Intelligent screw monitoring system of coal mining machine

Abstract

The invention belongs to the technical field of coal mining machines, and discloses an intelligent screw monitoring system of a coal mining machine, which comprises a displacement sensing unit, a data collector and a main control unit, the displacement sensing unit comprises a plurality of screws and a plurality of displacement sensing sensors, one end of each screw is mounted on a machine body of the coal mining machine, and the other end of each screw is mounted on the main control unit; the displacement sensing sensors are mounted at the other end of the main control unit, each displacement sensing sensor is in communication connection with the data acquisition unit, and the data acquisition unit is in communication connection with the main control unit. According to the technical scheme, historical data of stress changes of the hydraulic screw can be effectively monitored, powerful data support is provided for monitoring of the mechanical performance of the coal mining machine, and meanwhile the service life of the coal mining machine can be prolonged.

Description

Technical Field

[0001] The invention belongs to the technical field of coal shearers, and in particular relates to an intelligent screw monitoring system for coal shearers. Background Art

[0002] As the core equipment for comprehensive mining, the mechanical properties of the shearer directly affect the user's production efficiency. The main body of the shearer consists of three parts: the electric control box, the left traction unit, and the right traction unit. The various parts are connected by 4 to 6 long screw assemblies and multiple groups of short screws. Among them, the stability and reliability of the hydraulic screw assembly are the key factors that determine the overall performance of the shearer. However, the current field of coal mining technology has not yet formed a special monitoring system for hydraulic screws. With the advancement of the intelligent process of coal mine comprehensive mining, real-time monitoring of the operating status of the hydraulic screw has become an important direction for the intelligent development of coal mining machines.

[0003] The working conditions of fully mechanized mining faces used by shearers vary widely. Factors such as vibration amplitude, changes in working face inclination, and fluctuations in longitudinal pitch angles during operation can all lead to dynamic changes in the stress on the hydraulic screw. Currently, there is a lack of effective real-time monitoring and data analysis methods for these stress changes, which rely primarily on the operator's experience and judgment. During shearer coal cutting operations, emergencies frequently occur, and the stress on the hydraulic screw can change dramatically, even causing fracture accidents. Once a fracture occurs, the lack of historical data supporting stress changes makes it difficult to analyze the cause of the accident, hindering the subsequent optimization of equipment operations and the development of maintenance strategies. Summary of the Invention

[0004] The purpose of the present invention is to provide an intelligent screw monitoring system for a coal mining machine to solve the problems existing in the above-mentioned prior art.

[0005] To achieve the above-mentioned objectives, the present invention provides an intelligent screw monitoring system for a coal mining machine, including a displacement sensing unit, a data collector and a main control unit. The displacement sensing unit includes a plurality of screws and a plurality of displacement sensing sensors. One end of each of the screws is installed on the body of the coal mining machine, and the other end is installed with the displacement sensing sensor. Each of the displacement sensing sensors is communicatively connected to the data collector, and the data collector is communicatively connected to the main control unit.

[0006] Optionally, each of the screw rods is provided with a mounting hole, and the displacement sensing sensor is installed in the mounting hole.

[0007] Optionally, one end of each displacement sensing sensor away from the screw is connected to a junction box, and the data collector is serially connected to the plurality of junction boxes for communication.

[0008] Optionally, the data collector is externally connected to a power supply.

[0009] Optionally, the data collector is connected to the main control unit via a 485 communication circuit and Ethernet.

[0010] Optionally, the main control unit includes a main controller and a display module electrically connected to the main controller.

[0011] The technical effects of the present invention are:

[0012] The present invention can effectively monitor the historical data of hydraulic screw stress changes, provide strong data support for monitoring the mechanical performance of the coal mining machine, and at the same time can improve the service life of the coal mining machine.

[0013] The monitoring system provided by the present invention can monitor the stress changes of the hydraulic screw in real time, and can provide detailed historical data to facilitate fault analysis and equipment maintenance and repair. In addition, this embodiment has corresponding early warning and protection functions, which can prevent direct and indirect losses caused by instantaneous breakage of the hydraulic screw. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in 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 paying any creative work.

