Chain tension monitoring apparatus and method for flight conveyors

Abstract

The present application relates to the technical field of scraper conveyor, and particularly relates to a chain tension monitoring device and method of scraper conveyor, which comprises a fixed support, a wear plate, a first capacitor plate, a second capacitor plate, an elastic component and a guide column; the U-shaped mouth of the fixed support is aligned with the scraper of the scraper conveyor and is fixed to the upper edge of the transition groove of the scraper conveyor, the two ends of the wear plate are slidably connected with the inner wall of the fixed support and the wear plate is opposite to the scraper, and the elastic component is arranged between the two ends of the wear plate and the top of the fixed support; the top of the fixed support is provided with a mounting portion, the first capacitor plate and the second capacitor plate are arranged in the mounting portion in a spaced manner, one end of the guide column is connected with the wear plate, the other end of the guide column is connected with the first capacitor plate, the two ends of the first capacitor plate are slidably connected with the inner wall of the mounting portion respectively, and the second capacitor plate is fixed above the first capacitor plate. In this way, the present application improves the accuracy of the tension detection result of the scraper chain.

Description

Technical Field

[0001] This invention relates to the field of scraper conveyor technology, and more specifically to a chain tension monitoring device and method for scraper conveyors. Background Technology

[0002] Scraper conveyors are crucial equipment in mechanized coal mining at fully mechanized longwall faces. Their working principle involves a motor sequentially driving a hydraulic coupling, reducer, and sprocket, ultimately rotating the sprocket. The sprocket meshes with the scraper chain, causing the chain and the scrapers fixed to it to move. Thus, the scrapers circulate together with the chain. The scrapers and chain propel the material on the conveyor plates from the tail to the head. As the working principle shows, the scraper chain is a key component, serving as the traction mechanism and directly transmitting traction force and scraping material. Operating under sliding friction conditions, the chain withstands significant static and dynamic loads, as well as erosion from mine water, resulting in a typically high failure rate. Typical failure modes of scraper chains include chain jamming, chain skipping, and chain breakage. Studies have shown that the reliability of scraper conveyors decreases exponentially with operating time. When failures occur, maintenance is time-consuming and labor-intensive, severely impacting coal mine productivity. Therefore, fault monitoring of scraper chains is extremely important.

[0003] In some scenarios, the tension of the scraper chain is a crucial parameter characterizing its operating status. Excessive or insufficient tension can negatively impact the safe operation of the scraper conveyor. Insufficient tension can cause the scraper chain to slacken at the drive sprocket separation point, potentially leading to chain breakage, jamming, or tooth breakage. Excessive tension, on the other hand, can cause an abnormal increase in the overall power consumption of the scraper conveyor. Traditionally, tension sensors are used to detect scraper chain tension. However, the sensor body is in direct contact with the scraper, making the sensor contact surface prone to wear, thus affecting the tension detection results. Furthermore, because this sensor relies on changes in sensor angle to characterize tension changes, contact with coal or gangue can also trigger angle changes, resulting in low accuracy in the scraper chain tension detection. Summary of the Invention

[0004] To address the technical problem of low accuracy in scraper chain tension detection results, the present invention aims to provide a chain tension monitoring device and method for scraper conveyors, the specific technical solution of which is as follows:

