Scraper conveyer ultrasonic dumbbell strain state monitoring system and method

Abstract

The invention relates to an ultrasonic dumbbell strain state monitoring system and method for a scraper conveyor, and belongs to the technical field of intelligent mining of scraper conveyors. Due to the fact that the number of scrapper conveyor dumbbells is large and long-term high-load operation is achieved, manual inspection consumes time and labor, real-time monitoring cannot be achieved, and if dumbbell state faults cannot be found in time, normal operation of the scrapper conveyor is affected, and safety accidents are likely to be caused. According to the scraper conveyor ultrasonic dumbbell strain state monitoring system and method, the strong penetration characteristic of ultrasonic waves is utilized, the dumbbell shape change is reflected by measuring the length of a dumbbell, the measurement result is uploaded to a controller through a wireless base station, and the controller calculates dumbbell strain and analyzes whether the current dumbbell strain state is normal or not; when the dumbbell strain reaches a set alarm value, alarm prompt information is sent out, a maintainer is prompted to deal with the dumbbell in time, detailed information of the faulted dumbbell is uploaded to an underground centralized control system and a ground dispatching center, and dynamic real-time monitoring of the dumbbell state is achieved.

Description

Technical Field

[0001] The invention relates to a scraper conveyor ultrasonic dumbbell strain state monitoring system and method, belonging to the technical field of scraper conveyor intelligent mining. Background Art

[0002] Scraper conveyor is an important transportation equipment in coal mines. Its dumbbell, as a key connecting component, is subjected to alternating loads for a long time and is prone to deformation or even breakage, which seriously affects the safe production of coal mines. The traditional dumbbell status monitoring method mainly relies on manual regular inspections, which has the disadvantages of low efficiency, poor real-time performance, and difficulty in detecting early faults. The realization of the real-time monitoring function of the scraper conveyor dumbbell status can effectively reduce the failures caused by dumbbell damage, improve the operating reliability and service life of the equipment, and at the same time, help to improve the intelligent level of coal mine production and promote the sustainable development of the coal mining industry.

[0003] In the prior art, there is a scraper conveyor connection dumbbell detachment detection device, which consists of a scraper conveyor chute, a connection dumbbell and a sensor. The sensor is embedded in the connection dumbbell. The sensor has a built-in magnetic excitation source to magnetize the dumbbell socket of the scraper conveyor chute. The sensor detects the change in the magnetic field when the connection dumbbell falls off the scraper conveyor chute to complete the dumbbell detachment detection. The device only detects the scraper conveyor dumbbell detachment state, lacks monitoring of the dumbbell strain state, and in actual use, the dumbbell detachment phenomenon occurs less frequently.

[0004] Utilizing the strong penetrating characteristics of ultrasound, the length of the dumbbell is measured to reflect the change in the dumbbell's shape, and the measurement result is uploaded to the chute controller via wireless transmission. The controller calculates the dumbbell strain and analyzes whether the current dumbbell strain state is normal. When the dumbbell strain reaches the set alarm value, an alarm prompt message is issued. At the same time, when the wireless base station cannot receive the dumbbell signal, it is determined that the dumbbell has fallen off, and the maintenance personnel are prompted to deal with it in time. The detailed information and alarm reminder of the faulty dumbbell are uploaded to the underground centralized control system and the ground dispatching center, realizing dynamic real-time monitoring of the dumbbell status. Summary of the invention

[0005] The purpose of the present invention is to overcome the shortcomings of the prior art and design a scraper conveyor ultrasonic dumbbell strain state monitoring system and method. The present invention mainly aims at the shortcomings of the traditional dumbbell state monitoring method such as low efficiency, poor real-time performance, and difficulty in detecting early faults, and proposes a scraper conveyor ultrasonic dumbbell strain state monitoring system and method.

[0006] The object of the present invention is achieved in that: An ultrasonic dumbbell strain state monitoring system and method for a scraper conveyor. The system includes a dumbbell, an ultrasonic sensor, a wireless transmitter, a wireless base station, and a controller. Among them: The dumbbell is a component connecting the middle trough of the scraper conveyor. The ultrasonic sensor is used to measure the length of the dumbbell, and transmits the data of the dumbbell to the wireless base station through the wireless transmitter, and at the same time uploads it to the controller through a wired transmission method. The controller calculates the strain of the dumbbell through a built-in program and analyzes whether the current strain state of the dumbbell is normal. When the strain of the dumbbell reaches the set alarm value, the controller will send out an audible and visual alarm signal to remind the maintenance personnel to replace the dumbbell, and at the same time upload the strain and alarm information of the dumbbell to the underground centralized control system and the ground dispatching center.

