An explosion-proof passive intelligent detection system for roller faults in underground coal mines

Abstract

The present invention discloses an explosion-proof passive intelligent detection system for roller faults in underground coal mines. The system installs a single-phase generator at the end of the roller, generates a current drive signal frequency-locked transmission amplifier circuit by roller rotation, and realizes the transmission of LED light and radio pulse signals. The system can monitor the operation status of the roller in real time, and stop sending signals when a fault occurs, so that manual or robot inspections can timely discover and handle roller faults. The system has a simple structure, low cost, and is easy to install, and is suitable for explosion-proof environments in underground coal mines.

Description

Technical Field

[0001] The invention relates to the field of underground roller fault detection, and in particular to an underground explosion-proof passive intelligent roller fault detection system for a coal mine. Background Art

[0002] Belt conveyor is an important equipment for coal mining and transportation production in coal mines. One of its main components is the belt roller. The number and quality of the roller directly affect the operating efficiency and maintenance cost of the conveyor.

[0003] However, research has found that during long-term operation, the shaft and bearing of the roller are prone to wear, which causes the roller to rotate inflexibly or jam, thereby increasing the power consumption of the conveyor and even causing serious accidents such as conveyor belt damage, smoke and fire. According to statistics, the proportion of coal mine accidents related to belt conveyor failures is relatively high, and roller failure is one of the main reasons. Therefore, for a running conveyor, the main object of maintenance and replacement is the roller. Timely detection of roller failures, early warning, and replacement at any time are one of the important tasks of belt conveyor maintenance.

[0004] At present, traditional roller inspection mainly relies on manual inspection, which has problems such as harsh working environment, high labor intensity and low efficiency. Although robot inspection technology has been applied, there is still a lack of efficient and low-cost solutions for roller fault detection. Therefore, there is an urgent need for an intelligent system that can detect roller faults in real time, reliably and at low cost to improve the operating safety and maintenance efficiency of conveyors. Summary of the invention

[0005] The purpose of the present invention is to provide an explosion-proof passive intelligent detection system for roller faults in underground coal mines, which solves the above-mentioned technical problems pointed out in the prior art.

[0006] The present invention provides an underground explosion-proof passive intelligent detection system for roller faults in coal mines, comprising:

[0007] A signal transmitter installed at the end of the roller and a matching receiving and decoding device;

[0008] The signal transmitting device comprises a single-phase power generation device, a rectifier filter element, a signal frequency-locked transmission amplifier circuit, an LED drive circuit, a light-emitting diode LED and a radio pulse signal transmitting unit; wherein the single-phase power generation device is composed of two magnets (N and S poles) embedded in a circular mounting body, a circuit board and a conductor coil;

[0009] The circuit board is installed in a mounting box and fixedly mounted on the roller sealing outer cover; one end of the conductor coil is integrated and welded on the circuit board, and the other end of the conductive coil protrudes out of the mounting box to the annular mounting body to generate magnetic induction power with two magnets in the annular mounting body; the circuit board is also integrated with the rectifying and filtering element, the signal frequency-locked transmission amplifying circuit, the LED driving circuit, and the light-emitting diode LED; the LED driving circuit is electrically connected to the light-emitting diode LED;

[0010] The receiving and decoding device includes an antenna coupled to the radio signal frequency of the signal transmitting device, an amplifying circuit and a decoding circuit.

[0011] It should be noted that in the above technical solution, the signal frequency-locked transmission amplifier circuit drives a light-emitting diode LED and a specific frequency radio pulse signal for manual inspection identification or robot inspection detection. The specific frequency radio pulse signal is a set of digital codes, representing the encoding of this device. Since the current intensity generated by the single-phase power generation circuit will change periodically, when the current intensity after shaping and filtering is sufficient to drive the signal frequency-locked transmission amplifier circuit, the LED emits light (artificially recognizable light signal) and the pulse signal (machine-recognizable electromagnetic signal) is emitted;

[0012] Preferably, as an implementable embodiment, a transmitting antenna is also integrated and connected to the circuit board.

[0013] Preferably, as an implementable solution, an 8-bit DP dip switch is also integrated and connected on the circuit board; the 8-bit DP dip switch is used to set the number of the current roller.