[0005] In a first aspect, embodiments of the present invention disclose a chain tension monitoring device for a scraper conveyor. The chain tension monitoring device for the scraper conveyor includes: a fixed bracket, a wear-resistant plate, a first capacitor plate, a second capacitor plate, an elastic component, and a guide post. The fixed bracket is inverted U-shaped, with the U-shaped opening aligned with the scraper of the scraper conveyor and fixed to the upper edge of the transition groove of the scraper conveyor. Both ends of the wear-resistant plate are slidably connected to the inner wall of the fixed bracket, and the wear-resistant plate faces the scraper. The elastic component is disposed at both ends between the top of the wear-resistant plate and the top of the fixed bracket. The top of the fixed bracket is provided with a mounting portion, and the first and second capacitor plates are spaced apart at the mounting portion. One end of the guide post is connected to the wear-resistant plate. The other end of the guide post is connected to the first capacitor plate, and both ends of the first capacitor plate are slidably connected to the inner wall of the mounting part. The second capacitor plate is fixed above the first capacitor plate. When the scraper chain passes by and squeezes the wear-resistant plate, the wear-resistant plate slides relative to the inner wall of the fixed bracket and squeezes the elastic component. The guide post pushes the first capacitor plate to slide on the inner wall of the mounting part, so that the distance between the first capacitor plate and the second capacitor plate changes and outputs the capacitance value. The capacitance value and the deformation of the elastic component are related to the pressure on the wear-resistant plate. The pressure is related to the tension of the scraper chain. The pressure on the wear-resistant plate is the pressure applied by the scraper chain to the transition groove.

[0006] Secondly, embodiments of the present invention disclose a chain tension monitoring method for a scraper conveyor, comprising: acquiring the capacitance value output by a capacitance sensor composed of a first capacitor plate and a second capacitor plate; determining the pressure on the wear-resistant plate based on the correlation between the capacitance value and the deformation of the elastic component of the chain tension monitoring device and the pressure on the wear-resistant plate, wherein the pressure on the wear-resistant plate is the pressure applied by the scraper chain to the transition groove; and determining the tension on the scraper chain based on the correlation between the pressure and the tension of the scraper chain.

[0007] According to the technical solution disclosed in this invention, the chain tension monitoring device senses the pressure applied by the scraper chain to the transition groove through a wear-resistant plate, and then reflects the tension change through the deformation of the elastic component and the change in the distance between the first and second capacitor plates. This method avoids interference from debris such as coal lumps and gangue on the detection results, because only when the actual tension change of the scraper chain causes a change in the pressure of the wear-resistant plate will it lead to a change in the capacitance value, thereby improving the accuracy of the detection results. Furthermore, the wear-resistant plate of this monitoring device is opposite to the scraper, and the first and second capacitor plates do not directly contact the scraper chain. The wear-resistant plate can withstand the compression and friction of the chain, protecting the capacitor plates, reducing wear, and thus ensuring the accuracy and stability of the tension detection. The fixed bracket adopts an inverted U-shaped structure, with the U-shaped opening aligned with the scraper chain and fixed to the upper edge of the transition groove, facilitating installation and positioning. The two ends of the wear-resistant plate are slidably connected to the inner wall of the fixed bracket, and the elastic component is set at both ends between the wear-resistant plate and the top of the fixed bracket, allowing the wear-resistant plate to slide smoothly relative to the fixed bracket under force, while the elastic component can effectively convert the pressure on the wear-resistant plate into its own deformation. By observing minute changes in the spacing between capacitor plates, the variations in scraper chain tension can be accurately reflected. Furthermore, by establishing the correlation between capacitance value, elastic component deformation, pressure on the wear-resistant plate, and scraper chain tension, precise monitoring of scraper chain tension can be achieved. Attached Figure Description

[0008] Figure 1 This is a schematic diagram of the structure of a chain tension monitoring device for a scraper conveyor provided in an embodiment of the present invention.

[0009] Figure 2 This is a structural schematic diagram of a scraper conveyor provided in an embodiment of the present invention.

[0010] Figure 3 This is a flowchart illustrating a chain tension monitoring method for a scraper conveyor provided in an embodiment of the present invention.

[0011] Reference numerals: fixed bracket 101, wear-resistant plate 102, first capacitor plate 103, second capacitor plate 104, elastic component 105, guide post 106, vertical ring 201, flat ring 202, scraper 203, guide plate 107, upper edge of transition groove 10. Detailed Implementation

[0012] To further illustrate the technical means and effects adopted by the present invention to achieve its intended purpose, the following, in conjunction with the accompanying drawings and preferred embodiments, details the specific implementation, structure, features, and effects of a chain tension monitoring device and a scraper conveyor according to the present invention. In the following description, different "one embodiment" or "another embodiment" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics in one or more embodiments can be combined in any suitable form.

