Dumbbell pin fault detection device and method for scraper conveyor

Abstract

A dumbbell pin fault detection device and method for a scraper conveyor includes the following steps: obtaining the dumbbell pin deformation and dumbbell pin position data in real time; comparing the dumbbell pin deformation in each cycle with a pre-set deformation threshold; if the dumbbell pin deformation is within a normal range, it indicates that the dumbbell pin is normal; if not, it indicates that the dumbbell pin is abnormal; comparing the dumbbell pin position in each cycle with a pre-set position threshold; if the dumbbell pin position is within a normal range, it indicates that the dumbbell pin is normal; if not, it indicates that the dumbbell pin position is abnormal; obtaining the judgment result, uploading the normal information and abnormal information in a timely manner, and feeding back to the human-machine interface for display, and issuing an alarm warning for abnormal dumbbell pin information. The present invention solves the drawback that the traditional scraper conveyor dumbbell pin inspection is entirely manual, greatly saves manpower, reduces labor intensity, ensures detection accuracy, and improves work efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of scraper conveyors, and in particular to a dumbbell pin fault detection device and method for scraper conveyors. Background Art

[0002] Scraper conveyors are a vital component of underground coal mining and transportation systems. Dumbbell pins are key components of these equipment, connecting the scraper's central trough and enabling adjustment of the scraper conveyor to the length of the coal face. During the coal mining and conveying process, these pins are subjected to significant impact loads, often leading to stretching, breakage, and loss. In severe cases, these pins can cause the central trough to become misaligned or damaged, leading to hydraulic support misalignment and other faults. These can impact the normal operation of the entire coal mining system and even paralyze it, severely impacting mining efficiency and posing safety risks to equipment and personnel.

[0003] Currently, fault diagnosis for dumbbell pins relies primarily on manual inspection. First, manual inspections are performed one by one to determine if any dumbbell pins are missing or broken. If so, they are replaced one by one. Deformation or cracks are then determined based on manual experience, identifying any pins that pose safety risks. However, coal mining faces are often subject to harsh conditions, and dumbbell pins are often buried in coal or other debris. This makes checking their integrity extremely difficult, time-consuming, and labor-intensive, making it difficult to accurately diagnose faults. Summary of the Invention

[0004] In order to solve the technical problems existing in the above technology, it is necessary to provide a dumbbell pin fault detection method for a scraper conveyor.

[0005] A method for detecting a fault of a dumbbell pin for a scraper conveyor comprises the following steps:

[0006] Step S1: acquiring dumbbell pin deformation and dumbbell pin position data in real time;

[0007] Step S2: Compare the dumbbell pin deformation in each cycle with a preset deformation threshold to determine whether the dumbbell pin deformation is within a normal range; if the dumbbell pin deformation is within the normal range, it indicates that the dumbbell pin is normal; if not, it indicates that the dumbbell pin is abnormal;

[0008] Step S3: Compare the dumbbell pin position in each cycle with a preset position threshold to determine whether the dumbbell pin position is within a normal range; if the dumbbell pin position is within the normal range, it indicates that the dumbbell pin is normal; if not, it indicates that the dumbbell pin position is abnormal;

[0009] Step S4: Obtain the judgment results obtained in step S2 and step S3, upload normal information and abnormal information in a timely manner, and feed back to the human-machine interface for display. For abnormal information of the dumbbell pin, an alarm warning reminder will be issued.

[0010] Preferably, in step S2, whether the dumbbell pin deformation is within the normal range is determined in the following manner:

[0011] S21: Determine the limit deformation ΔS of the dumbbell pin according to the specifications of the scraper conveyor dumbbell pin;

[0012] S22: Divide the dumbbell pin deformation into three segments and determine the ranges ΔS1, ΔS2, and ΔS3 corresponding to the dumbbell pin deformation in each segment; wherein the deformation ΔS1 allows long-term operation, the deformation ΔS2 allows a duration of T2, and the deformation ΔS3 allows a duration of T3;

[0013] S23: Obtain the dumbbell pin deformation D in real time;

[0014] S24: performing real-time comparison and judgment on the dumbbell pin deformation D obtained in real time with the deformation ranges ΔS1, ΔS2, and ΔS3, and recording the duration T of each segment;

[0015] S25: Determine whether the dumbbell pin is normal based on the deformation range and duration T borne by the dumbbell pin.

