A slurry pump flow passage component life monitoring system

Abstract

The application provides a slurry pump flow passage component life monitoring system, belonging to the technical field of slurry pump monitoring, comprising a monitoring unit, a gap adjusting unit and a control unit, the monitoring unit comprising a plurality of first ultrasonic sensors arranged on a front guard plate and facing an impeller, for emitting, receiving and generating sound wave data; the gap adjusting unit is used for driving the impeller to move axially to adjust the flow passage gap between the impeller and the front guard plate; the control unit is electrically connected with the first ultrasonic sensors and the gap adjusting unit, receives the sound wave data to calculate the real-time value of the residual wall thickness of the front guard plate and the flow passage gap, and controls the gap adjusting unit to adjust the flow passage gap to a preset minimum threshold value when the real-time value exceeds the maximum value of the gap range threshold value. The slurry pump flow passage component life monitoring system provided by the application realizes real-time monitoring of the wear state of the flow passage component, life judgment and intelligent adjustment of the gap under normal operation of the slurry pump, and forms a complete monitoring and adjustment closed loop.

Description

Technical Field

[0001] This invention belongs to the field of slurry pump monitoring technology, and more specifically, relates to a slurry pump flow component life monitoring system. Background Technology

[0002] As a key piece of equipment for conveying media containing solid particles, slurry pumps experience wear on their flow-through components (impeller, front guard plate, rear guard plate, etc.) during operation due to the abrasion caused by the conveyed medium. This wear leads to excessive gaps between the impeller and the pump body, reducing the pump's efficiency and accelerating component failure due to cumulative wear, thus shortening its actual service life. Therefore, improving the service life of flow-through components requires addressing the problem of excessive gaps caused by wear. Current technology typically relies on manually adjusting the impeller position using bolts to mitigate this issue. However, this method requires downtime, is time-consuming and labor-intensive, disrupts production continuity, reduces efficiency, and makes it impossible to monitor the wear status of the flow-through components in real time, hindering the assessment of damage levels and making it difficult for operators to evaluate the remaining lifespan of the components. Summary of the Invention

[0003] The purpose of this invention is to provide a slurry pump flow component life monitoring system, which can monitor the wear status of flow components in real time during normal operation of the slurry pump, thereby reducing maintenance costs and production risks for enterprises and improving the operating efficiency of the slurry pump.

[0004] To achieve the above objectives, the technical solution adopted by the present invention is: to provide a slurry pump flow component life monitoring system, comprising:

[0005] The monitoring unit includes multiple first ultrasonic sensors, which are arranged on the front guard plate and facing the impeller side, for transmitting and receiving sound wave signals and generating sound wave data information.

[0006] The clearance adjustment unit is used to drive the impeller to move axially in order to adjust the flow clearance between the impeller and the front guard plate.

[0007] The control unit is electrically connected to the first ultrasonic sensor and the gap adjustment unit. It is used to receive the acoustic wave data information from the first ultrasonic sensor, calculate the real-time values ​​of the remaining wall thickness of the front guard plate and the flow gap, and when the real-time value exceeds the maximum value of the gap range threshold, the control unit controls the gap adjustment unit to adjust the real-time value of the flow gap to the minimum value of the gap range threshold.

[0008] In one possible implementation, the gap range threshold is 1-2 mm.

[0009] In one possible implementation, the slurry pump includes a bracket body, on which a bearing assembly is slidably disposed, a pump body is fixedly connected to the front end of the bracket body, a front guard plate is fixedly connected to the front end of the pump body, the impeller is located inside the pump body, and one end of the bearing assembly passes through the pump body and is connected to the impeller.

[0010] The gap adjustment unit includes:

[0011] An axial adjustment mechanism is fixed on the bracket body, and its actuating end is connected to the bearing assembly, which is used to drive the bearing assembly to move the impeller axially.

[0012] A clamping and positioning mechanism is fixed on the bracket body, and its actuating end presses against the bearing assembly on the bracket body to form an axial constraint on the bearing assembly.

[0013] In one possible implementation, the axial adjustment mechanism includes:

[0014] The first mounting bracket is fixedly connected to the bracket body;

[0015] The first worm gear screw jack is fixed on the first mounting frame, and its actuating end is connected to the bearing assembly;

[0016] The first servo motor is fixed on the first mounting bracket and is connected to the first worm gear screw jack via transmission.