[0013] 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 specific embodiment of a chain tension monitoring device for a scraper conveyor provided by this invention is described below in conjunction with the accompanying drawings.

[0014] Figure 1 This is a schematic diagram of the structure of a chain tension monitoring device for a scraper conveyor provided in an embodiment of the present invention. Figure 2 This is a structural schematic diagram of a scraper conveyor provided in an embodiment of the present invention. Figure 3 This is a flowchart illustrating a chain tension monitoring method for a scraper conveyor provided in an embodiment of the present invention.

[0015] like Figure 1 As shown in the embodiment of the present invention, a chain tension monitoring device for a scraper conveyor includes: a fixed bracket 101, a wear-resistant plate 102, a first capacitor plate 103, a second capacitor plate 104, an elastic component 105, and a guide column 106.

[0016] The fixed bracket 101 is inverted U-shaped, with the U-shaped opening of the fixed bracket 101 aligned with the scraper of the scraper conveyor and fixed to the upper edge 10 of the transition groove of the scraper conveyor. The two ends of the wear-resistant plate 102 are slidably connected to the inner wall of the fixed bracket 101 and the wear-resistant plate 102 is opposite to the scraper. The elastic member 105 is disposed at both ends between the wear-resistant plate 102 and the top of the fixed bracket 101.

[0017] The top of the fixed bracket 101 is provided with a mounting part. The first capacitor plate 103 and the second capacitor plate 104 are spaced apart in the mounting part. One end of the guide post 106 is connected to the wear-resistant plate 102, and the other end of the guide post 106 is connected to the first capacitor plate 103. Both ends of the first capacitor plate 103 are slidably connected to the inner wall of the mounting part. The second capacitor plate 104 is fixed above the first capacitor plate 103. When the scraper chain passes by and squeezes the wear-resistant plate 102, the wear-resistant plate 104... 2. The guide post 106 slides and presses against the inner wall of the fixed bracket 101 and the elastic member 105. The guide post 106 pushes the first capacitor plate 103 to slide against the inner wall of the mounting part, so that the distance between the first capacitor plate 103 and the second capacitor plate 104 changes and outputs a capacitance value. The capacitance value and the deformation of the elastic member 105 are related to the pressure on the wear-resistant plate 102. The pressure is related to the tension of the scraper chain. The pressure on the wear-resistant plate 102 is the pressure applied to the transition groove by the scraper chain.

[0018] Specifically, such as Figure 1 As shown, the chain tension monitoring device in this embodiment of the invention is positioned above the scraper chain, which includes a vertical ring 201, a flat ring 202, and a scraper 203. The scraper chain rotates cyclically under the drive of the sprocket. When the tail tensioning cylinder of the scraper conveyor tensions the chain, the components such as the vertical ring 201, flat ring 202, and scraper 203 come into close contact with and compress the wear-resistant plate 102. As the tension of the scraper chain increases, the scraper chain exerts increasing pressure on the upper edge of the transition groove. The tension of the scraper chain and the pressure exerted on the upper edge of the transition groove are positively correlated. Therefore, this embodiment of the invention uses the measurement of the pressure applied by the scraper chain to the upper edge of the transition groove to determine the tension on the scraper chain.

[0019] Furthermore, the scraper chain exerts pressure on the upper edge of the transition groove. A spring is installed on the transition groove; according to Hooke's Law, the spring will deform differently under different pressures. Correlating the spring deformation with the change in the distance between the capacitor plates, the magnitude of the spring deformation directly reflects the distance between the capacitor plates, and the size of the distance between the capacitor plates causes a change in the capacitance. Therefore, the magnitude of the pressure exerted by the scraper chain on the upper edge of the transition groove can be determined by the capacitance value.