[0016] Preferably, the dumbbell pin deformation D and the deformation ranges ΔS1, ΔS2, and ΔS3 are determined as follows:

[0017] The dumbbell pin deformation D is less than ΔS1, and the dumbbell pin is normal;

[0018] The dumbbell pin deformation ΔS1≤D<ΔS2, when T≤T2, the dumbbell pin is normal, when T>T2, the dumbbell pin is abnormal;

[0019] The deformation of the dumbbell pin is ΔS2≤D<ΔS3. When T≤T3, the dumbbell pin is normal; when T>T3, the dumbbell pin is abnormal.

[0020] Preferably, the dumbbell pin deformation D is obtained by reading the alloy resistance wire sensor signal built into the dumbbell pin in real time and measuring the bridge using a resistance strain gauge.

[0021] Preferably, in step S3, whether the dumbbell pin position is within the normal range is determined in the following manner:

[0022] S31: Determine the reference value L of the dumbbell pin according to the specifications of the scraper conveyor dumbbell pin and preset the time Q;

[0023] S32: Obtain the dumbbell pin position reference value ΔL in real time;

[0024] S33: Compare the dumbbell pin position reference value ΔL obtained in real time with the dumbbell pin reference value L to determine whether the dumbbell pin position is normal.

[0025] Preferably, the dumbbell pin position reference value ΔL and the dumbbell pin reference value Ld are determined as follows:

[0026] If the judgment reference value ΔL is less than L, the dumbbell pin position is normal;

[0027] If the reference value ΔL>L, start timing T1;

[0028] After judging that T1>T, a second judgment is performed. If the reference value ΔL<L, the dumbbell pin position is normal. If the reference value ΔL≥L, the dumbbell pin position is abnormal.

[0029] It is also necessary to provide a dumbbell pin fault detection device for a scraper conveyor.

[0030] A dumbbell pin fault detection device for a scraper conveyor, used to implement the above-mentioned dumbbell pin fault detection method for a scraper conveyor, comprising a controller, and a wireless stress sensor and a wireless position sensor built into the dumbbell pin;

[0031] The controller includes a wireless gateway, an information acquisition module, a wireless communication module, a calculation control module, an information output module, and an alarm display module;

[0032] The wireless gateway is installed in the controllers set at the head, middle and tail of the scraper conveyor, and is used to provide a dedicated wireless local area network to the outside world;

[0033] The information acquisition module is used to receive real-time information from the built-in sensor of the dumbbell pin of the scraper conveyor;

[0034] The calculation control module is used to calculate the deformation degree of the dumbbell pin of the scraper conveyor and compare it with the limit deformation range of the dumbbell pin to determine whether the deformation of the dumbbell pin is within the normal range. The calculation control module is also used to calculate the relative position of the dumbbell pin of the scraper conveyor to determine whether the position of the dumbbell pin is abnormal;

[0035] The information output module is used to transmit normal or abnormal information of the calculation control module to the alarm display module;

[0036] The alarm display module is used to display normal or abnormal information of the dumbbell pin and can alarm when abnormal information appears on the dumbbell pin.

[0037] Preferably, the wireless stress sensor includes an alloy resistance wire sensor, a signal acquisition and calculation circuit, and a wireless communication circuit;

[0038] The alloy resistance wire sensor is built into the dumbbell pin and is used to monitor the deformation of the dumbbell pin;

[0039] The signal acquisition and calculation circuit is built into the dumbbell pin, and the signal acquisition and calculation circuit is electrically connected to the alloy resistance wire sensor, and is used to process the data acquired by the alloy resistance wire sensor;

[0040] The wireless communication circuit is built into the dumbbell pin, and the wireless communication circuit establishes a wireless local area network with the wireless gateway for data signal transmission. The wireless communication circuit is electrically connected to the signal acquisition and calculation circuit for sending the processed data to the information acquisition module.