[0017] In one possible implementation, the clamping and positioning mechanism includes:

[0018] The second mounting bracket is fixedly connected to the bracket body;

[0019] The second worm gear screw jack is fixed on the second mounting frame, and its actuating end is connected to the bearing assembly;

[0020] The second servo motor is fixed on the second mounting bracket and is connected to the second worm gear screw jack via transmission.

[0021] In one possible implementation, the second worm gear screw jack is located at the upper end of the bracket body, and its actuating end is provided with a pressure column. There is a limiting space between the pressure column and the bracket body. The bearing assembly is disposed within the limiting space to prevent the bearing assembly from moving up and down. A pressure sensor is provided on the pressure-applying end face of the pressure column. When the pressure of the pressure column on the bearing assembly reaches a preset pressure value, the bearing assembly is in a locked state. When the pressure of the pressure column on the bearing assembly is zero, the bearing assembly is in a free axial state.

[0022] In one possible implementation, the monitoring unit further includes a plurality of second ultrasonic sensors arranged on the rear guard plate and facing the impeller side. The second ultrasonic sensors are electrically connected to the control unit and are used to detect the remaining wall thickness of the rear guard plate.

[0023] In one possible implementation, the control unit has a built-in timer for sending a synchronization trigger signal to the first ultrasonic sensor and the second ultrasonic sensor, causing the first ultrasonic sensor and the second ultrasonic sensor to alternately emit ultrasonic waves.

[0024] In one possible implementation, the monitoring unit further includes:

[0025] Temperature sensor, used to collect real-time temperature data of slurry;

[0026] Concentration sensor, used to collect real-time concentration data of slurry;

[0027] The control unit is equipped with a sound velocity dynamic calibration module, which corrects the propagation speed of ultrasound in the slurry based on the real-time temperature data and the real-time concentration data.

[0028] In one possible implementation, the control unit is equipped with an alarm module that triggers an alarm when the remaining wall thickness of the current guard plate and / or the rear guard plate is lower than a wall thickness threshold or when the gap adjustment unit fails to complete the adjustment action within a preset adjustment time.

[0029] The beneficial effects of the slurry pump flow component life monitoring system provided by this invention are as follows: Compared with the prior art, this slurry pump flow component life monitoring system can, through a first ultrasonic sensor, collect real-time and accurate data on the remaining thickness of the front liner and the gap between the impeller and the front liner during normal operation of the slurry pump. It can obtain the wear status of the flow components without stopping the pump for inspection, avoiding production interruptions caused by traditional shutdown inspections. Furthermore, compared with experience-based estimation, it significantly improves the accuracy of wear data collection, providing a reliable basis for life assessment. The control unit, by receiving data from the first ultrasonic sensor and calculating the remaining wall thickness of the front liner, can scientifically determine the wear degree and remaining life of the front liner, avoiding material waste caused by premature replacement of flow components due to experience-based misjudgments, effectively reducing enterprise maintenance costs. Through the gap adjustment unit, when the impeller is worn but not yet failed, the distance between the impeller and the front liner can be adjusted to ensure a reasonable gap after adjustment, avoiding a decrease in slurry pump operating efficiency or accelerated wear of flow components due to abnormal gaps, thereby improving the operating efficiency of the slurry pump. The present invention provides a slurry pump flow component life monitoring system, which realizes real-time monitoring of the wear status of the flow component under normal operation of the slurry pump, life judgment and intelligent adjustment of the clearance, forming a complete monitoring and adjustment closed loop. This not only reduces the production risk caused by the sudden failure of the flow component, but also further reduces the overall cost of the enterprise through precise maintenance and efficiency improvement. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 A three-dimensional structural schematic diagram of a slurry pump flow component life monitoring system provided in an embodiment of the present invention;

[0032] Figure 2 This is a cross-sectional structural schematic diagram of a slurry pump flow component life monitoring system provided in an embodiment of the present invention;

[0033] Figure 3 This is a schematic diagram of the assembly structure of the bracket body and bearing assembly provided in an embodiment of the present invention;

[0034] Figure 4 An exploded structural diagram of the bracket body and bearing assembly provided in an embodiment of the present invention;

[0035] Figure 5 for Figure 1 A magnified structural diagram at point M.