[0020] Furthermore, such as Figure 1 As shown, the fixed bracket 101 in this embodiment of the invention is an inverted U-shape, with the U-shaped opening of the fixed bracket 101 aligned with the scraper of the scraper conveyor and fixed to the upper edge of the transition trough of the scraper conveyor. In an optional embodiment of the invention, the fixed bracket 101 is detachably fixed to the upper edge of the transition trough of the scraper conveyor using bolts. This embodiment of the invention eliminates the need for destructive modifications to the transition trough, reducing the difficulty of equipment assembly and subsequent maintenance. Secondly, when the monitoring equipment needs repair, replacement, or position adjustment, it can be quickly disassembled and assembled, reducing downtime and ensuring continuous operation of the scraper conveyor. Finally, the bolted connection provides strong stability, ensuring that the fixed bracket 101 remains stable during equipment operation and preventing tension detection accuracy from being affected by bracket loosening.

[0021] Furthermore, the wear-resistant plate 102 is made of wear-resistant material, thereby preventing damage from the scraper chain and extending the service life of the equipment. In one optional embodiment of the invention, the wear-resistant plate 102 has a T-shaped structure. The vertical rod of the T-shaped structure is embedded in the transition groove, and the two ends of the horizontal rod of the T-shaped structure are slidably connected to the inner wall of the fixed bracket 101. The guide post 106 is located at the middle position of the wear-resistant plate 102, and the mounting part is opposite to the middle position of the wear-resistant plate 102. Figure 1As shown, in this embodiment of the invention, the T-shaped vertical rod is embedded in the transition groove to ensure the stability of the monitoring equipment and improve the stability and reliability of the monitoring results. The T-shaped vertical rod embedded in the transition groove and the horizontal rod connected to the bracket can stably bear the pressure of the scraper chain and avoid deviation; the guide post 106 and the mounting part are both aligned with the middle of the wear-resistant plate 102, which allows the pressure to be evenly transmitted to the capacitor plates and reduces detection errors. The overall design makes the force more balanced, further improving the stability and accuracy of tension monitoring.

[0022] Furthermore, as an optional embodiment of the present invention, the elastic component is a helical spring. One end of the helical spring is welded and fixed to the upper surface of the wear-resistant plate, and the other end is welded and fixed to the lower surface of the top of the fixed bracket. In its natural state, the distance between the lower surface of the wear-resistant plate and the upper surface of the scraper conveyor is 1-3mm, so as to ensure that the scraper chain can accurately squeeze the wear-resistant plate and trigger elastic deformation during operation.

[0023] Furthermore, as an optional embodiment of the present invention, the inner wall of the fixed bracket is provided with a groove extending in the vertical direction, and both ends of the wear-resistant plate are provided with sliders adapted to the groove. The sliders are embedded in the groove and slidably connected to the inner wall of the groove. The outer wall of the slider is provided with a polytetrafluoroethylene wear-resistant layer with a thickness of 0.5-1mm, so as to reduce the frictional resistance when the wear-resistant plate slides and extend its service life.

[0024] Furthermore, as an optional embodiment of the present invention, the mounting part is a rectangular groove formed on the top of the fixed bracket. The inner wall of the rectangular groove is provided with a guide rail in the vertical direction. The two ends of the first capacitor plate are provided with sliding protrusions adapted to the guide rail. The sliding protrusions are embedded in the guide rail and are in clearance fit with the inner wall of the rail. The clearance width is 0.1-0.2mm to ensure that the first capacitor plate slides smoothly in the vertical direction and avoids lateral displacement affecting the capacitance value detection accuracy.

[0025] Furthermore, as an optional embodiment of the present invention, the guide post has a cylindrical structure. One end of the guide post is detachably connected to the upper surface of the wear-resistant plate by bolts, and the other end passes through the through hole at the top of the fixing bracket and is bonded and fixed to the lower surface of the first capacitor plate. The inner diameter of the through hole is 0.2-0.3 mm larger than the outer diameter of the guide post, and a rubber sealing ring is provided on the inner wall of the through hole to prevent dust from entering the mounting part and affecting the insulation performance of the capacitor plate.