[0041] Preferably, the wireless position sensor includes a reference positioning part, a signal judgment part, and a wireless communication circuit;

[0042] The reference positioning portion is installed in a middle groove fixed relative to the dumbbell pin;

[0043] The signal judging part is built into the dumbbell pin, and the signal judging part and the reference part are matched one by one, and are used to judge whether the dumbbell pin is within the normal installation position range;

[0044] The wireless communication circuit is built into the dumbbell pin, and the wireless communication circuit establishes a wireless local area network with the wireless gateway for data signal transmission. The wireless communication circuit is electrically connected to the signal judgment part and is used to send the data processed by the signal judgment part to the information acquisition module.

[0045] Compared with the prior art, the present invention provides a device and method for detecting dumbbell pin faults in a scraper conveyor. A wireless stress sensor is installed inside the dumbbell pin to monitor the deformation of the dumbbell pin in real time and transmit the information to the outside via wireless communication. Receivers installed at the head, middle, and tail of the machine receive the deformation information and calculate and analyze it with the maximum allowable deformation of the dumbbell pin to determine whether the dumbbell pin is normal. A wireless position sensor is installed inside the dumbbell pin, and a positioning signal device is installed at a fixed position relative to the middle slot and the dumbbell pin. The position sensor inside the dumbbell pin reads the positioning signal in real time and transmits the position signal to the outside via wireless communication. Receivers installed at the head, middle, and tail of the machine receive the dumbbell pin position signal and compare it with the reference position signal to determine whether the dumbbell pin is installed in the correct position. By detecting dumbbell pin faults, the present invention can address the drawback of traditional scraper conveyor dumbbell pin inspections that rely entirely on manual labor, greatly saving manpower, reducing labor intensity, ensuring detection accuracy, and improving work efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0047] Figure 1 The figure is a control flow diagram of the dumbbell pin fault detection method for a scraper conveyor according to the present invention.

[0048] Figure 2 This is a structural schematic diagram of the wireless stress sensor of the present invention installed on a dumbbell pin.

[0049] Figure 3 Schematic diagram of the installation position of the wireless position sensor of the present invention.

[0050] Figure 4 Schematic diagram of a dumbbell pin fault detection device for a scraper conveyor according to the present invention.

[0051] In the figure: controller 01, wireless gateway 11, information acquisition module 12, calculation control module 13, information output module 14, alarm display module 15, wireless stress sensor 02, alloy resistance wire sensor 21, signal acquisition and calculation circuit 22, wireless communication circuit 23, wireless position sensor 03, reference positioning part 31, signal judgment part 32, wireless communication circuit 33, dumbbell pin 04, middle slot 05. DETAILED DESCRIPTION

[0052] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0053] In the description of the present invention, it should be understood that the terms "upper", "middle", "outer", "inner", "lower" and the like indicating directions or positional relationships are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the components or elements referred to must have a specific direction, be constructed and operate in a specific direction, and therefore should not be understood as limiting the present invention.

[0054] Please see Figure 1 In one embodiment, the present invention provides a method for detecting a fault of a dumbbell pin for a scraper conveyor, comprising the following steps:

[0055] Step S1: acquiring dumbbell pin deformation and dumbbell pin position data in real time;

[0056] Step S2: Compare the dumbbell pin deformation in each cycle with a preset deformation threshold to determine whether the dumbbell pin deformation is within a normal range; if the dumbbell pin deformation is within the normal range, it indicates that the dumbbell pin is normal; if not, it indicates that the dumbbell pin is abnormal;

[0057] Step S3: Compare the dumbbell pin position in each cycle with a preset position threshold to determine whether the dumbbell pin position is within a normal range; if the dumbbell pin position is within the normal range, it indicates that the dumbbell pin is normal; if not, it indicates that the dumbbell pin position is abnormal;

[0058] Step S4: Obtain the judgment results obtained in step S2 and step S3, upload normal information and abnormal information in a timely manner, and feed back to the human-machine interface for display. For abnormal information of the dumbbell pin, an alarm warning reminder will be issued.