[0007] The data packet uploaded through the wireless transmitter contains a dumbbell code for distinguishing different dumbbells.

[0008] The ultrasonic sensor consists of an ultrasonic transducer, a battery, and a temperature sensor. The ultrasonic transducer is used to send pulsed ultrasonic waves, the battery is used to supply power to the ultrasonic transducer and the temperature sensor, and the temperature sensor is used to measure the temperature of the dumbbell in the current environment.

[0009] Dumbbell length measurement method: The ultrasonic transducer emits an initial pulsed ultrasonic wave. The longitudinal wave of the initial pulsed ultrasonic wave propagates in the dumbbell. When it encounters the other end section of the interface between the dumbbell and the air, a very significant echo pulse will be formed, so as to measure the time difference Δ between the initial pulse and the echo pulse. t At a specific temperature, the sound speed of the dumbbell material V p is constant, and then the current length of the dumbbell is calculated L : (I) L —— Dumbbell length, unit mm; V p —— Ultrasonic sound speed of the dumbbell material, unit mm / ms; Δ t —— Time difference between the initial pulse and the echo pulse, unit ms.

[0010] Dumbbell strain calculation method: First, measure the initial length L s0 of the dumbbell in the free state at an ambient temperature of 20°C through formula (I) L d and the length T of the dumbbell in the current stressed state; then, measure the current temperature α of the dumbbell through the temperature sensor built in the ultrasonic sensor, and combine it with the temperature elongation coefficient L tPerform temperature compensation on the current dumbbell and calculate the length of the dumbbell under the current stress state at 20°C L s , and then calculate the elongation Δ of the scraper conveyor dumbbell under the current stress state L , and finally calculate the strain of the scraper conveyor dumbbell ε .

[0011] (II) ——Elongation of the dumbbell at the current temperature, unit: mm; α ——Temperature elongation coefficient of the dumbbell material, unit: 1 / °C; T ——Current temperature of the dumbbell, unit: °C; L s0 —— Initial length of the dumbbell in the free state at 20°C, unit: mm; (III) L s ——Length of the dumbbell under the current stress state at 20°C, unit: mm; L d ——Length of the dumbbell under the current stress state, unit: mm; (IV) Δ L—— Elongation of the dumbbell under the current stress state, unit: mm; (V) ε ——Dumbbell strain, unit: %.

[0012] Method for calculating the dumbbell stress: Combine the elastic modulus of the dumbbell material E to calculate the stress of the current dumbbell under the stress state σ .

[0013] (VI) σ ——Dumbbell stress, unit: GPa; E ——Elastic modulus of the dumbbell material, unit: GPa.

[0014] When the wireless base station cannot receive the wireless signal of a certain numbered dumbbell, the control box determines that the dumbbell has fallen off and is lost. At the same time, an audible and visual alarm signal is issued, and the information of the fallen dumbbell and the alarm information are uploaded to the underground centralized control system and the ground dispatching center together. Description of the Drawings

[0015] The present invention will be further described in detail below in conjunction with the drawings and specific embodiments: Figure 1 is the structure diagram of the ultrasonic dumbbell of the present invention; Figure 2 is the system framework diagram of the present invention. Specific Embodiments

[0016] The structure and calculation process of the present invention will be described below in conjunction with specific embodiments.

[0017] A monitoring system and method for the strain state of an ultrasonic dumbbell of a scraper conveyor according to the present invention, as shown in Figure 1 、 2 . The present invention utilizes the strong penetration characteristic of ultrasonic waves, reflects the morphological change of the dumbbell by measuring the length of the dumbbell, uploads the measurement result to the gateway controller in the gate end by wireless transmission, and the controller calculates the strain of the dumbbell and analyzes whether the current strain state of the dumbbell is normal. When the strain of the dumbbell reaches the set alarm value, an alarm prompt message is sent. At the same time, when the wireless base station cannot receive the dumbbell signal, it is judged that the dumbbell has fallen off, prompting the maintenance personnel to deal with it in time, and uploading the detailed information and alarm reminder of the faulty dumbbell to the underground centralized control system and the ground dispatching center, realizing the dynamic real-time monitoring of the dumbbell state.