[0015] The accompanying drawings, which constitute part of this application, are intended to provide a further understanding of this application. The exemplary embodiments and descriptions of this application are intended to explain this application and do not constitute an improper limitation on this application. In the accompanying drawings:

[0016] Figure 1 Schematic diagram of the network structure of the intelligent screw and monitoring system in an embodiment of the present invention;

[0017] Figure 2 This is a topological diagram of the intelligent screw and monitoring system in an embodiment of the present invention;

[0018] Figure 3 This is a design diagram for the intelligent transformation of the long screw in an embodiment of the present invention. DETAILED DESCRIPTION

[0019] Various exemplary embodiments of the present invention will now be described in detail. This detailed description should not be considered as limiting the present invention, but rather as a more detailed description of certain aspects, features, and embodiments of the present invention.

[0020] It should be understood that the terms described herein are intended only to describe particular embodiments and are not intended to limit the present invention. In addition, for numerical ranges herein, it should be understood that each intermediate value between the upper and lower limits of the range is also specifically disclosed. Each smaller range between any intermediate value within a stated value or stated range and any other stated value or intermediate value within the stated range is also encompassed by the present invention. The upper and lower limits of these smaller ranges may be independently included or excluded within the scope.

[0021] To facilitate understanding of the present invention, the present invention will be described more comprehensively below with reference to the relevant drawings, and several embodiments of the present invention are given. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thorough and comprehensive.

[0022] It should be noted that when an element is referred to as being "fixed to" another element, it may be directly on the other element or there may be an intermediate element. When an element is referred to as being "connected to" another element, it may be directly connected to the other element or there may be an intermediate element. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are for illustrative purposes only.

[0023] It will be apparent to those skilled in the art that various modifications and variations may be made to the specific embodiments of the present invention without departing from the scope or spirit of the invention. Other embodiments will be apparent to those skilled in the art from the present invention. The present description and examples are intended to be illustrative only.

[0024] The words “include,” “including,” “have,” “contain,” etc. used in this article are open-ended terms, meaning including but not limited to.

[0025] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments in this application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0026] like Figure 1 - Figure 3As shown, this embodiment provides an intelligent screw monitoring system for a coal mining machine, including a displacement sensing unit, a data collector, and a main control unit. The displacement sensing unit includes a plurality of screws and a plurality of displacement sensing sensors. One end of each screw is mounted on the body of the coal mining machine, and the other end is mounted with the displacement sensing sensor. Each displacement sensing sensor is communicatively connected to the data collector, and the data collector is communicatively connected to the main control unit. The technical solution described in this embodiment can effectively monitor the historical data of hydraulic screw stress changes, provide strong data support for monitoring the mechanical performance of the coal mining machine, and at the same time improve the service life of the coal mining machine.

[0027] The intelligent screw and its monitoring system proposed in this embodiment are applied to coal mining equipment on the fully mechanized mining face of a coal mine for the first time. The intelligent screw and its monitoring system mainly consist of a GUD1000 intrinsically safe bolt strain transmitter for mining (intelligent screw), a YJC127 explosion-proof and intrinsically safe data collector for mining (data collector), and a JHH-3 intrinsically safe circuit junction box (junction box). The data collector connects the bus to multiple intelligent screws through the junction box. The data collector communicates with the intelligent screws via wired communication, and transmits the axial force signal of the intelligent screw to the data server. The system structure is as follows: Figure 1 、 Figure 2 shown.

[0028] The measurement principle of the smart screw:

[0029] The intelligent screw consists of a screw and a displacement sensing module, powered by an external power supply. The signal measured by the sensing unit is communicated with the data acquisition device via wired communication.

[0030] The intelligent screw sensing unit drills a small hole (typically no larger than 3.5mm) in the center of the bolt, installs a special measuring rod in the hole, and mounts a micro-sensor element at the head of the measuring rod to monitor its displacement in real time. When the bolt is tightened, it is subjected to axial force, causing it to elongate. This elongation causes the measuring rod to displace relative to the bolt head. This displacement is sensed by the micro-sensor element, which converts it into an electrical signal and transmits it wirelessly or wired to a signal receiving device associated with the intelligent screw. This displacement represents the deformation of the bolt by the corresponding length. Substituting this displacement into the following formula yields the magnitude of the axial force acting on the screw.

[0031] F=E×A×△L / L

[0032] Where F is the axial force of the smart fastener, E is the elastic modulus of the screw material, A is the radial cross-sectional area of the screw, and L is the length of the measured portion of the screw. E, A, and L are all fixed constants. The signal collector outputs the specific axial force value and transmits it to the shearer's electronic control system. The real-time detected and fed-back axial force value has an error range of ±5% compared to the actual, absolute axial force.