[0059] To be more specific, in step S2, it is determined whether the dumbbell pin deformation is within the normal range in the following manner:

[0060] S21: Determine the limit deformation ΔS of the dumbbell pin according to the specifications of the scraper conveyor dumbbell pin;

[0061] S22: Divide the dumbbell pin deformation into three segments and determine the ranges ΔS1, ΔS2, and ΔS3 corresponding to the dumbbell pin deformation in each segment; wherein the deformation ΔS1 allows long-term operation, the deformation ΔS2 allows a duration of T2, and the deformation ΔS3 allows a duration of T3;

[0062] S23: Obtain the dumbbell pin deformation D in real time;

[0063] S24: performing real-time comparison and judgment on the dumbbell pin deformation D obtained in real time with the deformation ranges ΔS1, ΔS2, and ΔS3, and recording the duration T of each segment;

[0064] S25: Determine whether the dumbbell pin is normal based on the deformation range and duration T borne by the dumbbell pin.

[0065] Of course, the following method can be used to determine the dumbbell pin deformation D and the deformation range ΔS1, ΔS2, and ΔS3:

[0066] The dumbbell pin deformation D is less than ΔS1, and the dumbbell pin is normal;

[0067] The dumbbell pin deformation ΔS1≤D<ΔS2, when T≤T2, the dumbbell pin is normal, when T>T2, the dumbbell pin is abnormal;

[0068] The deformation of the dumbbell pin is ΔS2≤D<ΔS3. When T≤T3, the dumbbell pin is normal; when T>T3, the dumbbell pin is abnormal.

[0069] To explain more specifically, the dumbbell pin deformation D is obtained by reading the signal of the alloy resistance wire sensor 21 built into the dumbbell pin in real time and measuring the bridge using a resistance strain gauge.

[0070] To be more specific, in step S3, it is determined whether the dumbbell pin position is within the normal range in the following manner:

[0071] S31: Determine the reference value L of the dumbbell pin according to the specifications of the scraper conveyor dumbbell pin and preset the time Q;

[0072] S32: Obtain the dumbbell pin position reference value ΔL in real time;

[0073] S33: Compare the dumbbell pin position reference value ΔL obtained in real time with the dumbbell pin reference value L to determine whether the dumbbell pin position is normal.

[0074] Of course, the following method can be used to determine the dumbbell pin position reference value ΔL and the dumbbell pin reference value Ld:

[0075] If the judgment reference value ΔL is less than L, the dumbbell pin position is normal;

[0076] If the reference value ΔL>L, start timing T1;

[0077] After judging that T1>T, a second judgment is performed. If the reference value ΔL<L, the dumbbell pin position is normal. If the reference value ΔL≥L, the dumbbell pin position is abnormal.

[0078] Please see Figures 2 to 4 In one embodiment, the present invention provides a dumbbell pin fault detection device for a scraper conveyor, which is used to implement the dumbbell pin fault detection method for a scraper conveyor, including a controller 01, and a wireless stress sensor 02 and a wireless position sensor 03 built into the dumbbell pin;

[0079] The controller 01 includes a wireless gateway 11, an information collection module 12, a calculation and control module 13, an information output module 14, and an alarm display module 15;

[0080] As for the wireless gateway 11, it is installed in the controller 01 set at the head, middle and tail of the scraper conveyor, and is used to provide a dedicated wireless local area network to the outside world;

[0081] As for the information collection module 12, it is used to receive real-time information from the built-in sensor of the dumbbell pin of the scraper conveyor;

[0082] The calculation and control module 13 is used to calculate the deformation degree of the scraper conveyor dumbbell pin and compare it with the limit deformation range of the dumbbell pin to determine whether the deformation of the dumbbell pin is within the normal range. In addition, the calculation and control module 13 is also used to calculate the relative position of the scraper conveyor dumbbell pin installation and determine whether the dumbbell pin position is abnormal.

[0083] As for the information output module 14, it is used to transmit the normal or abnormal information of the calculation control module 13 to the alarm display module 15;

[0084] As for the alarm display module 15, it is used to display the normal or abnormal information of the dumbbell pin and to alarm when abnormal information occurs on the dumbbell pin.