[0018] A monitoring system and method for the strain state of an ultrasonic dumbbell of a scraper conveyor, the system includes a dumbbell, an ultrasonic sensor, a wireless transmitter, a wireless base station and a controller. Among them: the dumbbell is a component connecting the middle trough of the scraper conveyor, the ultrasonic sensor is used to measure the length of the dumbbell, and transmits the data of the dumbbell to the wireless base station through the wireless transmitter, and at the same time uploads it to the controller through a wired transmission method. The controller calculates the strain of the dumbbell through a built-in program and analyzes whether the current strain state of the dumbbell is normal. When the strain of the dumbbell reaches the set alarm value, the controller will send an audible and visual alarm signal to remind the maintenance personnel to replace the dumbbell, and at the same time upload the strain and alarm information of the dumbbell to the underground centralized control system and the ground dispatching center.

[0019] The data packet uploaded through the wireless transmitter has a dumbbell code for distinguishing different dumbbells.

[0020] The ultrasonic sensor is composed of an ultrasonic transducer, a battery and a temperature sensor. The ultrasonic transducer is used to send pulsed ultrasonic waves, the battery is used to supply power to the ultrasonic transducer and the temperature sensor, and the temperature sensor is used to measure the temperature of the dumbbell in the current environment.

[0021] Dumbbell length measurement method: The ultrasonic transducer emits an initial pulse ultrasonic wave. The longitudinal wave of the initial pulse ultrasonic wave propagates in the dumbbell. When it encounters the other end section of the dumbbell-air interface, a very significant echo pulse will be formed, thereby measuring the time difference Δ between the initial pulse and the echo pulse. t , at a specific temperature, the sound velocity of the dumbbell material V p is constant, and then the current dumbbell length is calculated. L : (I) L —— Dumbbell length, unit: mm; V p —— Ultrasonic sound velocity of the dumbbell material, unit: mm / ms; Δ t —— Time difference between the initial pulse and the echo pulse, unit: ms.

[0022] Dumbbell strain calculation method: First, measure the initial length of the dumbbell in the free state at an ambient temperature of 20°C through formula (I) L s0 and the length in the current stressed state L d ; Then, measure the current temperature of the dumbbell through the temperature sensor built in the ultrasonic sensor T , and combine it with the temperature elongation coefficient of the dumbbell material α to calculate the temperature elongation of the dumbbell L t Perform temperature compensation on the current dumbbell and calculate the length of the dumbbell in the current stressed state at 20°C L s , and then calculate the elongation Δ of the scraper conveyor dumbbell in the current stressed state L , and finally calculate the strain of the scraper conveyor dumbbell ε .

[0023] (II) —— Elongation of the dumbbell at the current temperature, unit: mm; α —— Temperature elongation coefficient of the dumbbell material, unit: 1 / °C; T —— Current temperature of the dumbbell, unit: °C; L s0 —— Initial length of the dumbbell in the free state at 20°C, unit: mm; (III) Ls —— The length of the dumbbell under the current stress state at 20°C, unit: mm; L d —— The length of the dumbbell under the current stress state, unit: mm; (IV) Δ L—— The elongation of the dumbbell under the current stress state, unit: mm; (V) ε —— The strain of the dumbbell, unit: %.

[0024] Dumbbell stress calculation method: Combine the elastic modulus of the dumbbell material E Calculate the stress of the dumbbell under the current stress state σ .

[0025] (VI) σ —— The stress of the dumbbell, unit: GPa; E —— The elastic modulus of the dumbbell material, unit: GPa.

[0026] When the wireless base station cannot receive the wireless signal of a dumbbell with a certain number, the control box determines that the dumbbell has fallen off and is lost. At the same time, it emits an audible and visual alarm signal, and uploads the information of the fallen dumbbell and the alarm information to the underground centralized control system and the ground dispatching center.

