Device for detecting welding quality of roller of coal mining machine

Abstract

The invention discloses a coal mining machine roller welding quality detection device, belongs to the field of sheet metal part processing technology and electrical automation integrated control, and solves the problem of low detection efficiency of the existing coal mining machine roller welding detection device. A display screen is fixed on the side wall of a box body, a pressure testing machine body is arranged in the box body, and a water injection valve is arranged at a water inlet of a water tank of the pressure testing machine body; a pressure test pump of the pressure test machine guides water in a water tank into the to-be-tested coal mining machine roller through a water outlet pipe; a pressure transmitter is used for collecting pressure in the water tank, a liquid level meter is used for collecting liquid level signals in the water tank, and a pressure relief valve is arranged on a pressure relief opening. The controller judges whether the coal mining machine roller weld joint has a pseudo welding spot or not according to a pressure signal collected by the pressure transmitter, judges whether the water tank needs to be supplemented with water or not according to the water tank liquid level collected by the liquid level meter, and controls the water injection valve to be opened for supplementing water if the water tank needs to be supplemented with water. The method is suitable for detecting the welding quality of the roller of the coal mining machine.

Description

Technical Field

[0001] The invention belongs to the field of sheet metal processing technology and electrical automation integrated control. Background Art

[0002] After the shearer drum is welded, it is necessary to conduct a water pressure test to check for leaks. However, existing testing equipment on the market cannot meet user requirements in terms of electrical integrated control or appearance. The current coal mining drum detection device uses an ordinary scale pressure gauge that can be distinguished by the naked eye. It has no liquid level alarm device and cannot provide timely and accurate feedback on the amount of water. The water tank is empty only when the pressure test pump fails to pump water. When filling water, a manual ball valve is used to open and close the water, and people are required to observe the amount of water injected. All of these greatly increase manpower. At the same time, the detection efficiency is significantly lower. Summary of the Invention

[0003] The present invention aims to solve the problem of low detection efficiency in existing coal mining machine drum welding detection devices, and provides a coal mining machine drum welding quality detection device.

[0004] The coal mining machine drum welding quality detection device of the present invention comprises a pressure testing machine body, a box body, a controller, a liquid level gauge and a pressure transmitter;

[0005] A display screen is fixed to the side wall of the box, the pressure test machine body is arranged in the box, and a water inlet and a water outlet are opened on the box, the water inlet corresponds to the water inlet of the water tank of the pressure test machine body; the water inlet of the water tank of the pressure test machine body is provided with a water filling valve;

[0006] The water outlet of the box body corresponds to the water outlet of the water tank of the pressure test machine body. The water outlet of the water tank of the pressure test machine body is provided with a pressure test pump, and the pressure test pump is used to introduce the water in the water tank into the drum of the coal mining machine to be tested through the water outlet pipe;

[0007] The water outlet of the water tank of the pressure test machine body is also provided with a pressure transmitter, which is used to collect the pressure in the water tank and transmit the pressure signal to the controller;

[0008] A liquid level gauge is also provided in the water tank of the pressure test machine body, and the liquid level gauge is used to collect the liquid level signal in the water tank and transmit the liquid level signal to the controller;

[0009] The pressure test machine body water tank is also provided with a pressure relief port, and a pressure relief valve is provided on the pressure relief port; the control signal input end of the pressure relief valve is connected to the pressure relief control signal output end of the controller;

[0010] The controller determines whether there are cold welds in the shearer drum weld based on the pressure signal collected by the pressure transmitter, and determines whether the water tank needs to be replenished based on the water tank level collected by the liquid level gauge. If the water tank needs to be replenished, the controller controls the water injection valve to open for replenishment.

[0011] Furthermore, in the present invention, the water outlet of the water tank is further provided with a water outlet valve, and the control signal input end of the water outlet valve is connected to the water outlet control signal output end of the controller.

[0012] Furthermore, in the present invention, the box body has a door on the front side and a partition is provided in the middle, which divides the box body into two spaces, the upper and lower spaces. The water tank is arranged in the lower space, and the controller is arranged in the upper space.