[0085] In one embodiment, the wireless stress sensor 02 includes an alloy resistance wire sensor 21, a signal acquisition and calculation circuit 22, and a wireless communication circuit 23;

[0086] Among them, the alloy resistance wire sensor 21 is built into the dumbbell pin to monitor the deformation of the dumbbell pin;

[0087] The signal acquisition and calculation circuit 22 is built into the dumbbell pin, and the signal acquisition and calculation circuit 22 is electrically connected to the alloy resistance wire sensor 21, and is used to process the data obtained by the alloy resistance wire sensor 21;

[0088] Among them, the wireless communication circuit 23 is built into the dumbbell pin, and the wireless communication circuit 23 establishes a wireless local area network with the wireless gateway for data signal transmission. The wireless communication circuit 23 is electrically connected to the signal acquisition and calculation circuit 22 for sending the processed data to the information acquisition module 12.

[0089] In one embodiment, the wireless position sensor 03 includes a reference positioning part 31, a signal determination part 32, and a wireless communication circuit 33;

[0090] Wherein, the reference positioning portion 31 is installed in the middle groove fixed relative to the dumbbell pin;

[0091] Among them, the signal judgment part 32 is built into the dumbbell pin, and the signal judgment part 32 and the reference part are matched one by one to judge whether the dumbbell pin is within the normal installation position range;

[0092] Among them, the wireless communication circuit 33 is built into the dumbbell pin, the wireless communication circuit 33 establishes a wireless local area network with the wireless gateway for data signal transmission, and the wireless communication circuit 33 is electrically connected to the signal judgment part 32 for sending the data processed by the signal judgment part 32 to the information acquisition module 12.

[0093] The above disclosure is only a preferred embodiment of the present invention, and it is certainly not intended to limit the scope of the present invention. A person skilled in the art can understand that all or part of the processes of the above embodiment and equivalent changes made in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A method for detecting faults of dumbbell pins for scraper conveyors, characterized in that: The following steps are included: Step S1: acquiring dumbbell pin deformation and dumbbell pin position data in real time; Step S2: Compare the dumbbell pin deformation in each cycle with a preset deformation threshold to determine whether the dumbbell pin deformation is within a normal range; if the dumbbell pin deformation is within the normal range, it indicates that the dumbbell pin is normal; if not, it indicates that the dumbbell pin is abnormal; Among them, the following method is used to judge whether the deformation of the dumbbell pin is within the normal range: S21: Determine the limit deformation ΔS of the dumbbell pin according to the specifications of the scraper conveyor dumbbell pin; S22: Divide the dumbbell pin deformation into three segments and determine the ranges ΔS1, ΔS2, and ΔS3 corresponding to the dumbbell pin deformation in each segment; wherein the deformation ΔS1 allows long-term operation, the deformation ΔS2 allows a duration of T2, and the deformation ΔS3 allows a duration of T3; S23: Obtain the dumbbell pin deformation D in real time; S24: performing real-time comparison and judgment on the dumbbell pin deformation D obtained in real time with the deformation ranges ΔS1, ΔS2, and ΔS3, and recording the duration T of each segment; S25: judging whether the dumbbell pin is normal according to the deformation range and duration T of the dumbbell pin; Step S3: Compare the dumbbell pin position in each cycle with a preset position threshold to determine whether the dumbbell pin position is within a normal range; if the dumbbell pin position is within the normal range, it indicates that the dumbbell pin is normal; if not, it indicates that the dumbbell pin position is abnormal; Step S4: Obtain the judgment results obtained in step S2 and step S3, upload normal information and abnormal information in a timely manner, and feed back to the human-machine interface for display. For abnormal information of the dumbbell pin, an alarm warning reminder will be issued.

2. The method for detecting a fault of a dumbbell pin for a scraper conveyor according to claim 1, wherein: The determination method of dumbbell pin deformation D and deformation range ΔS1, ΔS2, ΔS3 is as follows: The dumbbell pin deformation D is less than ΔS1, and the dumbbell pin is normal; The deformation of the dumbbell pin ΔS1≤D<ΔS2, when T≤T2, the dumbbell pin is normal, when T>T2, the dumbbell pin is abnormal; the deformation of the dumbbell pin ΔS2≤D<ΔS3, when T≤T3, the dumbbell pin is normal, when T>T3, the dumbbell pin is abnormal.