[0036] Explanation of reference numerals in the attached figures:

[0037] 1. Bracket body; 11. U-shaped storage groove; 111. Limiting plane; 112. Clearance slot; 2. Bearing assembly; 21. Bearing body; 22. Power shaft; 23. Limiting block; 24. Connecting block; 3. Pump body; 4. Impeller; 5. Front guard plate; 6. Rear guard plate; 7. Connecting plate; 8. Pump cover; 9. Pressing column; 91. Connecting section; 92. Pressing section; 100. First ultrasonic sensor; 200. Second ultrasonic sensor; 300. Axial adjustment mechanism; 301. First mounting bracket; 302. First worm gear screw jack; 303. First servo motor; 400. Pressing and positioning mechanism; 401. Second mounting bracket; 402. Second worm gear screw jack; 403. Second servo motor; 500. Stepped hole; 501. First hole body; 502. Second hole body. Detailed Implementation

[0038] To make the technical problems to be solved, the technical solutions, and the beneficial effects of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and are not intended to limit the present invention.

[0039] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0040] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention.

[0041] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0042] Please see Figures 1 to 5This invention provides a slurry pump flow component life monitoring system. The slurry pump flow component life monitoring system is applied to a slurry pump, which includes a bracket body 1, a bearing assembly 2, a pump body 3, an impeller 4, a front guard plate 5, and a rear guard plate 6. The bearing assembly 2 includes a bearing body 21, with a drive shaft passing through it. The drive shaft and bearing body 21 are rotatably connected via a bearing. The pump body 3 is bolted to the front end of the bracket body 1 via a connecting plate 7. The front end of the connecting plate 7 is bolted to the rear end of the pump body 3, and the rear guard plate 6 is inserted into the port at the rear end of the pump body 3. A pump cover 8 is bolted to the front end of the pump body 3, and the front guard plate 5 is bolted to the rear end of the pump cover 8, also inserted into the port at the front end of the pump body 3. The impeller 4 is located inside the pump body 3, between the front guard plate 5 and the rear guard plate 6. One end of the drive shaft passes through the connecting plate 7 and is threaded onto the impeller 4 via the rear guard plate 6. The other end of the drive shaft is used to connect to a drive motor.

[0043] The present invention provides a slurry pump flow component life monitoring system, which includes a monitoring unit, a gap adjustment unit and a control unit.

[0044] The monitoring unit includes four first ultrasonic sensors 100, which are arranged on the front guard plate 5 and facing the impeller 4. They are used to transmit and receive sound wave signals and generate sound wave data information. In specific applications, four threaded mounting holes are pre-drilled on the non-flow end face of the front guard plate 5. The four mounting holes are on the same circumference, and the radius of the circumference where the four mounting holes are located is smaller than the radius of the impeller 4. The four mounting holes are located at the 1 o'clock, 3 o'clock, 9 o'clock and 11 o'clock positions, respectively. All four mounting holes are blind holes. The wall thickness between the bottom of the mounting hole and the flow end face of the front guard plate 5 is not less than 10 mm. The pump cover 8 is provided with clearance through holes corresponding to the four mounting holes. During installation, ultrasonic coupling agent is first injected into the mounting hole. A torque wrench is used to screw the first ultrasonic sensor 100 into the mounting hole so that the ultrasonic coupling agent fills the space between its probe and the inner wall of the mounting hole.