Claims

1. An ultrasonic dumbbell strain state monitoring system for a scraper conveyor, characterized in that: The system includes dumbbells (1), ultrasonic sensors (2), wireless transmitters (3), wireless base stations (4), and controllers (5); among which: the dumbbells (1) are components connecting the middle troughs of scraper conveyors, the ultrasonic sensors (2) are used to measure the lengths of the dumbbells (1), and transmit the data of the dumbbells (1) to the wireless base stations (4) through the wireless transmitters (3), and at the same time upload them to the controller (5) through a wired transmission method. The controller (5) calculates the strain of the dumbbells (1) through a built-in program and analyzes whether the current dumbbell strain state is normal. When the strain of the dumbbells (1) reaches the set alarm value, the controller (5) will send out an audible and visual alarm signal to remind maintenance personnel to replace the dumbbells, and at the same time upload the strain and alarm information of the dumbbells (1) to the underground centralized control system and the ground dispatching center.

2. The ultrasonic dumbbell strain state monitoring system for a scraper conveyor according to claim 1, wherein: The data packets uploaded through the wireless transmitter (3) have dumbbell codes for distinguishing different dumbbells (1).

3. A dumbbell ultrasonic strain state monitoring system for a scraper conveyor according to claim 1, characterized in that: The ultrasonic sensor (2) consists of an ultrasonic transducer (21), a battery (22), and a temperature sensor (23). The ultrasonic transducer (21) is used to send pulsed ultrasonic waves (211), the battery (22) is used to supply power to the ultrasonic transducer (21) and the temperature sensor (23), and the temperature sensor (23) is used to measure the temperature of the dumbbells in the current environment.

4. A method for monitoring the ultrasonic dumbbell strain state of a scraper conveyor according to claim 1, characterized in that: Method for measuring the length of a dumbbell (1): An ultrasonic transducer (21) emits an initial pulse ultrasonic wave. The longitudinal wave of the initial pulse ultrasonic wave propagates within the dumbbell (1). When it encounters the other cross-section of the interface between the dumbbell and air, a very significant echo pulse will be formed, thereby measuring the time difference Δ between the initial pulse and the echo pulse t , at a specific temperature, the sound velocity of the material of the dumbbell (1) V p is constant, and then the current length of the dumbbell (1) is calculated L : （I） L ——Length of dumbbell, unit: mm; V p —— Ultrasonic sound velocity of dumbbell material, unit: mm / ms; Δ t —— Time difference between the start pulse and the echo pulse, unit: ms.

5. A method for monitoring the ultrasonic dumbbell strain state of a scraper conveyor according to claim 1, characterized in that: Strain calculation method for the dumbbell (1): First, measure the initial length of the dumbbell (1) in the free state at an ambient temperature of 20°C through formula (I). L s0 and the length in the current stress state L d ; Then, measure the current temperature of the dumbbell (1) through the temperature sensor (23) built in the ultrasonic sensor (2). T , and combine with the temperature elongation coefficient of the dumbbell material α to calculate the temperature elongation of the dumbbell L t Perform temperature compensation on the current dumbbell and calculate the length of the dumbbell (1) in the current stress state at 20°C L s , and then calculate the elongation Δ of the scraper conveyor dumbbell (1) in the current stress state L , and finally calculate the strain of the scraper conveyor dumbbell (1) ε : (II) —— Elongation of the dumbbell at the current temperature, unit: mm; α —— Temperature elongation coefficient of the dumbbell material, unit: 1 / °C; T —— Current dumbbell temperature, unit: °C; L s0 —— Initial length of the dumbbell in the free state at 20°C, unit: mm; (III) L s —— The length of the dumbbell under the current force at 20°C, unit: mm; L d —— The length of the dumbbell under the current stress state, unit: mm; (IV) Δ L—— The elongation of the dumbbell under the current stress state, unit: mm; (V) ε ——Dumbbell strain, unit: %.

6. The ultrasonic dumbbell strain state monitoring method for a scraper conveyor according to claim 1, characterized in that: Stress calculation method for dumbbell (1): Combining the elastic modulus of the dumbbell material E Calculate the stress under the current stress state of the dumbbell σ ; (VI) σ ——Dumbbell stress, unit: GPa; E —— Elastic modulus of the dumbbell material, unit: GPa.

7. A method for monitoring the ultrasonic dumbbell strain state of a scraper conveyor according to claim 1, characterized in that: When the wireless base station (4) cannot receive the signal of a certain numbered dumbbell, the control box (5) determines that the dumbbell has fallen off and is lost, and at the same time sends out an audible and visual alarm signal, and uploads the information of the fallen dumbbell and the alarm information to the underground centralized control system and the ground dispatching center together.

Images