3. The method for detecting a fault of a dumbbell pin for a scraper conveyor according to claim 1, wherein: The dumbbell pin deformation D is obtained by reading the alloy resistance wire sensor signal built into the dumbbell pin in real time and measuring the bridge using a resistance strain gauge.

4. The method for detecting a fault of a dumbbell pin for a scraper conveyor according to claim 1, wherein: In step S3, it is determined whether the dumbbell pin position is within the normal range, using the following method: S31: Determine the reference value L of the dumbbell pin according to the specifications of the scraper conveyor dumbbell pin and preset the time Q; S32: Obtain the dumbbell pin position reference value ΔL in real time; S33: Compare the dumbbell pin position reference value ΔL obtained in real time with the dumbbell pin reference value L to determine whether the dumbbell pin position is normal.

5. The method for detecting a fault of a dumbbell pin for a scraper conveyor according to claim 4, wherein: The dumbbell pin position reference value ΔL and the dumbbell pin reference value L are determined as follows: If the judgment reference value ΔL is less than L, the dumbbell pin position is normal; If the reference value ΔL>L, start timing T1; After judging that T1>Q, a second judgment is performed. If the reference value ΔL<L, the dumbbell pin position is normal. If the reference value ΔL≥L, the dumbbell pin position is abnormal.

6. A dumbbell pin fault detection device for a scraper conveyor, used to implement the dumbbell pin fault detection method for a scraper conveyor according to any one of claims 1 to 5, characterized in that: It includes a controller, a wireless stress sensor and a wireless position sensor built into the dumbbell pin; The controller includes a wireless gateway, an information acquisition module, a calculation control module, an information output module, and an alarm display module; The wireless gateway is installed in the controllers set at the head, middle and tail of the scraper conveyor, and is used to provide a dedicated wireless local area network to the outside world; The information acquisition module is used to receive real-time information from the built-in sensor of the dumbbell pin of the scraper conveyor; The calculation control module is used to calculate the deformation degree of the dumbbell pin of the scraper conveyor and compare it with the limit deformation range of the dumbbell pin to determine whether the deformation of the dumbbell pin is within the normal range. The calculation control module is also used to calculate the relative position of the dumbbell pin of the scraper conveyor to determine whether the position of the dumbbell pin is abnormal; The information output module is used to transmit normal or abnormal information of the calculation control module to the alarm display module; The alarm display module is used to display normal or abnormal information of the dumbbell pin and can alarm when abnormal information appears on the dumbbell pin.

7. The dumbbell pin fault detection device for a scraper conveyor according to claim 6, characterized in that: The wireless stress sensor includes an alloy resistance wire sensor, a signal acquisition and calculation circuit, and a wireless communication circuit; The alloy resistance wire sensor is built into the dumbbell pin and is used to monitor the deformation of the dumbbell pin; The signal acquisition and calculation circuit is built into the dumbbell pin, and the signal acquisition and calculation circuit is electrically connected to the alloy resistance wire sensor, and is used to process the data acquired by the alloy resistance wire sensor; The wireless communication circuit is built into the dumbbell pin, and the wireless communication circuit establishes a wireless local area network with the wireless gateway for data signal transmission. The wireless communication circuit is electrically connected to the signal acquisition and calculation circuit for sending the processed data to the information acquisition module.

8. The dumbbell pin fault detection device for a scraper conveyor according to claim 6, characterized in that: The wireless position sensor includes a reference positioning part, a signal judgment part, and a wireless communication circuit; The reference positioning part is installed in the middle groove fixed relative to the dumbbell pin; The signal judging part is built into the dumbbell pin, and the signal judging part and the reference positioning part are matched one by one, and are used to judge whether the dumbbell pin is within the normal installation position range; The wireless communication circuit is built into the dumbbell pin, and the wireless communication circuit establishes a wireless local area network with the wireless gateway for data signal transmission. The wireless communication circuit is electrically connected to the signal judgment part and is used to send the data processed by the signal judgment part to the information acquisition module.

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