[0045] The gap adjustment unit is used to drive the impeller 4 to move axially to adjust the flow gap between the impeller 4 and the front guard plate 5. In practical applications, the upper end of the bracket body 1 is provided with a support part, and a U-shaped storage groove 11 is transversely arranged on the support part. The bearing body 21 is slidably arranged in the U-shaped storage groove 11. In application, the bearing body 21 is a cylindrical structure. Two limiting blocks 23 are provided on the outer walls of the left and right sides of the bearing body 21 along the front and rear directions. On the left and right sides of the upper end of the U-shaped storage groove 11, corresponding to the limiting blocks 23, limiting planes 111 are provided that fit against the outer walls of the limiting blocks 23. The limiting planes 111 fit against the limiting blocks 23 to form a mechanical limit, restricting the bearing body 21 from rotating in the U-shaped storage groove 11. A downwardly protruding connecting block 24 is provided on the bottom side wall of the bearing body 21. A clearance slot 112 is provided at the bottom of the U-shaped storage groove 11 corresponding to the connecting block 24, which penetrates the support plate. The connecting block 24 passes through the clearance slot 112, and the lower end of the connecting block 24 extends into the space below the support part. The circumferential gap between the connecting block 24 and the clearance slot 112 is not less than 50mm.

[0046] In this embodiment, the gap adjustment unit includes an axial adjustment mechanism 300 and a clamping and positioning mechanism 400. The axial adjustment mechanism 300 is fixed to the bracket body 1, and its actuating end is connected to the bearing assembly 2, used to drive the bearing assembly 2 to move the impeller 4 axially. Specifically, the axial adjustment mechanism 300 includes a first mounting frame 301, a first worm gear screw jack 302, and a first servo motor 303. In application, the first mounting frame 301 is a flat plate structure mounted longitudinally on the bracket body 1, and is placed in the lower space of the supporting part of the bracket body 1. The fixed end of the first worm gear screw jack 302 is bolted to the first mounting frame 301, and the screw of the first worm gear screw jack 302 is bolted to the connecting block 24 of the bearing body 21. The first servo motor 303 is bolted to the first mounting frame 301 and is connected to the first worm gear screw jack 302 for transmission, providing it with power.

[0047] In this embodiment, the clamping and positioning mechanism 400 is fixed on the bracket body 1, and its actuating end presses against the bearing assembly 2 on the bracket body 1 to form an axial constraint on the bearing assembly 2. Specifically, the clamping and positioning mechanism 400 includes a second mounting frame 401, a second worm gear screw jack 402, and a second servo motor 403. The second mounting frame 401 is a horizontally arranged flat plate structure, bolted to the top of the support portion of the bracket body 1, located on the left and right sides of the U-shaped storage groove 11. In this embodiment, there are four second worm gear screw jacks 402, which are evenly distributed and bolted to two second mounting frames 401, corresponding to the four limiting blocks 23 on the bearing body 21. Each second worm gear screw jack 402 is equipped with a second servo motor 403 to provide power, and the screw end of the second worm gear screw jack 402 is connected to a pressing column 9. In this embodiment, the pressing column 9 is longitudinally positioned directly above the limiting block 23 and fits against the upper end face of the limiting block 23. In this way, a limiting space is formed between the pressing column 9 and the U-shaped storage groove 11 to restrict the vertical movement of the bearing body 21. The upper limit of the bearing body 21 is formed by the surface-to-surface cooperation between the pressing column 9 and the limiting block 23, and the lower limit of the bearing body 21 is formed by the surface-to-surface cooperation between the lower end of the bearing body 21 and the bottom of the U-shaped storage groove 11, thereby preventing the bearing body 21 from moving up and down.

[0048] In this embodiment, a pressure sensor is provided on the pressure-applying end face of the pressure column 9. In application, the pressure sensor is electrically connected to the control unit. The control unit controls the opening and closing of the second servo motor 403 based on the pressure information collected by the pressure sensor. When the pressure of the pressure column 9 on the limit block 23 reaches the preset pressure value, a sufficiently large static friction force can be generated between the bearing body 21 and the bracket body 1, thereby locking the bearing body 21 in the U-shaped storage groove 11 of the bracket body 1 and putting it into a locked state. When the pressure of the pressure column 9 on the bearing assembly 2 is zero, the bearing body 21 applies pressure to the bracket body 1 only by its own weight. The static friction force generated is small and can be easily overcome by the thrust applied by the first worm gear screw jack 302 through the connecting block 24, causing relative movement between the bearing body 21 and the bracket body 1. That is, in this case, the bearing body 21 is in a free state, and the axial adjustment mechanism 300 can adjust the axial position of the impeller 4 by means of the bearing body 21, changing the size of the flow gap between the impeller 4 and the front guard plate 5.