[0014] Preferably, as an implementable embodiment, a coding modulation circuit element is also integrated and connected on the circuit board; the coding modulation circuit element is used to encode the electrical signal that controls the light-emitting state of the light-emitting diode LED and then outputs a radio pulse signal.

[0015] Preferably, as an implementable embodiment, the signal frequency-locked transmission amplifier circuit is used to first undergo rectification and filtering processing by a rectification and filtering element, and then detect the current intensity generated by a single-phase power generation device, control the light-emitting state of the light-emitting diode LED and output the transmission of a radio pulse signal that has been encoded and processed by a coding modulation circuit element.

[0016] Preferably, as an implementable solution, the receiving and decoding device is used to receive the radio pulse signal generated as the rotation speed of the roller changes periodically; and then judge whether the current roller is operating normally based on the comparison between the current radio pulse signal and the radio pulse signal generated during the normal operation of the roller.

[0017] Preferably, as an implementable embodiment, the amplifying circuit on the receiving and decoding device is used to amplify the received radio pulse signal.

[0018] Preferably, as an implementable embodiment, the decoding circuit on the receiving and decoding device is used to decode the radio pulse signal processed by the amplifying circuit and convert it into a digital code to identify the current roller number and the lighting state of the light-emitting diode LED (from which the operating state of the roller can be inferred).

[0019] Preferably, as an implementable embodiment, the installation box is a non-metal installation box; the non-metal installation box is installed on the roller sealing outer cover.

[0020] Compared with the prior art, the embodiments of the present invention have at least the following technical advantages:

[0021] It can be known from the analysis of the above-mentioned coal mine underground explosion-proof passive intelligent detection roller fault system provided by the present invention that in specific applications, a simple single-phase power generation device (i.e., part of the signal transmitting device) is additionally installed at the end of the existing roller, and the generated current is shaped and filtered to drive a signal frequency-locked transmission amplifier circuit, which drives a light-emitting diode LED and a radio pulse signal of a specific frequency for manual inspection identification or robot inspection detection. Among them, the signal frequency-locked transmission amplifier circuit is used to first undergo rectification and filtering processing by the rectification and filtering element, and then detect the current intensity generated by the single-phase power generation device, control the light-emitting state of the light-emitting diode LED and output the transmission of the radio pulse signal encoded by the coding modulation circuit element. The receiving and decoding device is used to receive the radio pulse signal generated by the periodic change of the roller rotation speed; then, the current radio pulse signal is compared with the radio pulse signal generated during the normal operation of the roller to determine whether the current roller is operating normally.

[0022] The above-mentioned explosion-proof passive intelligent detection roller fault system for underground coal mines uses electromechanical and electronic technology to install a signal transmitter with a single-phase power generation function on the roller, which dynamically reflects the operating status of the roller in real time for direct identification by manual inspection or robot inspection. The above-mentioned system is simple, reliable, low-cost, and easy to install, while meeting the strict explosion-proof design requirements of underground coal mines. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic diagram of the principle of a coal mine underground explosion-proof passive intelligent detection roller fault system;

[0024] Figure 2 The present invention is a schematic diagram of the partial circuit principle of a signal transmitting device in an explosion-proof passive intelligent detection roller fault system in underground coal mines.

[0025] Reference numerals:

[0026] Single-phase power generation device 10; rectification and filtering element 11; signal frequency-locked transmission amplifier circuit 12; LED drive circuit 13; radio pulse signal transmission unit 14; coding modulation circuit element 15;

[0027] The receiving and decoding device 20. DETAILED DESCRIPTION

[0028] The technical solution of the present invention will be described clearly and completely below 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 creative work are within the scope of protection of the present invention.

[0029] The present invention is further described in detail below through specific embodiments in conjunction with the accompanying drawings.