[0026] Furthermore, as an optional embodiment of the present invention, both the first capacitor plate and the second capacitor plate are circular metal plates with a diameter of 30-50 mm and a thickness of 2-3 mm. The first capacitor plate is made of brass, and the second capacitor plate is made of stainless steel. The relative surfaces of the two plates are polished, with a surface roughness Ra≤0.8μm, in order to reduce the influence of impurities on the plate surface on the stability of the capacitance value.

[0027] Furthermore, as an optional embodiment of the present invention, guide grooves are provided at both ends of the inner wall of the fixed bracket 101. The two ends of the wear-resistant plate 102 are slidably connected to the guide grooves 1010 at both ends of the inner wall of the fixed bracket 101, so that the wear-resistant plate 102 slides relative to the fixed bracket 101 in the guide grooves. Specifically, in this embodiment of the present invention, guide grooves are provided at both ends of the inner wall of the fixed bracket 101. The wear-resistant plate 102 can move up and down in the guide grooves, thereby driving the guide post 106 to move up and down, and the distance between the first capacitor plate 103 and the second capacitor plate 104 will also change accordingly. Thus, the guide grooves in this embodiment of the present invention can precisely constrain the movement direction of the wear-resistant plate 102, preventing it from deviating or jamming during sliding, and ensuring that it only moves up and down along a preset path after being subjected to force. A stable sliding path allows the scraper chain pressure borne by the wear-resistant plate 102 to be transmitted more evenly to the guide post 106 and the capacitor plates, reducing detection errors caused by displacement deviations. By guiding the sliding through the guide groove, abnormal wear caused by direct friction between the wear-resistant plate 102 and the inner wall of the bracket can be avoided, thus extending the service life of the component.

[0028] Furthermore, in this embodiment of the invention, the elastic component 105 can be a spring, which can be fixed at both ends between the wear-resistant plate 102 and the top of the fixed bracket 101. One end of the spring is connected to the wear-resistant plate 102, and the other end of the spring is connected to the top of the fixed bracket 101, thereby providing sufficient thrust to the wear-resistant plate 102. When selecting the spring model, a suitable spring model can be selected according to the pressure.

[0029] Furthermore, the first capacitor plate 103, the second capacitor plate 104, and the guide post 106 constitute an adjustable capacitive sensor. In an optional embodiment of the invention, both the first capacitor plate 103 and the second capacitor plate 104 are conductive metal plates. These conductive metal plates possess excellent conductivity. This superior conductivity allows the plates to respond quickly to changes in spacing, accurately outputting a stable capacitance value and avoiding weak or distorted signals due to poor conductivity, thus ensuring the accuracy of tension data. The high conductivity of the metal plate reduces signal transmission loss, enabling the plates to sensitively capture even minute changes in spacing, thereby improving the monitoring capability for subtle fluctuations in the tension of the scraper chain. The metal material itself possesses a certain strength, can adapt to the vibration environment during equipment operation, is not easily damaged, extends the service life of the capacitor plates, and ensures long-term stable operation of the monitoring equipment.

[0030] Furthermore, as an optional embodiment of the present invention, the top of the fixed bracket 101 is provided with an opening, and the wire 108 is connected to the first capacitor plate 103, the second capacitor plate 104, and the external controller through the opening. Thus, when the distance between the first capacitor plate 103 and the second capacitor plate 104 changes, generating a capacitance value, the measured capacitance value is transmitted to the external controller for processing via the wire.