[0049] In this embodiment, the control unit is electrically connected to the first ultrasonic sensor 100 and the first servo motor 303 and second servo motor 403 in the gap adjustment unit. The control unit receives the acoustic wave data from the first ultrasonic sensor 100 and calculates the real-time values ​​of the remaining wall thickness of the front guard plate 5 and the flow gap using the acoustic wave data. When the real-time value exceeds the maximum value of the gap range threshold, the control unit controls the gap adjustment unit to adjust the real-time value of the flow gap to the minimum value of the gap range threshold. In practical applications, the flow gap range threshold is 1-2 mm.

[0050] The operating procedure of the slurry pump flow component life monitoring system provided by this invention is as follows:

[0051] S1. Under the control of the control unit, the first ultrasonic sensor 100 emits a 200kHz high-frequency ultrasonic pulse. The ultrasonic pulse propagates through the coupling agent and the flow material, generating reflected echoes on the inner wall of the front guard plate 5 and the surface of the impeller 4, respectively. After receiving the echo signal, the first ultrasonic sensor 100 converts it into an electrical signal containing acoustic wave data information, which is transmitted to the control unit. The acoustic wave data information is the echo time difference.

[0052] S2. The control unit calculates the remaining thickness of the front guard plate 5 and the flow clearance between the impeller 4 and the front guard plate 5 based on the acoustic wave data; wherein, the formula for calculating the remaining thickness of the front guard plate 5 is:

[0053] d 板 For the remaining thickness of the front skid plate 5, t 板 For the time difference of the 5 echoes from the front skid plate, υ 钢 The velocity of ultrasound in steel;

[0054] The formula for calculating the flow clearance is:

[0055] d 间隙 t represents the value of the flow gap. 总 To receive the echo time of impeller 4, υ 浆液 The velocity of the ultrasonic wave in the slurry within the flow gap.

[0056] S3. Determine whether the front guard plate 5 has reached its service life based on the remaining thickness of the front guard plate 5. When the remaining thickness is less than 5mm, it is determined that the front guard plate 5 has reached its service life and needs to be replaced. Determine whether the clearance needs to be adjusted based on the overflow gap value. When the overflow gap value is greater than 2mm, the control unit controls the second servo motor 403 to act, causing the second worm gear screw jack 402 to release the axial constraint on the bearing body 21. Then, the control unit controls the first servo motor 303 to start, driving the first worm gear screw jack 302 to push the bearing body 21 and drive the impeller 4 to move to the front guard plate 5 side. When the overflow gap is detected to be equal to 1mm, the first servo motor 303 stops, and the second servo motor 403 acts again, causing the second worm gear screw jack 402 to press the bearing body 21 and reapply the axial constraint to the bearing body 21.

[0057] This invention provides a slurry pump flow component life monitoring system. Compared with existing technologies, the system uses a first ultrasonic sensor 100 to collect real-time and accurate data on the remaining thickness of the front guard plate 5 and the gap between the impeller 4 and the front guard plate 5 during normal operation of the slurry pump. This allows for the acquisition of the wear status of the flow components without stopping the pump for inspection, avoiding production interruptions caused by traditional shutdown inspections. Furthermore, compared to experience-based estimations, this significantly improves the accuracy of wear data collection, providing a reliable basis for lifespan assessment. The control unit receives data from the first ultrasonic sensor 100 and calculates the remaining wall thickness of the front guard plate 5, enabling a scientific assessment of the wear degree and remaining lifespan of the front guard plate 5. This avoids material waste caused by premature replacement of flow components due to experience-based misjudgments, effectively reducing enterprise maintenance costs. The gap adjustment unit allows for adjustment of the gap between the impeller 4 and the front guard plate 5 when the impeller 4 is worn but not yet failed, ensuring a reasonable gap after adjustment. This prevents a decrease in slurry pump operating efficiency or accelerated wear of flow components due to abnormal gaps, thereby improving the slurry pump's operating efficiency. The present invention provides a slurry pump flow component life monitoring system, which realizes real-time monitoring of the wear status of the flow component under normal operation of the slurry pump, life judgment and intelligent adjustment of the clearance, forming a complete monitoring and adjustment closed loop. This not only reduces the production risk caused by the sudden failure of the flow component, but also further reduces the overall cost of the enterprise through precise maintenance and efficiency improvement.

