Breakpoint positioning method for broken chain of scraper conveyer

Abstract

The invention relates to a breaking point positioning method for broken chains of a scraper conveyer, which comprises the following specific steps of: customizing a chain with a groove in the middle in a factory, pasting a flexible strain sensor at the bottom of the groove, packaging by using a flexible resin adhesive after the flexible strain sensor is pasted, installing a PCB (Printed Circuit Board) in the groove, connecting the flexible strain sensor with the PCB through a lead, and positioning the flexible strain sensor in the groove. A lead storage battery is welded to the PCB, a wireless communication antenna is installed on the PCB, the groove is sealed through a cover plate made of a PEEK material, and the intelligent scraper conveyer chain is obtained; the intelligent scraper conveyor chain is installed on the scraper conveyor and is spaced from the scraper conveyor by a certain distance; installing a gateway, a loudspeaker and an infrared thermal imaging scanner: starting the scraper conveyer, observing the resistance change of the flexible strain sensor, the sound wave collected by the loudspeaker and the thermal image generated by the infrared thermal imaging scanner at a background cloud server, and judging the breaking point position of the broken chain of the scraper conveyer. According to the invention, the breakpoint position can be judged more quickly and conveniently.

Description

Technical Field

[0001] This invention relates to the technical field of conveyor break point identification, and in particular to a method for locating the break point of a scraper conveyor chain. Background Technology

[0002] Scraper conveyors are mechanical devices used for the continuous transport of bulk materials, commonly found in industrial fields such as mines, coal mines, power plants, and ports. The chains of scraper conveyors can break after prolonged operation under alternating stress, significantly reducing the conveyor's efficiency and potentially causing personal injury to workers. Manually locating the breakage point is time-consuming, and conducting manual inspections under conditions like those in mines also poses safety hazards. Summary of the Invention

[0003] The present invention aims to overcome the problem of the inconvenience of manually checking the location of chain breaks in scraper conveyors, and provides a method for locating the break point of a scraper conveyor chain.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A method for locating the breakpoint of a scraper conveyor chain, comprising the following steps:

[0006] A method for locating the breakpoint of a scraper conveyor chain, comprising the following steps:

[0007] S1. Manufacturing the chain for the intelligent scraper conveyor:

[0008] A chain with a groove in the middle is custom-made in the factory, and a flexible strain sensor is attached to the bottom of the groove. After attachment, it is encapsulated with flexible resin glue. A PCB board is installed in the groove. The flexible strain sensor is connected to the PCB board through wires. A lead-acid battery is soldered on the PCB board and a wireless communication antenna is installed. Thermosetting resin glue is used for further encapsulation. Finally, the groove is sealed with a cover plate made of PEEK material to obtain the intelligent scraper conveyor chain.

[0009] The flexible strain sensor is a sensor with a serpentine conductive path printed on it. The flexible strain sensor consists of a sensing layer and a substrate. The sensing layer is composed of conductive filler and elastic paste, and the substrate is composed of polyimide. The conductive filler is made by mixing carbon black particles modified with copper / nickel metals with pure carbon black particles. The ink composed of conductive filler and elastic paste is printed on the polyimide film substrate using a screen printing process to obtain the flexible strain sensor.

[0010] S2. Install the intelligent scraper conveyor chain:

[0011] The intelligent scraper conveyor chains are installed on the scraper conveyor, with each chain spaced a certain distance from the others.

[0012] S3. Install the gateway, speaker, and infrared thermal imaging scanner:

[0013] A gateway is installed on one side of the middle section of the scraper conveyor, and an auxiliary detection group is installed at regular intervals on the side of the scraper conveyor. The auxiliary detection group includes a horn and an infrared thermal imaging scanner. The flexible strain sensor is connected to the cloud server through the gateway, and the horn and infrared thermal imaging scanner are connected to the cloud server.

[0014] S4. Run and determine the breakpoint location:

[0015] The scraper conveyor is started, and the resistance change of the flexible strain sensor, the sound wave collected by the horn and the thermal image generated by the infrared thermal imaging scanner are observed on the cloud server in the background. When the chain breaks, there will be a loud sound. The location of the break can be deduced by the speed of sound propagation. At the same time, the temperature at the break is high. The infrared thermal imaging can determine the specific location of the break.

[0016] When a break occurs in one of the ordinary chains between two adjacent intelligent scraper conveyor chains and the break occurs within the signal reception range of the gateway, the resistance of the flexible strain sensors on both intelligent scraper conveyor chains will drop significantly, thus determining that the chain break occurs between the two intelligent scraper conveyor chains.

