A non-metallic chain scraper operation monitoring system and monitoring method

Abstract

The invention discloses a non-metallic chain scraper operation monitoring system and a monitoring method, which relate to the technical field of scraper monitoring, and include: a traction chain tension monitoring structure, including a tension sensor, which is connected to the end of a tensioning shaft through a metal rope; a guide sprocket stroke monitoring structure, including a plurality of metal signal patches, which are evenly arranged on the outer periphery of the guide sprocket, and a proximity signal sensor is arranged on the support of the guide sprocket; a torque limiting structure, including an overload signal sensor and a ball, the ball moves along the axial direction of a driving wheel, and the overload signal sensor is connected to the ball drive; a monitoring unit, which is controllably connected to the traction chain tension monitoring structure, the guide sprocket stroke monitoring structure and the torque limiting structure; the monitoring system can reduce the continuous damage caused by the operation of the drive chain after a fault occurs, reduce the recovery period of the torque overload of the reduction motor, and realize real-time cloud monitoring of the scraper operation.

Description

Technical Field

[0001] The present invention belongs to the technical field of scraper monitoring, and more specifically, relates to a non-metallic chain scraper operation monitoring system and a monitoring method. Background Art

[0002] The existing non-metal chain scraper adopts a double-row chain traction form. The traction chain of the equipment is equipped with a scraper chain link every 3 meters. The scraper chain link is fixed to the scraper, and the whole is formed into a ring through the chain link. The scraper contacts the guide rail set at the bottom of the pool and moves slowly, scraping the sludge at the bottom of the pool into the sludge tank at the end of the pool, and at the same time scraping the scum and floating oil on the surface of the pool into the scum tank, creating conditions for mud and slag discharge.

[0003] The traction chain of the non-metallic chain scraper is the main force-bearing component of the whole machine, which is responsible for transmitting the driving force output by the drive device to each scraper, driving the scraper to scrape the sludge at the bottom of the pool into the sludge bucket. There are two main common faults of existing scrapers:

[0004] 1. Traction chain breakage: At present, the fault signal is fed back through the scraper chain monitoring device. The principle is that when the traction chain on one side breaks, the scraper on this side cannot feed back the running signal within the predetermined time range and the equipment is judged to be faulty;

[0005] 2. Motor overload: Currently, current overload protection and drive wheel shear pin are used to prevent overload from causing damage to the motor.

[0006] The existing scraper operation monitoring and protection measures mainly have the following problems:

[0007] The monitoring period of traction chain breakage (fault) is too long, and the scraper monitoring signal interval is 3 minutes;

[0008] The shear pin of the driving wheel is a physical protection measure. There is no immediate signal feedback after it breaks, and the machine cannot be shut down in time;

[0009] Replacing the drive wheel shear pin is time-consuming and laborious. Summary of the invention

[0010] The purpose of the present invention is to address the deficiencies in the prior art and provide a non-metallic chain scraper operation monitoring system and monitoring method, which can reduce the continuous damage caused by the operation of the drive chain after a fault occurs, reduce the recovery period of the reduction motor torque overload, and realize real-time cloud monitoring of the scraper operation.

[0011] In order to achieve the above object, the present invention provides a non-metallic chain scraper operation monitoring system, comprising:

[0012] A traction chain tension monitoring structure, comprising a tension sensor, wherein the tension sensor is connected to the end of the tensioning shaft through a metal rope;

[0013] The guide sprocket travel monitoring structure comprises a plurality of metal signal patches, the metal signal patches are evenly arranged on the outer periphery of the guide sprocket, a proximity signal sensor is arranged on the support of the guide sprocket, and the metal signal patches cooperate with the proximity signal sensor;

[0014] The torque limiting structure comprises an overload signal sensor and a ball, wherein the ball moves along the axial direction of the driving wheel, and the overload signal sensor is drivingly connected to the ball;

[0015] The monitoring unit is controllably connected to the traction chain tension monitoring structure, the guide sprocket stroke monitoring structure and the torque limiting structure.

[0016] Optionally, the tension sensors are respectively arranged at both ends of the tensioning shaft.

[0017] Optionally, the tension sensor is arranged in the vertical direction, the guide wheel is arranged at the same height as the tensioning shaft, and the metal rope is wound around the outer circumference of the guide wheel.