[0058] In some embodiments, please refer to Figure 1 , Figure 2 and Figure 5The aforementioned second mounting bracket 401 includes a connecting plate, which is bolted to the upper end face of the bracket body 1. A stepped hole 500 is provided through the connecting plate corresponding to the limiting block 23 of the bearing body 21. The stepped hole 500 includes a first hole 501 and a second hole 502 arranged vertically. The diameter of the first hole 501 is smaller than the diameter of the second hole 502. The second worm gear screw jack 402 is fixed to the connecting plate. The screw of the second worm gear screw jack 402 is longitudinally inserted into the first hole 501. A pressure post 9 is connected to the lower end of the screw of the second worm gear screw jack 402. The pressure post 9 includes a connecting section 91 and a pressure-applying section 92 connected to each other. The connecting section 91 is inserted into the first hole 501 and connected to the screw of the second worm gear screw jack 402, applying pressure... Section 92 is set inside the second hole 502. The diameter of the pressure section 92 is between the diameters of the first hole 501 and the second hole 502. In application, the mating surface of the first hole 501 and the second hole 502 is a longitudinal limiting surface. The distance between the longitudinal limiting surface and the upper end of the limiting block 23 is the same as the height of the pressure section 92. That is, when the pressure section 92 contacts the upper end surface of the limiting block 23 and the pressure on the limiting block 23 is zero, the upper end surface of the pressure section 92 contacts the longitudinal limiting surface. The longitudinal limiting surface forms a mechanical block on the pressure section 92, restricting its upward movement, thereby limiting the position of the pressure section 92. In turn, the pressure section 92 limits the position of the limiting block 23, thereby preventing the first worm gear screw jack 302 from longitudinally moving when adjusting the bearing body 21.

[0059] In some embodiments, please refer to Figure 1 and Figure 2The monitoring unit also includes four second ultrasonic sensors 200, which are arranged on the rear guard plate 6 and facing the impeller 4. The second ultrasonic sensors 200 are electrically connected to the control unit and are used to detect the remaining wall thickness of the rear guard plate 6. In application, the installation layout of the second ultrasonic sensors 200 is the same as that of the first ultrasonic sensor 100. Four threaded mounting holes are pre-drilled on the non-flow end face of the rear guard plate 6. The four mounting holes are on the same circumference, and the radius of the circumference where the four mounting holes are located is smaller than the radius of the impeller 4. The four mounting holes are located at the 1 o'clock, 3 o'clock, 9 o'clock and 11 o'clock positions, respectively. All four mounting holes are blind holes. The wall thickness between the bottom of the mounting hole and the flow end face of the front guard plate 5 is not less than 10 mm. The connecting plate 7 is provided with clearance through holes corresponding to the four mounting holes. During installation, ultrasonic coupling agent is first injected into the mounting hole, and a torque wrench is used to screw the second ultrasonic sensor 200 into the mounting hole so that the ultrasonic coupling agent fills the space between its probe and the inner wall of the mounting hole. By setting a second ultrasonic sensor 200 to collect acoustic data of the rear guard plate 6, the control unit uses the acoustic data to calculate the remaining thickness of the rear guard plate 6 and determine its remaining lifespan. The calculation method for the remaining thickness of the rear guard plate 6 is the same as the calculation method for the remaining thickness of the front guard plate 5. When the remaining thickness of the rear guard plate 6 is less than 5mm, it is determined that the rear guard plate 6 has reached its service life.

[0060] In this embodiment, to avoid mutual interference between the first ultrasonic sensor 100 and the second ultrasonic sensor 200 during operation, a timer is built into the control unit to send a synchronization trigger signal to the first ultrasonic sensor 100 and the second ultrasonic sensor 200, so that the first ultrasonic sensor 100 and the second ultrasonic sensor 200 alternately emit ultrasonic waves.

[0061] In some embodiments, the monitoring unit further includes a temperature sensor and a concentration sensor. The temperature sensor is installed inside the slurry flow chamber at the inlet of the slurry pump. The temperature sensor probe needs to be in direct contact with the slurry to collect real-time temperature data of the slurry. It also collects real-time temperature data of the slurry around the flow path, providing temperature parameters for sound velocity correction. Because the propagation speed of ultrasound in slurry increases with temperature, temperature data is one of the core variables for sound velocity correction.