[0017] If the breakage does not occur within the signal reception range of the gateway, the sound of the chain breaking is first received by the speaker. The location of the breakage point is then determined by the propagation speed of the sound. After the chain breaks, the surface temperature changes, which is monitored by an infrared thermal imaging scanner to determine whether the breakage point is above or below the scraper conveyor.

[0018] In step S1, the preparation process of the conductive filler is as follows:

[0019] P1. Carbon black raw materials with a particle size of 20-100nm undergo desulfurization and purification treatment to remove sulfide impurities: using limestone as raw material, an alkaline slurry is prepared with pH=9-12. The carbon black raw material is mixed with the alkaline slurry, and the temperature is controlled at 45℃ and the reaction time is 12 hours to convert sulfides into sulfates.

[0020] P2. Place the desulfurized carbon black raw material in a 5% HNO3 solution and sonicate it at 60°C for 2 hours to remove surface impurities and introduce hydroxyl groups.

[0021] P3. Prepare the plating solution with the following components: NiSO4·6H2O 20g / L, NaH2PO2·H2O 30g / L, sodium citrate 15g / L, pH=9. Add the pretreated carbon black raw material to the plating solution and stir at 60℃ for 1h. Filter, wash, and dry. Nickel metal is discretely coated on the carbon black surface to form Ni@CB.

[0022] P4. Ni@CB is placed in a magnetron sputtering apparatus under an argon atmosphere at a pressure of 0.5 Pa, using a copper target as the sputtering source with a purity of 99.99%, a power of 100 W, and a deposition time of 10 min to obtain nickel / copper coated carbon black particles Ni / Cu@CB. Ni / Cu@CB is then uniformly mixed with pure carbon black particles at a mass ratio of 1:1 to obtain a conductive filler.

[0023] The groove in the middle of the chain of the intelligent scraper conveyor has an elongated oval structure.

[0024] The number of lead-acid batteries soldered on the PCB board is three.

[0025] The distance between two adjacent intelligent scraper conveyor chains on the scraper conveyor is 8m.

[0026] The spacing between the auxiliary detection groups is 16m.

[0027] The gateway is 3m away from the scraper conveyor.

[0028] The beneficial effects of this invention are: this invention can determine the location of chain breakage by measuring the resistance change of the flexible strain sensor on the chain of the intelligent scraper conveyor, and can also be monitored with the assistance of a horn and an infrared thermal imaging scanner, which expands the range of breakage monitoring, improves the monitoring effect, and enables faster and more convenient determination of the breakage location. Attached Figure Description

[0029] Figure 1 This is a diagram illustrating the method steps of the present invention;

[0030] Figure 2 This is a schematic diagram of the flexible strain sensor in this invention;

[0031] Figure 3 This is a schematic diagram of the nickel / copper coated carbon black particles in this invention;

[0032] Figure 4 This is a schematic diagram illustrating the sensitivity and linearity when using carbon black as the conductive filler in this invention.

[0033] Figure 5 This is a schematic diagram illustrating the sensitivity and linearity of using Ni@CB as a conductive filler in this invention.

[0034] Figure 6This is a schematic diagram illustrating the sensitivity and linearity of using Ni / Cu@CB as a conductive filler in this invention.

[0035] Figure 7 This is a schematic diagram illustrating the sensitivity and linearity of using a Ni / Cu@CB + pure carbon black mixture as a conductive filler in this invention.

[0036] Figure 8 This is a layout diagram of a specific embodiment of the present invention;

[0037] Figure 9 This is a schematic diagram of the groove in the middle of the chain of the intelligent scraper conveyor of the present invention;

[0038] In the image: 1-Intelligent scraper conveyor chain; 2-Gateway; 3-Horn; 4-Infrared thermal imaging scanner;

[0039] The following will describe in detail, with reference to the accompanying drawings, embodiments of the present invention. Detailed Implementation

[0040] The principles and features of the present invention are described below with reference to the accompanying drawings. The embodiments given are for illustrative purposes only and are not intended to limit the scope of the invention. The invention is described more specifically in the following paragraphs by way of example with reference to the accompanying drawings. The advantages and features of the invention will become clearer from the following description. It should be noted that the drawings are in a very simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of the invention.