[0033] Installation location of smart screw:

[0034] The connection between the three sections of the coal mining machine body is mainly achieved through 8 screws, which need to be intelligently modified. According to the screw design drawings, sensors are embedded in the ends of the screws. Figure 3 shown.

[0035] The sensor is embedded in the screw, and after the screw is tightened, the cable plug can be inserted to transmit data. It is recommended to leave at least 80mm of space for the cable plug.

[0036] The sensor is connected with M8 thread and fixed with thread anti-loosening glue. The hole connection is sealed and fixed with waterproof glue, and double sealed. The above connection method will not cause loosening, rusting and other problems. The connection is reliable and meets the harsh working environment of the coal mining machine such as high frequency vibration, impact load, humidity, dust, etc.

[0037] The main technical parameters of the smart screw include:

[0038] The accuracy is ±5% of the standard shaft force, the response time is 0.25S, the operating temperature range is -40-65℃, the protection level is IP68, the communication method is RS485 bus communication and TCP / IP network interface, and the explosion-proof level is Ex Ib I Mb.

[0039] The data collector is built on a Linux embedded operating system, employing a modular, integrated hardware architecture and supporting multi-protocol data communication. Its primary function is to receive data from the intelligent screw in real time and transmit bolt axial force data to the shearer control system via RS-485 and Ethernet for data management. This provides reliable data storage, analysis, and status management services for the control platform. Its basic technical parameters are shown in Table 1.

[0040] Table 1

[0041] RS485 interface 4-way RS485 bus supports number of nodes 32 RS485 baud rate 9600～115200 Ethernet communication rate 10 / 100Mb Ethernet protocol ModbusTCP Supply voltage 12VDC Maximum operating current 1.3A Power consumption of a single sensor ≤200mW Operating temperature -40℃～85℃ Explosion-proof grade ExibIMb

[0042] Electrical connection of smart screw:

[0043] The intelligent screw transmits signals to the data collector through the RS485 bus. The intelligent screws are electrically connected with mining intrinsically safe shielded cables, and finally the signals are transmitted to the data collector. At the same time, the data collector provides working power for the intelligent screw. The data collector communicates with the coal mining machine BOC main control module through RS-485 after passing through the 485 communication isolation fence. The intelligent screw interface on the coal mining machine display screen displays the stress data of each stress.

[0044] In summary, the monitoring system provided in this embodiment can monitor the stress changes of the hydraulic screw in real time, and can provide detailed historical data to facilitate fault analysis and equipment maintenance and repair. In addition, this embodiment has corresponding early warning and protection functions, which can prevent direct and indirect losses caused by instantaneous breakage of the hydraulic screw.

[0045] The above description is merely a preferred embodiment of the present application, but the scope of protection of the present application is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present application should be included in the scope of protection of the present application. Therefore, the scope of protection of the present application should be based on the scope of protection of the claims.

Claims

1. An intelligent screw monitoring system for a coal mining machine, characterized in that: It includes a displacement sensing unit, a data collector and a main control unit. The displacement sensing unit includes a plurality of screws and a plurality of displacement sensing sensors. One end of each screw is installed on the body of the coal mining machine, and the other end is installed with the displacement sensing sensor. Each displacement sensing sensor is communicatively connected to the data collector, and the data collector is communicatively connected to the main control unit.

2. The intelligent screw monitoring system for coal mining machines according to claim 1 is characterized in that: Each of the screw rods is provided with a mounting hole, and the displacement sensing sensor is mounted in the mounting hole.

3. The intelligent screw monitoring system for coal mining machines according to claim 1 is characterized in that: One end of each displacement sensing sensor away from the screw is connected to a junction box, and the data collector is serially connected to the plurality of junction boxes for communication.

4. The intelligent screw monitoring system for coal mining machines according to claim 1, characterized in that: The data collector is externally connected to a power supply.

5. The intelligent screw monitoring system for coal mining machines according to claim 1 is characterized in that: The data collector is connected to the main control unit via a 485 communication circuit and Ethernet.

6. The intelligent screw monitoring system for coal mining machines according to claim 1, characterized in that: The main control unit includes a main controller and a display module electrically connected to the main controller.

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