[0018] Optionally, the tension sensor is located above the liquid level of the sedimentation tank, and the tension sensor is connected to the mobile phone app through a monitoring unit.

[0019] Optionally, a timing module is provided in the proximity signal sensor, and the timing module is controlled and connected to the non-metallic chain scraper.

[0020] Optionally, the metal signal patch is made of stainless steel.

[0021] Optionally, the guide sprocket is located in an upper area of ​​the non-metallic chain scraper.

[0022] Optionally, the torque limiting structure further includes a driven wheel corresponding to the driving wheel, a side of the driving wheel close to the driven wheel is connected to the ball bearing, and a side of the driving wheel away from the driven wheel is provided with a spring.

[0023] Optionally, the monitoring frequency of the monitoring unit is 10s.

[0024] The present invention also provides a non-metallic chain scraper operation monitoring method, the monitoring method comprising:

[0025] The traction chain tension monitoring structure monitors the tension value of the tensioning shaft, and when the tension changes abnormally, the traction chain tension monitoring structure sends an alarm message to the monitoring unit;

[0026] The guide sprocket travel monitoring structure monitors the signal generated by the proximity signal sensor, and when no signal is received, the guide sprocket travel monitoring structure sends fault information to the monitoring unit;

[0027] The torque limiting structure monitors the torque value of the non-metallic chain scraper. When the torque value is greater than a preset value, the ball moves to stop the non-metallic chain scraper.

[0028] The present invention provides a non-metallic chain scraper operation monitoring system and monitoring method, which have the following beneficial effects: the monitoring system is provided with a three-part structure, a traction chain tension monitoring structure can monitor the tension of the tensioning shaft, when the traction chain breaks, the tensioning shaft is no longer constrained by the traction chain, and the tension of the tensioning shaft drops to zero instantly, the traction chain tension monitoring structure can immediately send the monitoring result to the monitoring unit, in addition, the guide sprocket stroke monitoring structure can monitor the rotation of the guide sprocket, when the scraper blade fails, the rotation speed of the guide sprocket changes, so that the frequency of the signal generated by the proximity signal sensor changes, when the signal feedback time exceeds the set range, the guide sprocket stroke monitoring structure will send a fault signal to the monitoring unit; the torque limiting structure monitors the torque of the scraper, when the torque exceeds the preset value, the ball will move to disconnect the driving wheel and the driven wheel, so that the scraper will not be overloaded and the drive system will be avoided from being damaged.

[0029] Other features and advantages of the present invention will be described in detail in the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The above and other objects, features and advantages of the present invention will become more apparent through a more detailed description of exemplary embodiments of the present invention in conjunction with the accompanying drawings, wherein like reference numerals generally represent like components throughout the exemplary embodiments of the present invention.

[0031] Figure 1 A schematic structural diagram of a non-metallic chain scraper with a non-metallic chain scraper operation monitoring system according to an embodiment of the present invention is shown.

[0032] Figure 2 A schematic structural diagram of a traction chain tension monitoring structure according to an embodiment of the present invention is shown.

[0033] Figure 3 A schematic structural diagram of a guide sprocket stroke monitoring structure according to an embodiment of the present invention is shown.

[0034] Figure 4 A schematic structural diagram of a torque limiting structure according to an embodiment of the present invention is shown.

[0035] Description of reference numerals:

[0036] 1. Tension sensor; 2. Metal rope; 3. Tensioning shaft; 4. Metal signal patch; 5. Guide sprocket; 6. Proximity signal sensor; 7. Ball bearing; 8. Driving wheel; 9. Guide wheel; 10. Driven wheel; 11. Spring. DETAILED DESCRIPTION

[0037] The preferred embodiments of the present invention will be described in more detail below. Although the preferred embodiments of the present invention are described below, it should be understood that the present invention can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided to make the present invention more thorough and complete, and to fully convey the scope of the present invention to those skilled in the art.

[0038] The present invention provides a non-metal chain scraper operation monitoring system, comprising:

[0039] A traction chain tension monitoring structure includes a tension sensor, which is connected to the end of the tensioning shaft through a metal rope;

[0040] The guide sprocket travel monitoring structure includes a plurality of metal signal patches, which are evenly arranged on the outer periphery of the guide sprocket. A proximity signal sensor is arranged on the support of the guide sprocket, and the metal signal patch cooperates with the proximity signal sensor.