[0030] Embodiment 1

[0031] like Figure 1 As shown, the first embodiment of the present invention provides an underground explosion-proof passive intelligent detection system for roller faults in coal mines, comprising:

[0032] A signal transmitter installed at the end of the roller and a matching receiving and decoding device;

[0033] The signal transmitting device comprises a single-phase power generation device 10, a rectifying and filtering element 11, a signal frequency-locked transmitting amplifier circuit 12, an LED driving circuit 13, a light-emitting diode LED (hereinafter referred to as LED) and a radio pulse signal transmitting unit 14;

[0034] The single-phase power generation device is composed of two magnets (N and S poles) embedded in a circular mounting body, a circuit board and a conductor coil;

[0035] The circuit board is installed in a mounting box and fixedly mounted on the roller sealing outer cover; one end of the conductor coil is integrated and welded on the circuit board, and the other end of the conductive coil protrudes out of the mounting box into the annular mounting body to generate magnetic induction power with two magnets in the annular mounting body; the circuit board is also integrated and connected with the rectifying and filtering element, the signal frequency-locked transmission amplifying circuit, the LED driving circuit, and the light-emitting diode LED; the LED driving circuit is electrically connected to the light-emitting diode LED;

[0036] The receiving and decoding device 20 includes an antenna coupled to the radio signal frequency of the signal transmitting device, an amplifying circuit and a decoding circuit.

[0037] The purpose of the present invention is to provide an underground explosion-proof passive intelligent detection system for roller faults in coal mines, which can dynamically reflect the operating status of the roller in real time, realize timely early warning and identification of faults, and is suitable for manual inspection and robot inspection. The present invention is based on the principle of power generation and uses electromechanical and electronic technology to form a signal transmitter with an identification code installed on the roller, which dynamically reflects the operating status of the roller in real time for direct identification by manual inspection or robot inspection. It is simple, reliable, low-cost, easy to install, and can meet the intrinsically safe explosion-proof requirements.

[0038] The device is equipped with a simple single-phase power generation device at the end of the existing roller, and the generated current is shaped and filtered to drive a signal frequency-locked transmission amplifier circuit, which drives a light-emitting diode LED and a specific frequency radio pulse signal for manual inspection identification or robot inspection detection. The signal frequency-locked transmission amplifier circuit can generate a specific frequency radio pulse signal as a set of digital codes, which represents the code of the device. Since the current intensity generated by the single-phase power generation circuit will change periodically, when the current intensity after shaping and filtering is sufficient to drive the signal frequency-locked transmission amplifier circuit, the light-emitting diode LED emits light (artificially recognizable light signal) and the pulse signal (machine-recognizable electromagnetic signal) is emitted; and when the current intensity is insufficient to drive the signal frequency-locked transmission amplifier circuit, the light-emitting diode LED does not emit light and the pulse signal does not emit. The signal changes periodically with the rotation speed of the roller, reflecting whether the operation of the roller is normal. In conjunction with this, an antenna coupled to the radio signal frequency of this device and an amplification and decoding circuit are used to detect the signal emitted by the device and decode its digital number to identify the roller number for use by the inspection robot.

[0039] It should be noted that in the above technical solution, the signal frequency-locked transmission amplifier circuit drives a light-emitting diode LED and a specific frequency radio pulse signal for manual inspection identification or robot inspection detection. The specific frequency radio pulse signal is a set of digital codes, representing the encoding of this device. Since the current intensity generated by the single-phase power generation circuit will change periodically, when the current intensity after shaping and filtering is sufficient to drive the signal frequency-locked transmission amplifier circuit, the LED emits light (artificially recognizable light signal) and the pulse signal (machine-recognizable electromagnetic signal) is emitted;

[0040] In a specific technical solution, the single-phase power generation device is composed of two magnets (N and S poles) embedded in a circular mounting body, a circuit board and a conductor coil;

[0041] Among them, two magnets (N and S poles) are embedded in a circular mounting body, and the mounting body is fixed to one end of the roller bracket and surrounds the roller shaft. One end of the conductor coil is integrated and welded on the circuit board, and the other end of the conductive coil protrudes out of the mounting box into the circular mounting body to generate magnetic induction power with the two magnets in the circular mounting body. The circuit board is also integrated with the rectifier and filter element, the signal frequency-locked transmission amplifier circuit, the LED drive circuit, the light-emitting diode LED, etc.;

[0042] About installation method: The circuit board is installed in a non-metallic installation box, which is fixed on the sealed outer cover of the roller. The signal transmitter is fixed on the sealed outer cover of the roller, and all circuit components are installed in the non-metallic installation box to ensure that it meets the explosion-proof requirements.

[0043] Regarding rollers, although there are many specific structural forms of rollers, the structural principles are generally the same. Rollers are mainly composed of a spindle, a tube body, a bearing seat, a bearing and a sealing device, and most of them are made into fixed-axis type, so the rollers will not be described in detail.