[0013] Furthermore, the present invention further comprises a display screen, which is embedded in the front surface of the box body and located at the upper part of the box body.

[0014] Furthermore, the present invention also includes a power supply circuit, which is used to supply power to the pressure test pump, the controller and the display screen.

[0015] The present invention adopts a controller for control, so that the liquid level meter and the water injection control valve are linked to realize the automation of water injection. The liquid level meter detects the difference in high and low pressure of the water level, and then converts it into an electrical signal output to control the water injection control valve through the controller. No staff participation is required, which effectively improves the efficiency of detection and the degree of automation of detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a block diagram of the system principle of the present invention;

[0017] Figure 2 This is a power supply circuit diagram described in a specific embodiment;

[0018] Figure 3 The power control circuit described in the specific embodiment;

[0019] Figure 4 Time pressure curve for passing the test;

[0020] Figure 5 The time pressure curve for test failure is shown. DETAILED DESCRIPTION

[0021] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention. It should be noted that the embodiments of the present invention and the features in the embodiments can be combined with each other in the absence of conflict.

[0022] Specific embodiment 1: This embodiment is described in detail with reference to the drawings. The coal mining machine drum welding quality detection device described in this embodiment includes a pressure test machine body, a box body, a controller 4, a liquid level meter 6 and a pressure transmitter 7;

[0023] A display screen 8 is fixed to the side wall of the box, and the pressure test machine body is arranged in the box. A water inlet and a water outlet are opened on the box, and the water inlet corresponds to the water inlet of the water tank of the pressure test machine body; the water inlet of the water tank of the pressure test machine body is provided with a water filling valve 5;

[0024] The water outlet of the box body corresponds to the water outlet of the water tank of the pressure test machine body. The water outlet of the water tank of the pressure test machine body is provided with a pressure test pump 2, and the pressure test pump 2 is used to introduce the water in the water tank into the drum of the coal mining machine to be tested through the water outlet pipe;

[0025] The water outlet of the water tank of the pressure test machine body is also provided with a pressure transmitter 7, which is used to collect the pressure in the water tank and transmit the pressure signal to the controller 4;

[0026] A liquid level gauge 6 is also provided in the water tank of the pressure test machine body, and the liquid level gauge 6 is used to collect the liquid level signal in the water tank and transmit the liquid level signal to the controller 4;

[0027] The pressure test machine body water tank is also provided with a pressure relief port, and a pressure relief valve 1 is provided on the pressure relief port; the control signal input end of the pressure relief valve 1 is connected to the pressure relief control signal output end of the controller 4;

[0028] The controller 4 determines whether there are cold welds in the coal mining machine drum weld according to the pressure signal collected by the pressure transmitter 7, and determines whether the water tank needs to be replenished according to the water tank liquid level collected by the liquid level meter 6. If the water tank needs to be replenished, the water injection valve 5 is controlled to open for water replenishment.

[0029] Furthermore, in the present invention, the water outlet of the water tank is further provided with a water outlet valve 3 , and the control signal input end of the water outlet valve 3 is connected to the water outlet control signal output end of the controller 4 .

[0030] Furthermore, in the present invention, the box body has a door on the front side and a partition is provided in the middle, which divides the box body into two spaces, the upper and lower spaces. The water tank is arranged in the lower space, and the controller 4 is arranged in the upper space.

[0031] Furthermore, the present invention further comprises a display screen 8, which is embedded in the front surface of the box and located at the upper part of the box.

[0032] Furthermore, the present invention also includes a power supply circuit, which is used to supply power to the pressure test pump 2 , the controller 4 and the display screen 8 . Specific embodiments

[0033] Data acquisition process: Through the feedback of the 4-20mA signal from the pressure transmitter, the controller 4 reads the current real-time pressure, controls the motor to start, and opens the water injection valve. The pressure test machine's test pump starts to rotate the crosshead of the transmission box, which in turn moves left and right in the high and low pressure cylinders, squeezing the space inside the cylinders, thereby forming a pressure difference between the inside and outside of the cylinders, thereby pumping water from the water tank into the high and low pressure cylinders of the pressure test pump. The crosshead continuously reciprocates, and water continuously flows out of the water outlet into the coal mining machine drum connected to the pump until the pressure requirement is met. When the detected pressure exceeds the maximum set value and remains for a certain period of time, the pressure relief valve is opened to release the pressure.