[0062] Concentration sensors, installed in the inlet or outlet pipe of the slurry pump, are used to collect real-time concentration data of the slurry, providing concentration parameters for sound velocity correction. As the slurry concentration increases, the number of solid particles increases, which leads to enhanced ultrasonic scattering and a decrease in propagation speed. Concentration data is another core variable for correcting sound velocity.

[0063] The control unit is equipped with a dynamic sound velocity calibration module, which corrects the propagation speed of ultrasound in the slurry based on real-time temperature and concentration data.

[0064] The formula for correcting the speed of sound is: , where υ 声 The corrected sound velocity of the ultrasonic wave in the slurry within the flow gap is given by: T is the real-time temperature of the slurry, C is the real-time concentration of the slurry, and a, b, c, and d are fitting coefficients, which are obtained from experimental data.

[0065] The propagation speed of ultrasound in slurry is significantly affected by temperature and concentration, and traditional fixed sound velocity measurement methods can introduce large errors due to changes in operating conditions. By acquiring slurry parameters in real time using temperature and concentration sensors, data support is provided for sound velocity correction, ensuring that the sound velocity value matches the actual operating conditions. The dynamic sound velocity calibration module dynamically adjusts the sound velocity based on real-time slurry parameters, significantly improving the accuracy of gap measurement and thickness calculation, making the assessment of wear conditions of flow components more accurate, and providing a reliable technical basis for life assessment.

[0066] In some embodiments, the control unit is provided with an alarm module, which will sound an alarm when the remaining wall thickness of the current guard plate 5 and / or the rear guard plate 6 is lower than the wall thickness threshold or when the gap adjustment unit fails to complete the adjustment action within a preset adjustment time.

[0067] In this embodiment, the alarm module, as a built-in functional module of the control unit, establishes data interaction with the ultrasonic sensor and gap adjustment unit in the system. Its working logic is as follows:

[0068] The remaining wall thickness data of the front guard plate 5 and / or rear guard plate 6 transmitted by the ultrasonic sensor are received in real time and compared with the preset wall thickness threshold.

[0069] The working status of the gap adjustment unit is monitored in real time, the time from receiving the adjustment command to completing the adjustment action is recorded, and the time is compared with the preset adjustment time threshold.

[0070] When any of the above conditions are triggered (wall thickness is lower than the wall thickness threshold, or adjustment timeout), the alarm module will immediately activate the alarm.

[0071] In this embodiment, the wall thickness threshold of the remaining wall thickness of the front guard plate 5 and / or the rear guard plate 6 is 5mm, and the adjustment time threshold of the gap adjustment unit is 10s.

[0072] In this embodiment, by setting an alarm module, a timely warning can be issued when the remaining wall thickness of the front guard plate 5 and / or the rear guard plate 6 is lower than the wall thickness threshold, avoiding accidents such as slurry leakage and equipment shutdown caused by sudden failure of the flow components, and reducing production safety risks. When the gap adjustment unit exceeds the adjustment time and fails to complete the adjustment action, an alarm can be issued in time, allowing operators to immediately detect problems such as mechanical jamming and power failure, avoiding continuous abnormal gap due to adjustment failure, thereby reducing excessive wear of the impeller 4 and pump body 3 and extending the equipment life.