[0041] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0042] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0043] A method for locating the breakpoint of a scraper conveyor chain, such as... Figure 1 As shown, the specific steps are as follows:

[0044] S1. Manufacturing the intelligent scraper conveyor chain 1:

[0045] A chain with a groove in the middle is custom-made in the factory, and a flexible strain sensor is pasted at the bottom of the groove. After pasting, it is encapsulated with flexible resin glue. A PCB board is installed in the groove. The flexible strain sensor is connected to the PCB board through wires. A lead-acid battery is soldered on the PCB board and a wireless communication antenna is installed. Thermosetting resin glue is used for further encapsulation. Finally, the groove is sealed with a cover plate made of PEEK material to obtain the intelligent scraper conveyor chain 1.

[0046] The flexible strain sensor is connected to a PCB board that can transmit wireless signals. The PCB board is equipped with an antenna that can enhance the wireless signal and three lead-acid batteries. When the scraper conveyor is working, the flexible strain sensor will generate a change in resistance as the intelligent scraper conveyor chain 1 deforms. The PCB board can transmit the resistance signal to the external gateway 2, and the gateway 2 will then transmit the data to the cloud server.

[0047] Flexible strain sensors are sensors with printed serpentine conductive paths, such as... Figure 2 As shown, the flexible strain sensor consists of a sensing layer and a substrate.

[0048] The sensing layer is composed of conductive fillers and elastic paste, while the substrate is composed of polyimide.

[0049] The conductive filler is prepared by mixing copper / nickel modified carbon black particles with pure carbon black particles. The preparation process of the conductive filler is as follows:

[0050] P1. Carbon black raw materials with a particle size of 20-100nm undergo desulfurization and purification treatment to remove sulfide impurities: using limestone as raw material, an alkaline slurry is prepared with pH=9-12. The carbon black raw material is mixed with the alkaline slurry, and the temperature is controlled at 45℃ and the reaction time is 12 hours to convert sulfides into sulfates.

[0051] P2. Place the desulfurized carbon black raw material in a 5% HNO3 solution and sonicate it at 60°C for 2 hours to remove surface impurities and introduce hydroxyl groups.

[0052] P3. Prepare the plating solution with the following components: NiSO4·6H2O 20g / L, NaH2PO2·H2O 30g / L, sodium citrate 15g / L, pH=9. Add the pretreated carbon black raw material to the plating solution and stir at 60℃ for 1h. Filter, wash, and dry. Nickel metal is discretely coated on the carbon black surface to form Ni@CB.

[0053] P4. Place Ni@CB in a magnetron sputtering apparatus under an argon atmosphere at a pressure of 0.5 Pa, using a copper target as the sputtering source (99.99% purity), a power of 100 W, and a deposition time of 10 min to obtain Ni / Cu@CB carbon black particles coated with both nickel and copper. Figure 3As shown, Ni / Cu@CB and pure carbon black particles are uniformly mixed at a mass ratio of 1:1 to obtain a conductive filler.

[0054] A flexible strain sensor is obtained by screen printing an ink composed of conductive filler and elastic paste onto a polyimide film substrate. When the flexible strain sensor is subjected to stress, the substrate and sensing layer can generate large micro-strains, thereby causing a change in resistance.

[0055] Carbon black particles form a conductive network through point contacts, resulting in high contact resistance and susceptibility to deformation. First, nickel plating creates a conductive film on the carbon black surface, transforming the point contacts into surface contacts and significantly reducing interparticle contact resistance. Furthermore, nickel has a conductivity of approximately 1.4 × 10⁻⁶. 7 The S / m ratio is much higher than that of carbon black (10²-10³ S / m). The introduction of the metal layer makes current transmission more efficient and the resistance change more significant during deformation.

[0056] When copper plating is continued, and nickel / copper carbon black is mixed with uncoated carbon black, the metal-coated carbon black acts as the main conductive path, while the uncoated carbon black fills the gaps, creating a "bridging" effect. This dual-network structure responds synchronously to deformation: the metal layer provides high sensitivity, while the uncoated carbon black enhances network stability, making the resistance change linearly related to strain.

[0057] Using carbon black alone as a conductive filler results in sensitivity and linearity as... Figure 4 As shown, although the linearity is high, the sensitivity is low, which does not meet the application scenario of this method.

[0058] Using Ni@CB as the conductive filler, the sensitivity and linearity are as follows: Figure 5 As shown, the sensitivity is slightly improved, but the linearity is poor.

[0059] Using Ni / Cu@CB as the conductive filler, the sensitivity and linearity are as follows: Figure 6 As shown, the sensitivity continued to improve, but the linearity remained poor.