[0034] The controller 4 is implemented using a programmable logic controller (PLC). The PLC uses a 4-20 mA signal fed back by a liquid level gauge to read the current tank liquid level. When the level falls below a set level, water is added to replenish the tank level. The PLC transmits parameter values ​​and readouts via a PN bus to the touchscreen, where they are displayed on the touchscreen page. The corresponding parameters can be viewed in real time on the touchscreen panel.

[0035] The existing water pressure testing equipment is called a test pump. The structure is similar to most other equipment. Not only does it not meet the user's requirements in terms of electrical use, but it also cannot meet the user's requirements. The main structure and working principle of the existing test pump is that the test pump is a horizontal four-piston reciprocating pump, which consists of a motor, a reduction gear box, a transmission box, a high-pressure water cylinder, a low-pressure water cylinder, a water collector, a safety valve and a water tank. The working principle and structural diagram of the test pump are shown in the figure below. Figure 1 shown.

[0036] Existing pressure test pumps are similar in structure and principle, but the water pressure testing device described in this invention is significantly different from existing pressure test pumps. The system described in this invention not only meets the customer's needs for collecting data such as flow rate and pressure in terms of electrification, but also can add new testing indicators based on usage and can visualize the collected data on the screen in real time, allowing users to more intuitively view the test data and accurately judge the welding quality. In response to user requirements for appearance, a more aesthetically pleasing integrated frame and shell structure is specially designed, perfectly highlighting the appearance of the water pressure testing workstation described in this invention. The specific differences between them are detailed in the table below.

[0037] Table 1

[0038]

[0039] By comparison, it can be seen that the existing models use ordinary scale pressure gauges that can be distinguished by the naked eye. There is no liquid level alarm device, and it cannot provide timely and accurate feedback on the amount of water. The water tank can only be known to be out of water when the pressure test pump cannot pump up water. When filling water, a manual ball valve is used to open and close the water, and people are required to observe the amount of water added, which greatly increases manpower.

[0040] The present invention utilizes a diffused silicon pressure transmitter and level gauge with a 24V power supply and a 4-20mA signal output. These pressure transmitters and level gauges offer high precision, excellent stability, strong overload and impact resistance, waterproofing, shockproofing, dustproofing, corrosion resistance, strong anti-interference capabilities, and excellent temperature stability. They can perfectly transmit signals to the display screen via a PLC. The linkage between the level gauge and the water injection control valve enables automated water injection. The level gauge detects the difference in water pressure and converts it into a 4-20mA signal output, which is then controlled by the PLC to control the water injection control valve, thereby executing the water injection process. See the flow chart for details.

[0041] Water injection flow chart:

[0042] After the water injection is completed, it is time to prepare to start the water pressure test. The following preparations should be made before starting the test.

[0043] Preparations before operation: 1. Connect the outlet hydraulic hose to the workpiece to be tested; 2. Open the overflow valve of the new water pressure detection device; 3. Test run the water pressure detection device of the present invention under normal pressure. If there is no abnormal noise or blockage, the overflow pipe will discharge the medium. When the pointer of the pressure gauge fluctuates, the overflow valve can be closed. Then wait for the water pressure to reach 1.6MPa or above, then open the main line control valve to inject water into the coal mining machine drum. A water injection groove is reserved in advance inside the coal mining machine drum. After the groove is filled with water, the new water pressure detection workstation will continue to inject water. This will gradually increase the pressure between the water pressure detection workstation and the coal mining machine drum. When the pressure reaches 10Mpa, the pressure transmitter will output a 4-20mA signal to the PLC, and then the PLC will control the main line control valve to close and the motor to stop working. This can eliminate the risk of pressure relief from the pressure test pump itself and only detect the pressure change curve between the pipeline and the workpiece.