[0041] The torque limiting structure includes an overload signal sensor and a ball, the ball moves along the axial direction of the driving wheel, and the overload signal sensor is drivingly connected to the ball;

[0042] The monitoring unit is controllably connected with the traction chain tension monitoring structure, the guide sprocket stroke monitoring structure and the torque limiting structure.

[0043] Specifically, the monitoring system uses the tension value of the tensioning shaft, the rotation speed of the guide sprocket and the operating torque value as monitoring objects. When the scraper has abnormal tension value, rotation speed and abnormal torque, it can send an alarm signal to the monitoring unit. The staff can stop the scraper to avoid causing greater damage to the scraper.

[0044] Optionally, tension sensors are respectively arranged at both ends of the tensioning shaft.

[0045] Specifically, the traction chain tension monitoring structure is provided with tension sensors at both ends of the tensioning shaft. Since the scraper drives the scraper to scrape mud and push scum through the traction chains on both sides, when the traction chain on one side rotates abnormally, it will affect the operation effect of the scraper. Tension sensors are set at both ends to more accurately monitor the operation of the two traction chains of the scraper.

[0046] Optionally, the tension sensor is arranged in the vertical direction, the guide wheel is arranged at the same height as the tensioning shaft, and the metal rope is wound around the outer circumference of the guide wheel.

[0047] Optionally, the tension sensor is located above the liquid level of the sedimentation tank, and the tension sensor is connected to the mobile phone app through a monitoring unit.

[0048] Specifically, the tension sensor is connected to the tensioning shaft through a metal rope, so that the operating status of the traction chain can be accurately monitored. A guide wheel is provided in the traction chain tension monitoring structure, so that the tension sensor can be set away from the activity range of the scraper, and the tension sensor is set above the liquid surface to avoid contamination of the tension sensor by sewage in the sedimentation tank, thereby improving the service life of the monitoring system.

[0049] Optionally, a timing module is provided in the proximity signal sensor, and the timing module is connected to the control of the non-metallic chain scraper.

[0050] Optionally, the metal signal patch is made of stainless steel.

[0051] Optionally, the guide sprocket is located in an upper region of the non-metallic chain scraper.

[0052] Specifically, a timing module is set in the guide sprocket travel monitoring structure. When the traction chain rotates normally, the guide sprocket will rotate synchronously with the chain, so that the metal signal patch on the guide sprocket will regularly generate a proximity signal with the proximity signal. When the interval time of the proximity signal changes or is interrupted when the scraper runs at a constant speed, it will prove that there is a problem with the scraper operation. The staff will check the scraper to avoid continuous damage to the traction chain and cause greater failures. In addition, the guide sprocket travel monitoring structure is set on the guide sprocket above the scraper, so that the metal signal patch will not be affected by the sludge at the bottom of the sedimentation tank, ensuring the normal generation of the proximity signal.

[0053] Optionally, the torque limiting structure further includes a driven wheel corresponding to the driving wheel, a side of the driving wheel close to the driven wheel is connected to the ball bearing, and a side of the driving wheel away from the driven wheel is provided with a spring.

[0054] Specifically, a torque limiter is set in the torque limiting structure, which has the same structure as the torque limiters on the market. The spring drives the driving wheel to move in the axial direction. When the torque does not exceed the preset value, the spring pushes the driving wheel against the driven wheel, and the power output is achieved through the ball coupling transmission. When the torque exceeds the preset value, the spring is squeezed, the driving wheel and the driven wheel are separated, and the power transmission is disconnected to avoid damage to the drive system. When the overload is eliminated, the reduction motor is turned on, the torque limiter will automatically reset, and the driven wheel will receive power again without disassembling the drive chain and the driving wheel.

[0055] Optionally, the monitoring frequency of the monitoring unit is 10s.

[0056] Specifically, the non-metallic chain scraper operation monitoring system can reduce the time for judging the traction chain breakage fault from 3 minutes to less than 10 seconds, reduce the continuous damage caused by the operation of the drive chain after a fault occurs, reduce the recovery period of the reduction motor torque overload, and realize real-time cloud monitoring of the scraper operation.