[0073] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A slurry pump flow component life monitoring system, wherein the slurry pump includes a bracket body (1), a bearing assembly (2) is slidably disposed on the bracket body (1), a pump body (3) is fixedly connected to the front end of the bracket body (1), a front guard plate (5) is fixedly connected to the front end of the pump body (3), an impeller (4) is located inside the pump body (3), and one end of the bearing assembly (2) penetrates the pump body (3) and connects to the impeller (4); characterized in that, include: The monitoring unit includes multiple first ultrasonic sensors (100), which are arranged on the front guard plate (5) and facing the impeller (4) to transmit and receive sound wave signals and generate sound wave data information. The gap adjustment unit is used to drive the impeller (4) to move axially in order to adjust the flow gap between the impeller (4) and the front guard plate (5); The gap adjustment unit includes: An axial adjustment mechanism (300) is fixed on the bracket body (1), and its actuating end is connected to the bearing assembly (2) to drive the bearing assembly (2) to move the impeller (4) axially. A clamping and positioning mechanism (400) is fixed on the bracket body (1), and its actuating end presses against the bearing assembly (2) on the bracket body (1) to form an axial constraint on the bearing assembly (2); The axial adjustment mechanism (300) includes: The first mounting bracket (301) is fixedly connected to the bracket body (1); The first worm gear screw jack (302) is fixed on the first mounting frame (301), and its actuating end is connected to the bearing assembly (2); The first servo motor (303) is fixed on the first mounting bracket (301) and is connected to the first worm gear screw jack (302) for transmission. The clamping and positioning mechanism (400) includes: The second mounting bracket (401) is fixedly connected to the bracket body (1); The second worm gear screw jack (402) is fixed on the second mounting bracket (401), and its actuating end is connected to the bearing assembly (2); The second servo motor (403) is fixed on the second mounting bracket (401) and is connected to the second worm gear screw jack (402) for transmission. The control unit is electrically connected to the first ultrasonic sensor (100) and the gap adjustment unit, and is used to receive the acoustic wave data information of the first ultrasonic sensor (100) and synchronously calculate the real-time values ​​of the remaining wall thickness of the front guard plate (5) and the flow gap under normal operation of the slurry pump. When the real-time value of the flow gap is greater than 2mm, the control unit controls the second servo motor (403) to move, causing the second worm gear screw jack (402) to release the axial constraint on the bearing assembly (2), and then controls the first servo motor (303) to start, driving the first worm gear screw jack (302) to push the bearing assembly (2) and drive the impeller (4) to move towards the front guard plate (5). When the real-time value of the flow gap is detected to be equal to 1mm, the first servo motor (303) stops, and the second servo motor (403) moves again, causing the second worm gear screw jack (402) to press the bearing assembly (2) and reapply the axial constraint to the bearing assembly (2).

2. The slurry pump flow component life monitoring system as described in claim 1, characterized in that, The second worm gear screw jack (402) is located at the upper end of the bracket body (1), and its actuating end is provided with a pressure column (9). There is a limiting space between the pressure column (9) and the bracket body (1). The bearing assembly (2) is located in the limiting space to prevent the bearing assembly (2) from moving up and down. A pressure sensor is provided on the pressure end face of the pressure column (9). When the pressure of the pressure column (9) on the bearing assembly (2) reaches the preset pressure value, the bearing assembly (2) is in a locked state. When the pressure of the pressure column (9) on the bearing assembly (2) is zero, the axial direction of the bearing assembly (2) is in a free state.

3. The slurry pump flow component life monitoring system as described in claim 1, characterized in that, The monitoring unit also includes a plurality of second ultrasonic sensors (200), which are arranged on the rear guard plate (6) and facing the impeller (4). The second ultrasonic sensors (200) are electrically connected to the control unit and are used to detect the remaining wall thickness of the rear guard plate (6).

4. The slurry pump flow component life monitoring system as described in claim 3, characterized in that, The control unit has a built-in timer for sending a synchronous trigger signal to the first ultrasonic sensor (100) and the second ultrasonic sensor (200) so that the first ultrasonic sensor (100) and the second ultrasonic sensor (200) alternately emit ultrasonic waves.

5. The slurry pump flow component life monitoring system as described in claim 1, characterized in that, The monitoring unit also includes: Temperature sensor, used to collect real-time temperature data of slurry; Concentration sensor, used to collect real-time concentration data of slurry; The control unit is equipped with a sound velocity dynamic calibration module, which corrects the propagation speed of ultrasound in the slurry based on the real-time temperature data and the real-time concentration data.

6. The slurry pump flow component life monitoring system as described in claim 3, characterized in that, The control unit is equipped with an alarm module. When the remaining wall thickness of the current guard plate (5) and / or the rear guard plate (6) is lower than the wall thickness threshold or the gap adjustment unit fails to complete the adjustment action within the preset adjustment time, the alarm module will sound an alarm.

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