[0044] Under normal operating conditions, the current generated by the rotation of the roller is sufficient to drive the signal frequency lock transmission amplifier circuit, the LED continues to light up, and the radio pulse signal is sent stably, indicating that the roller is operating normally. When the roller fails and causes poor rotation or stalling, the generated current weakens or stops, the signal frequency lock transmission amplifier circuit fails, the LED goes out, and the radio pulse signal stops sending. The system promptly warns of roller failure through changes in the signal.

[0045] Preferably, as an implementable solution, a transmitting antenna is integrated on the circuit board. An 8-bit DP dial switch is integrated on the circuit board; the 8-bit DP dial switch is used to set the number of the current roller.

[0046] like Figure 2 As shown, the circuit board is also integrated with a coding modulation circuit element 15; the coding modulation circuit element 15 is used to encode the electrical signal for controlling the light-emitting state of the light-emitting diode LED and then output a radio pulse signal.

[0047] Preferably, as an implementable embodiment; wherein the signal frequency-locked transmitting amplifier circuit is used for 12 to first undergo rectification and filtering processing by the rectifying and filtering elements, and then detect the current intensity generated by the single-phase power generation device, control the light-emitting state of the light-emitting diode LED and output the sending of the radio pulse signal encoded by the coding modulation circuit element.

[0048] The receiving and decoding device 20 is used to receive the radio pulse signal generated as the rotation speed of the roller changes periodically; then compare the current radio pulse signal with the radio pulse signal generated during the normal operation of the roller to determine whether the current roller is operating normally.

[0049] Preferably, as an implementable embodiment, the amplifying circuit on the receiving and decoding device 20 is used to amplify the received radio pulse signal.

[0050] Preferably, as an implementable embodiment, the decoding circuit on the receiving and decoding device 20 is used to decode the radio pulse signal processed by the amplifying circuit and convert it into a digital code to identify the current roller number and the light-emitting state of the light-emitting diode LED (from which the operating state of the roller can be inferred).

[0051] Through the signal frequency-locked transmission amplifier circuit, the current signal generated by the single-phase generator is rectified and filtered to control the LED lighting state, and the processed signal is encoded and modulated and then wirelessly transmitted. Normally, the self-rotation of the roller is regular, but at this time, the conductor coil cuts the two magnets on the single-phase generator in a regular manner, thereby generating a regular power generation current. In this way, the detection of the current signal generated by the single-phase generator can be used to indirectly detect the operating state of the roller.

[0052] The amplifier circuit in the receiving and decoding device amplifies the received radio pulse signal to ensure that the signal strength and quality are sufficient for subsequent processing, thereby improving the reliability and anti-interference ability of the system. The decoding circuit converts the amplified radio pulse signal into a digital code, identifies the current roller number and the light-emitting state of the light-emitting diode LED, and thus calculates the specific operating state of the roller. By comparing the current signal with the signal during normal operation, it can accurately determine whether the roller is in normal operation.

[0053] This technical solution combines wireless transmission of roller operation information with signal amplification and decoding to monitor the operation status of each roller in real time and accurately, and effectively identify abnormal operation conditions through signal comparison, thereby improving the monitoring efficiency and reliability of the system and facilitating timely maintenance and management.

[0054] Preferably, as an implementable embodiment, the installation box is a non-metal installation box; the non-metal installation box is installed on the roller sealing outer cover.

[0055] In summary, the embodiment of the present invention provides an underground explosion-proof passive intelligent detection system for roller faults in coal mines. By installing a simple single-phase power generation device (i.e., part of the signal transmitter) at the end of the existing roller, the generated current is shaped and filtered to drive a signal frequency-locked transmission amplifier circuit, which drives a light-emitting diode LED and a radio pulse signal of a specific frequency for manual inspection identification or robot inspection detection. Among them, the signal frequency-locked transmission amplifier circuit is used to first undergo rectification and filtering processing by a rectification and filtering element, and then detect the current intensity generated by the single-phase power generation device, control the light-emitting state of the light-emitting diode LED and output the transmission of the radio pulse signal encoded by the coding modulation circuit element. The receiving and decoding device is used to receive the radio pulse signal generated by the periodic change of the roller rotation speed; then, the current radio pulse signal is compared with the radio pulse signal generated during the normal operation of the roller to determine whether the current roller is operating normally.