[0057] The present invention also provides a non-metallic chain scraper operation monitoring method, the monitoring method comprising:

[0058] The traction chain tension monitoring structure monitors the tension value of the tension shaft. When the tension changes abnormally, the traction chain tension monitoring structure sends an alarm message to the monitoring unit.

[0059] The guide sprocket travel monitoring structure monitors the signal generated by the proximity signal sensor, and when no signal is received, the guide sprocket travel monitoring structure sends fault information to the monitoring unit;

[0060] The torque limiting structure monitors the torque value of the non-metallic chain scraper. When the torque value is greater than a preset value, the ball moves to stop the non-metallic chain scraper.

[0061] Example

[0062] like Figures 1 to 4 As shown, the present invention provides a non-metallic chain scraper operation monitoring system, comprising:

[0063] The traction chain tension monitoring structure comprises a tension sensor 1, which is connected to the end of a tensioning shaft 3 through a metal rope 2;

[0064] The guide sprocket travel monitoring structure includes a plurality of metal signal patches 4, which are evenly arranged on the outer periphery of the guide sprocket 5. A proximity signal sensor 6 is arranged on the support of the guide sprocket 5, and the metal signal patches 4 cooperate with the proximity signal sensor 6.

[0065] The torque limiting structure comprises an overload signal sensor and a ball 7, wherein the ball 7 moves along the axial direction of the driving wheel 8, and the overload signal sensor is drivingly connected to the ball 7;

[0066] The monitoring unit is controllably connected with the traction chain tension monitoring structure, the guide sprocket stroke monitoring structure and the torque limiting structure.

[0067] In this embodiment, the tension sensors 1 are respectively arranged at two ends of the tensioning shaft 3 .

[0068] In this embodiment, the tension sensor 1 is arranged in the vertical direction, the guide wheel 9 is arranged at the same height as the tensioning shaft 3 , and the metal rope 2 is wound around the outer circumference of the guide wheel 9 .

[0069] In this embodiment, the tension sensor 1 is located above the liquid surface of the sedimentation tank, and the tension sensor 1 is connected to the mobile phone app through the monitoring unit.

[0070] In this embodiment, a timing module is provided in the proximity signal sensor 6, and the timing module is connected to the control of the non-metallic chain scraper.

[0071] In this embodiment, the metal signal patch 4 is made of stainless steel.

[0072] In the present embodiment, the guide sprocket 5 is located in the upper area of ​​the non-metallic chain scraper.

[0073] In this embodiment, the torque limiting structure further includes a driven wheel 10 corresponding to the driving wheel 8 . The side of the driving wheel 8 close to the driven wheel 10 is connected to the ball 7 , and the side of the driving wheel 8 away from the driven wheel 10 is provided with a spring 11 .

[0074] In this embodiment, the monitoring frequency of the monitoring unit is 10s.

[0075] The present invention also provides a non-metallic chain scraper operation monitoring method, the monitoring method comprising:

[0076] The traction chain tension monitoring structure monitors the tension value of the tension shaft. When the tension changes abnormally, the traction chain tension monitoring structure sends an alarm message to the monitoring unit.

[0077] The guide sprocket travel monitoring structure monitors the signal generated by the proximity signal sensor, and when no signal is received, the guide sprocket travel monitoring structure sends fault information to the monitoring unit;

[0078] The torque limiting structure monitors the torque value of the non-metallic chain scraper. When the torque value is greater than a preset value, the ball moves to stop the non-metallic chain scraper.

