S303: The monitoring substation obtains an average chain link length according to the time interval and the real-time running speed;

[0042] S304: The monitoring substation compares the average chain link length with the initial chain link length and determines the health status of the chain.

[0043] Specifically, two proximity sensors (Hall sensors) are provided corresponding to the two chains of the scraper conveyor in this embodiment, and the installation positions correspond to the two chains of the scraper conveyor. Figure 4 In addition, the proximity sensor based on the Hall principle with patent number ZL201922185866.5 can be used, which has the advantages of miniaturization, high sensitivity and non-contact measurement, is easy to integrate multiple functions, and reduces the volume of the overall system.

[0044] Based on the proximity sensor, it can monitor the signal when the flat and vertical rings of the chain pass through, and output the signal waveform to the signal processing module, which analyzes the signal waveform to determine the position and time of the flat and vertical rings of the chain. Combined with the chain running speed data provided by the monitoring substation, when a certain number of chain links pass through the sensor, the total length of the chain passing through the time period is obtained by integrating the time difference between the starting and ending positions, and then the average length of a single chain link is calculated.

[0045] By comparing with the initial value of the chain link length, the health status of the chain is judged.

[0046] Determination of the initial value of the chain link length For example, according to the GB / T2828.1-2003 sampling standard, the product is sampled and inspected. According to this standard, the counting sampling plan includes the sample size n, the judgment array Ac and Re, Re = Ac + 1. For a single sampling plan, n samples are drawn from the batch, and the samples are inspected one by one. If d unqualified products are found, if d ≤ Ac, it is considered qualified, and if d ≤ Re, it is considered unqualified.

[0047] For the double sampling plan, if the number of defective products in the first sampling is Ac1<d1<Re1, a second sampling is performed. If d1+d2≤Ac2, it is considered qualified; if d1+d2≤Re2, Re2=Ac2+1, it is considered unqualified.

[0048] The receiving quality limit AQL = 15 corresponds to a failure rate of 15% when the receiving probability is 99%, a failure rate of 18.5% when the receiving probability is 95%, and a failure rate of 20.6% when the receiving probability is 90%. The decision array is a sampling plan when the receiving probability is 99%.

[0049] According to information obtained from chain manufacturers and related literature, when the deformation of the chain link pitch due to wear and creep reaches 2.5%, the chain should be replaced in time. Because the object of monitoring is not a single chain link, but the spacing of multiple scrapers, the total stretching degree when the corresponding chain link fails must not be 2.5%, which requires analysis and calculation.

[0050] Assume that after a period of use, the stretch of the chain is assumed to be normally distributed:

[0051]

[0052] It is calculated that when the proportion of chain links with a stretch rate exceeding 2.5% reaches 15%, the stretch rate X of the entire chain, that is, the initial value of the chain link length can be determined as X.

[0053] Therefore, when the length of the entire chain exceeds X, it can be considered that the elongation of the chain has exceeded the allowable value and the health status of the chain is abnormal; the signal processing module sends an alarm signal to the monitoring substation, prompting maintenance and replacement of the chain, providing data support for timely replacement of the chain.

[0054] The scraper conveyor chain monitoring method based on the Hall principle provided in this application monitors the movement of the chain in real time by receiving the time interval between adjacent chain links of the chain obtained by the sensor module through the monitoring substation, and calculates the average chain link length in combination with the real-time running speed data of the chain to ensure the accuracy and reliability of the data. The monitoring substation determines the health status of the chain based on the comparison between the average chain link length and the initial chain link length, and provides a scientific basis for judgment. The monitoring substation can also communicate with the server, host computer, etc. to realize remote monitoring, etc. In addition, the scraper conveyor chain monitoring device based on the Hall principle adopted in this embodiment has a sensor set on a fully open plug plate, which will not occupy the external space of the conveyor and can prevent the sensor from being damaged by the outside. The protective cover covering the sensor can prevent the flying stones and other objects brought up during the operation of the chain from damaging the sensor, effectively ensuring the safety and stability of the entire device.

Claims

1. A scraper conveyor chain monitoring device based on the Hall principle, characterized in that: It comprises a fully-opening skylight plug-in plate (1), a sensor positioning plate (2), a sensor module (3), a signal processing module (4) and a monitoring substation (5); The fully-open skylight plug plate (1) is arranged at the middle groove of the scraper conveyor; a sensor positioning plate (2) is arranged on the side of the fully-open skylight plug plate (1) facing the scraper conveyor chain; the sensor module (3) is installed at a position on the sensor positioning plate (2) corresponding to the chain; The signal processing module (4) is used to receive the detection data of the sensor module (3) and calculate the real-time chain pitch data; the monitoring substation (5) is used to monitor the real-time running speed data of the scraper chain and determine the health status of the chain based on the real-time chain pitch length data of the signal processing module (4).

2. The device according to claim 1, characterized in that A sensor installation groove (21) is provided at a position corresponding to the chain on the sensor positioning plate (2); the sensor module (3) is detachably installed in the sensor installation groove (21) by means of bolts.

3. The device according to claim 2, characterized in that A protective cover (22) is also provided at the sensor installation groove (21) on the sensor positioning plate (2).

4. The device according to claim 3, characterized in that The protective cover (22) is movably connected to the sensor positioning plate (2), and the protective cover (22) is used to cover the sensor installation groove (21).

5. The device according to claim 1, characterized in that Also includes: and a power module (6); The power supply module (6) is used to supply power to the sensor module (3), the signal processing module (4) and the monitoring substation (5).

6. The device according to claim 1, characterized in that It also includes an alarm module (7) for issuing an alarm prompt when the monitoring substation (5) determines that the health status of the chain is abnormal.

7. A scraper conveyor chain monitoring method based on the Hall principle, characterized in that: include: The time interval between adjacent links of the chain is obtained by receiving the sensor module through the monitoring substation; Obtain the real-time running speed of the chain through monitoring substations; The monitoring substation obtains an average chain link length according to the time interval and the real-time running speed; The monitoring substation compares the average link length to the initial link length and determines the health of the chain.

8. The method according to claim 7, characterized in that The monitoring substation compares the average link length to the initial link length and determines the health of the chain, including: The monitoring substation calculates the elongation of the chain according to the average chain link length and the initial chain link length; If the elongation exceeds a preset threshold, it is determined that the health status of the chain is abnormal.

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