[0056] The above-mentioned explosion-proof passive intelligent detection roller fault system for underground coal mines uses electromechanical and electronic technology to install a signal transmitter with a single-phase power generation function on the roller, which dynamically reflects the operating status of the roller in real time for direct identification by manual inspection or robot inspection. The above-mentioned system is simple, reliable, low-cost, and easy to install, while meeting the strict explosion-proof design requirements of underground coal mines.

[0057] An embodiment of the present invention provides an explosion-proof passive intelligent detection roller fault system for underground coal mines. By utilizing electromechanical and electronic technology, a signal transmitting device with a single-phase power generation function is installed on the roller, which dynamically reflects the operating status of the roller in real time for direct identification by manual inspection or robot inspection. The system is simple, reliable, low-cost, and easy to install, while meeting the strict explosion-proof design requirements of underground coal mines.

[0058] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. A person skilled in the art may modify the technical solutions described in the above embodiments, or replace part or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An explosion-proof passive intelligent detection roller fault system for underground coal mines, characterized in that: include: A signal transmitter installed at the end of the roller and a matching receiving and decoding device; The signal transmitting device comprises a single-phase power generation device, a rectifying and filtering element, a signal frequency-locked transmitting amplifying circuit, an LED driving circuit, a light-emitting diode LED and a radio pulse signal transmitting unit; wherein the single-phase power generation device is composed of two magnets, a circuit board and a conductor coil embedded in a circular mounting body; The circuit board is installed in a mounting box and fixedly mounted on the roller sealing outer cover; one end of the conductor coil is integrated and welded on the circuit board, and the other end of the conductive coil protrudes out of the mounting box into the annular mounting body to generate magnetic induction power with two magnets in the annular mounting body; the circuit board is also integrated and connected with the rectifying and filtering element, the signal frequency-locked transmission amplifying circuit, the LED driving circuit, and the light-emitting diode LED; the LED driving circuit is electrically connected to the light-emitting diode LED; The receiving and decoding device includes an antenna coupled to the radio signal frequency of the signal transmitting device, an amplifying circuit and a decoding circuit.

2. The underground explosion-proof passive intelligent detection roller fault system of coal mine according to claim 1 is characterized in that: The circuit board is also integrated with a transmitting antenna.

3. The underground explosion-proof passive intelligent detection roller fault system of coal mine according to claim 2 is characterized in that: The circuit board is also integrated with an 8-bit DP dial switch; the 8-bit DP dial switch is used to set the number of the current roller.

4. The underground explosion-proof passive intelligent detection roller fault system of coal mine according to claim 3 is characterized in that: The circuit board is also integrated with a coding modulation circuit element; the coding modulation circuit element is used to encode the electrical signal for controlling the light-emitting state of the light-emitting diode LED and then output a radio pulse signal.

5. The underground explosion-proof passive intelligent detection roller fault system of coal mine according to claim 4 is characterized in that: The signal frequency-locked transmission amplifier circuit is used to first undergo rectification and filtering processing by the rectification and filtering elements, then detect the current intensity generated by the single-phase power generation device, control the light-emitting state of the light-emitting diode LED, and output the transmission of the radio pulse signal encoded by the coding modulation circuit element.

6. The underground explosion-proof passive intelligent detection roller fault system of coal mine according to claim 5 is characterized in that: The receiving and decoding device is used to receive the radio pulse signal generated by the periodic change of the rotation speed of the roller; Then, the current radio pulse signal is compared with the radio pulse signal generated when the normal roller is running to determine whether the current roller is running normally.

7. The underground explosion-proof passive intelligent detection roller fault system of coal mine according to claim 1 is characterized in that: The amplifying circuit on the receiving and decoding device is used to amplify the received radio pulse signal.

8. The underground explosion-proof passive intelligent detection roller fault system of coal mine according to claim 7, characterized in that: The decoding circuit on the receiving and decoding device is used to decode the radio pulse signal processed by the amplifying circuit and convert it into a digital code to identify the number of the current roller and the lighting state of the light-emitting diode LED.

9. The underground explosion-proof passive intelligent detection roller fault system of coal mine according to claim 1, characterized in that: The installation box is a non-metal installation box; the non-metal installation box is installed on the roller sealing outer cover.

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