[0079] In summary, the monitoring system adds a wire rope and a tension sensor 1 at both ends of the tensioning shaft 3. When the traction chain on one side or both sides breaks, the scraper is determined to be faulty based on the feedback signal generated by the tension change. The tension sensor 1 can provide real-time feedback on the operating tension of the scraper traction chain, send it to the PLC and transmit it remotely to the mobile phone app. The operation of the scraper can be monitored at any time. When an abnormal change in tension occurs, the scraper will be shut down immediately and an alarm message will be sent to the staff. In addition, a guide sprocket stroke monitoring structure is added to the guide sprocket support part in the upper area of ​​the scraper, 12 stainless steel signal patches are evenly inlaid on the guide sprocket 5, and a proximity signal sensor 6 is installed on the support of the guide sprocket 5. When the scraper is operating normally, as the reduction motor drives, the guide sprocket 5 will rotate at a uniform speed with the traction chain. At this time, the proximity signal sensor 6 will receive a proximity signal from the stainless steel patch every 10 seconds. When the scraper fails and stops running, the guide sprocket will stop rotating immediately, and the guide sprocket monitoring signal feedback time will exceed the set range, judging that the scraper has an operating failure. The signal feedback setting time is 20 seconds. If no feedback signal is received within 20 seconds, the system judges that the equipment is faulty and feeds back the signal to the PLC. A torque limiter is also added between the driving wheel 8 and the reduction motor of the scraper to replace the shear pin in the existing structure. When the torque exceeds the preset value, the ball 7 and the driving wheel 8 are separated from the driven wheel 10 and roll freely, so that the driving and driven components are completely disengaged to prevent damage to the drive system; when the torque limiter is overloaded, the signal sensor will feed back the fault signal to the PLC and stop running. When the overload is eliminated, the reduction motor is turned on and the torque limiter will automatically resume transmission without disassembling the drive chain and driving wheel.

[0080] The embodiments of the present invention have been described above, and the above description is exemplary, not exhaustive, and is not limited to the disclosed embodiments. Many modifications and changes will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments.

Claims

1. A non-metallic chain scraper operation monitoring system, characterized in that: include: A traction chain tension monitoring structure, comprising a tension sensor, wherein the tension sensor is connected to the end of the tensioning shaft through a metal rope; The guide sprocket travel monitoring structure comprises a plurality of metal signal patches, the metal signal patches are evenly arranged on the outer periphery of the guide sprocket, a proximity signal sensor is arranged on the support of the guide sprocket, and the metal signal patches cooperate with the proximity signal sensor; The torque limiting structure comprises an overload signal sensor and a ball, wherein the ball moves along the axial direction of the driving wheel, and the overload signal sensor is drivingly connected to the ball; The monitoring unit is controllably connected to the traction chain tension monitoring structure, the guide sprocket stroke monitoring structure and the torque limiting structure.

2. The non-metallic chain scraper operation monitoring system according to claim 1 is characterized in that: The tension sensors are respectively arranged at two ends of the tensioning shaft.

3. The non-metallic chain scraper operation monitoring system according to claim 1 is characterized in that: The tension sensor is arranged along the vertical direction, the guide wheel is arranged at the same height as the tensioning shaft, and the metal rope is wound around the outer circumference of the guide wheel.

4. The non-metallic chain scraper operation monitoring system according to claim 1 is characterized in that: The tension sensor is located above the liquid level of the sedimentation tank, and the tension sensor is connected to the mobile phone app through a monitoring unit.

5. The non-metallic chain scraper operation monitoring system according to claim 1 is characterized in that: A timing module is arranged in the proximity signal sensor, and the timing module is control-connected to the non-metallic chain scraper.

6. The non-metallic chain scraper operation monitoring system according to claim 1 is characterized in that: The material of the metal signal patch is stainless steel.

7. The non-metallic chain scraper operation monitoring system according to claim 1 is characterized in that: The guide sprocket is located in the upper area of ​​the non-metallic chain scraper.

8. The non-metallic chain scraper operation monitoring system according to claim 1 is characterized in that: The torque limiting structure also includes a driven wheel corresponding to the driving wheel, a side of the driving wheel close to the driven wheel is connected to the ball bearing, and a side of the driving wheel away from the driven wheel is provided with a spring.

9. The non-metallic chain scraper operation monitoring system according to claim 1, characterized in that: The monitoring frequency of the monitoring unit is 10s.

10. A method for monitoring the operation of a non-metallic chain scraper, characterized in that: The monitoring method includes: The traction chain tension monitoring structure monitors the tension value of the tensioning shaft, and when the tension changes abnormally, the traction chain tension monitoring structure sends an alarm message to the monitoring unit; The guide sprocket travel monitoring structure monitors the signal generated by the proximity signal sensor, and when no signal is received, the guide sprocket travel monitoring structure sends fault information to the monitoring unit; The torque limiting structure monitors the torque value of the non-metallic chain scraper. When the torque value is greater than a preset value, the ball moves to stop the non-metallic chain scraper.

Images