[0044] If the pressure zone line on the display is within 5 minutes and the curve is almost a straight line, it can be determined that the welding of the coal mining machine drum is qualified. Then the main line control valve and overflow valve should be started to release all the water in the main line back to the water tank. At this time, the pressure zone line on the display will show a steeply declining curve, and the pressure will drop to 0Mpa quickly. Then remove the hydraulic hose connected to the drum coal mining machine, lift the coal mining machine drum away, and complete the whole process of water pressure detection. The pressure display curve of the display during this process is as follows Figure 4 If the pressure zone line on the display shows a continuous downward curve within 5 minutes, it indicates leakage and failure. If water is spraying or seeping out, the shearer drum welding is unqualified and needs to be hoisted back for repair welding. After the repair welding is completed, continue to test until it passes the test. The pressure display curve of the display during this process is as follows Figure 5 shown.

[0045] Although the present invention is described herein with reference to specific embodiments, it should be understood that these embodiments are merely illustrative of the principles and applications of the invention. It should be understood that many modifications may be made to the illustrative embodiments, and that other arrangements may be devised, without departing from the spirit and scope of the invention as defined by the appended claims. It should be understood that the various dependent claims and features described herein may be combined in ways other than those described in the original claims. It should also be understood that features described in conjunction with individual embodiments may be used in conjunction with other described embodiments.

Claims

1. Coal mining machine drum welding quality detection device, characterized in that: It includes a pressure test machine body, a box, a controller (4), a liquid level gauge (6) and a pressure transmitter (7); A display screen (8) is fixed to the side wall of the box, the pressure test machine body is arranged in the box, and a water inlet and a water outlet are provided on the box, the water inlet corresponds to the water inlet of the water tank of the pressure test machine body; the water inlet of the water tank of the pressure test machine body is provided with a water filling valve (5); The water outlet of the box body corresponds to the water outlet of the water tank of the pressure test machine body, and the water outlet of the water tank of the pressure test machine body is provided with a pressure test pump (2), and the pressure test pump (2) is used to guide the water in the water tank into the drum of the coal mining machine to be tested through the water outlet pipe; The water outlet of the water tank of the pressure test machine body is also provided with a pressure transmitter (7), and the pressure transmitter (7) is used to collect the pressure in the water tank and transmit the pressure signal to the controller (4); A liquid level meter (6) is also provided in the water tank of the pressure test machine body, and the liquid level meter (6) is used to collect the liquid level signal in the water tank and transmit the liquid level signal to the controller (4); The pressure test machine body water tank is also provided with a pressure relief port, and a pressure relief valve (1) is provided on the pressure relief port; the control signal input end of the pressure relief valve (1) is connected to the pressure relief control signal output end of the controller (4); The controller (4) determines whether there are any cold welds in the weld seam of the shearer drum according to the pressure signal collected by the pressure transmitter (7), and determines whether the water tank needs to be replenished according to the water tank liquid level collected by the liquid level meter (6). If the water tank needs to be replenished, the water injection valve (5) is controlled to open for replenishment.

2. The coal mining machine drum welding quality detection device according to claim 1, characterized in that: The water outlet of the water tank is further provided with a water outlet valve (3), and the control signal input end of the water outlet valve (3) is connected to the water outlet control signal output end of the controller (4).

3. The coal mining machine drum welding quality detection device according to claim 1, characterized in that: The box body has a door on the front side and a partition is provided in the middle, which divides the box body into two spaces, an upper space and an lower space. The water tank is arranged in the lower space, and the controller (4) is arranged in the upper space.

4. The coal mining machine drum welding quality detection device according to claim 1, characterized in that: It also includes a display screen (8), which is embedded in the front surface of the box body and located at the upper part of the box body.

5. The coal mining machine drum welding quality detection device according to claim 1, characterized in that: It also includes a power supply circuit, which is used to supply power to the pressure test pump (2), the controller (4) and the display screen (8).

Images