[0060] Using a Ni / Cu@CB + pure carbon black mixture as the conductive filler, the sensitivity and linearity are as follows: Figure 7 As shown, it exhibits extremely high sensitivity and linearity.

[0061] S2. Install the intelligent scraper conveyor chain 1:

[0062] The intelligent scraper conveyor chain 1 is installed on the scraper conveyor, with each chain spaced a certain distance apart from the others.

[0063] S3. Install gateway 2, speaker 3, and infrared thermal imaging scanner 4:

[0064] A gateway 2 is installed on one side of the middle of the scraper conveyor, and an auxiliary detection group is installed at regular intervals on the side of the scraper conveyor. The auxiliary detection group includes a horn 3 and an infrared thermal imaging scanner 4. The flexible strain sensor is connected to the cloud server through the gateway 2, and the horn 3 and the infrared thermal imaging scanner 4 are connected to the cloud server.

[0065] S4. Run and determine the breakpoint location:

[0066] The scraper conveyor is started, and the resistance change of the flexible strain sensor, the sound wave collected by the speaker 3 and the thermal image generated by the infrared thermal imaging scanner 4 are observed on the cloud server in the background. After the chain breaks, there will be a loud sound. The location of the break can be deduced by the speed of sound propagation. At the same time, the temperature at the break is high. The infrared thermal imaging can determine the specific location of the break.

[0067] When a common chain between two adjacent intelligent scraper conveyor chains 1 breaks and the break occurs within the signal receiving range of gateway 2, the resistance of the flexible strain sensors on both intelligent scraper conveyor chains 1 will drop significantly, thus determining that the chain break occurs between the two intelligent scraper conveyor chains 1.

[0068] If the breakage does not occur within the signal reception range of gateway 2, the sound of the chain breaking is first received by speaker 3. The location of the breakage point is determined by the propagation speed of the sound. After the chain breaks, the surface temperature changes, which is monitored by infrared thermal imaging scanner 4 to determine whether the breakage point is above or below the scraper conveyor.

[0069] Example 1:

[0070] like Figure 3 As shown, five flexible strain sensors are externally connected to five PCB boards; three lead-acid batteries are soldered to each PCB board; an antenna is installed on each PCB board; the flexible strain sensors are respectively pasted to the bottom of the grooves of the intelligent scraper conveyor chain 1, the PCB boards are installed inside the grooves, and the grooves are sealed with plastic covers; the intelligent scraper conveyor chain 1 is installed on a 40m long scraper conveyor, with each chain spaced 8m apart; a gateway 2 is installed 3m away from the middle of the scraper conveyor, and a horn 3 and an infrared thermal imaging scanner 4 are installed every 16m; the scraper conveyor is started, and the resistance of the flexible strain sensors, the sound waves collected by the horn 3, and the thermal images generated by the infrared thermal imaging scanner 4 are observed in the background.

[0071] The groove in the middle of the chain of the intelligent scraper conveyor has an elongated oval structure, such as... Figure 9 As shown.

[0072] When a common chain between two adjacent intelligent scraper conveyor chains 1 breaks and the break occurs within the gateway signal receiving range, the resistance of the flexible strain sensors on both intelligent scraper conveyor chains 1 will drop significantly. At this point, it can be determined that the chain break occurs between the two intelligent scraper conveyor chains 1.

[0073] If the breakage does not occur within the signal reception range of gateway 2, the sound of the chain breaking can be received by speaker 3 to determine the approximate location of the breakage point. On the other hand, the surface temperature changes after the chain breaks, and infrared thermal imaging scanner 4 can be used to monitor this and determine whether the breakage point is above or below the scraper conveyor. This method greatly expands the range of breakage point monitoring.

[0074] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any improvements made using the inventive concept and technical solution of the present invention, or direct application to other occasions without modification, are all within the protection scope of the present invention.

Claims

1. A method for locating the breakpoint of a scraper conveyor chain, characterized in that, The specific steps are as follows: S1. Manufacturing the chain for the intelligent scraper conveyor (1): A chain with a groove in the middle is custom-made in the factory, and a flexible strain sensor is pasted at the bottom of the groove. After pasting, it is encapsulated with flexible resin glue. A PCB board is installed in the groove. The flexible strain sensor is connected to the PCB board through wires. A lead-acid battery is soldered on the PCB board and a wireless communication antenna is installed. Thermosetting resin glue is used for further encapsulation. Finally, the groove is sealed with a cover plate made of PEEK material to obtain the intelligent scraper conveyor chain (1). The flexible strain sensor is a sensor with a serpentine conductive path printed on it. The flexible strain sensor consists of a sensing layer and a substrate. The sensing layer is composed of conductive filler and elastic paste, and the substrate is composed of polyimide. The conductive filler is made by mixing carbon black particles modified with copper / nickel metals with pure carbon black particles. The ink composed of conductive filler and elastic paste is printed on the polyimide film substrate using a screen printing process to obtain the flexible strain sensor. S2. Install the intelligent scraper conveyor chain (1): The intelligent scraper conveyor chain (1) is installed on the scraper conveyor, with a certain distance between each other; S3. Install the gateway (2), speaker (3), and infrared thermal imaging scanner (4): A gateway (2) is installed on one side of the middle of the scraper conveyor, and an auxiliary detection group is installed at regular intervals on the side of the scraper conveyor. The auxiliary detection group includes a horn (3) and an infrared thermal imaging scanner (4). The flexible strain sensor encapsulated in the chain is connected to the cloud server through the gateway (2), and the horn (3) and the infrared thermal imaging scanner (4) are connected to the cloud server. S4. Run and determine the breakpoint location: Start the scraper conveyor and observe the resistance change of the flexible strain sensor, the sound waves collected by the horn (3) and the thermal image generated by the infrared thermal imaging scanner (4) on the background cloud server. After the chain breaks, there will be a loud noise. The location of the break can be deduced by the speed of sound propagation. At the same time, the temperature at the break is high. The infrared thermal imaging can determine the specific location of the break. When a common chain between two adjacent intelligent scraper conveyor chains (1) breaks and the break occurs within the signal receiving range of the gateway (2), the resistance of the flexible strain sensors on the two intelligent scraper conveyor chains (1) will drop significantly, thus determining that the chain break occurs between the two intelligent scraper conveyor chains (1). If the break does not occur within the signal reception range of the gateway (2), the speaker (3) first receives the sound of the chain breaking, and the location of the break point is determined by the propagation speed of the breaking sound. After the chain breaks, the surface temperature changes, and the infrared thermal imaging scanner (4) is used to monitor it, and then it is determined whether the break point is above or below the scraper conveyor.

2. The method for locating the breakpoint of a scraper conveyor chain according to claim 1, characterized in that, In step S1, the preparation process of the conductive filler is as follows: P1. Carbon black raw materials with a particle size of 20-100nm undergo desulfurization and purification treatment to remove sulfide impurities: using limestone as raw material, an alkaline slurry is prepared with pH=9-12. The carbon black raw material is mixed with the alkaline slurry, and the temperature is controlled at 45℃ and the reaction time is 12 hours to convert sulfides into sulfates. P2. Place the desulfurized carbon black raw material in a 5% HNO3 solution and sonicate it at 60°C for 2 hours to remove surface impurities and introduce hydroxyl groups. P3. Prepare the plating solution with the following components: NiSO4·6H2O 20g / L, NaH2PO2·H2O 30g / L, sodium citrate 15g / L, pH=9. Add the pretreated carbon black raw material to the plating solution and stir at 60℃ for 1h. Filter, wash, and dry. Nickel metal is discretely coated on the carbon black surface to form Ni@CB. P4. Ni@CB is placed in a magnetron sputtering apparatus under an argon atmosphere at a pressure of 0.5 Pa, using a copper target as the sputtering source with a purity of 99.99%, a power of 100 W, and a deposition time of 10 min to obtain nickel / copper coated carbon black particles Ni / Cu@CB. Ni / Cu@CB is then uniformly mixed with pure carbon black particles at a mass ratio of 1:1 to obtain a conductive filler.

3. The method for locating the breakpoint of a scraper conveyor chain according to claim 1, characterized in that, The groove in the middle of the chain (1) of the intelligent scraper conveyor is an elongated oval structure.

4. The method for locating the breakpoint of a scraper conveyor chain according to claim 1, characterized in that, The number of lead-acid batteries soldered on the PCB board is three.

5. The method for locating the breakpoint of a scraper conveyor chain according to claim 1, characterized in that, The distance between two adjacent intelligent scraper conveyor chains (1) on the scraper conveyor is 8m.

6. The method for locating the breakpoint of a scraper conveyor chain according to claim 5, characterized in that, The spacing between the auxiliary detection groups is 16m.

7. The method for locating the breakpoint of a scraper conveyor chain according to claim 6, characterized in that, The distance between the gateway (2) and the scraper conveyor is 3m.

Images