[0031] Furthermore, such as Figure 1 As shown, in an optional embodiment of the present invention, the chain tension monitoring device of the scraper conveyor further includes a guide plate 107. Both ends of the guide plate 107 are fixed to the mounting portion and located below the first capacitor plate 103. An opening is provided on the guide plate 107 opposite to the guide post 106, and the guide post 106 passes through the opening and connects to the first capacitor plate 103. One end of the guide post 106 is connected to a wear-resistant plate 102, and the other end of the guide post 106 is connected to the first capacitor plate 103 through the opening. The guide plate 107 provides guidance for the up-and-down movement of the guide post 106. The first capacitor plate 103 moves with the up-and-down movement of the guide post 106, thereby changing the distance between the first capacitor plate 103 and the second capacitor plate 104. Thus, the opening on the guide plate, in conjunction with the guide post 106, can strictly limit the movement direction of the guide post 106, preventing it from shifting or wobbling when pushing the first capacitor plate 103, ensuring that the plate slides smoothly only in the vertical direction. The stable movement of the guide post 106 ensures uniform changes in the spacing between the first and second capacitor plates, preventing abnormal fluctuations in capacitance values ​​due to plate misalignment, and further improving the stability and accuracy of tension detection data. By constraining the movement of the guide post 106, friction between it and the inner wall of the mounting section is reduced, while avoiding collisions or compression of the capacitor plates due to the guide post 106 being tilted, thus extending the service life of the core detection component.

[0032] Furthermore, in this embodiment of the invention, the change in the distance between the first capacitor plate 103 and the second capacitor plate 104 exhibits a linear relationship with the change in capacitance, as shown in the following formula: ;

[0033] In the above formula, This indicates the capacitance value. This represents the relative permittivity between the first capacitor plate 103 and the second capacitor plate 104. This represents the area of ​​the first capacitor plate 103 and the second capacitor plate 104. The distance between the first capacitor plate 103 and the second capacitor plate 104 is the difference between the original distance d0 between the first capacitor plate 103 and the second capacitor plate 104 and the deformation x of the elastic component.

[0034] As can be seen from the formula, the capacitance C is linearly inversely proportional to the distance d between the first capacitor plate 103 and the second capacitor plate 104. When the distance d between the electrodes increases, the capacitance C decreases, and when the distance d between the electrodes decreases, the capacitance C increases.

[0035] Furthermore, the distance d between the first capacitor plate 103 and the second capacitor plate 104 is related to the compression ratio of the elastic component 105. According to Hooke's Law, the deformation of an elastic object within its elastic range is linearly related to the applied external force: F = kx, where F is the applied force (corresponding to the pressure applied by the scraper chain to the transition groove in this embodiment), k is the elastic coefficient, and x is the deformation. From the formula, it can be seen that when the chain is tensioned, the scraper chain applies pressure to the wear-resistant plate 102. The applied pressure is converted into spring deformation, which ultimately reflects in the change of capacitance. Therefore, a relationship can be established between the pressure applied by the scraper chain to the transition groove and the capacitance C: ;

[0036] In the above formula, This indicates the pressure applied by the scraper chain to the transition groove. This represents the elasticity coefficient. This represents the relative permittivity between the first capacitor plate 103 and the second capacitor plate 104. This represents the area of ​​the first capacitor plate 103 and the second capacitor plate 104. This represents the capacitance value. d0 represents the distance between the primary plates of the first capacitor plate 103 and the second capacitor plate 104.

[0037] Thus, in the above formula, , , , Since all parameters are known, the solution can be obtained. .

[0038] Furthermore, such as Figure 2 As shown, Figure 2 This is a schematic diagram of a scraper conveyor according to an embodiment of the present invention. The scraper conveyor includes a chain tension monitoring device and a scraper conveyor body as described in the above embodiment. Wherein, as... Figure 2 As shown, there is a linear relationship between the tension on the scraper chain and the pressure exerted by the scraper chain on the transition groove. By decomposing the pressure exerted by the scraper chain on the transition groove, the horizontal component is the force with the same magnitude but opposite direction to the tension. Therefore, an equation can be established between the tension on the scraper chain and the pressure exerted by the scraper chain on the transition groove: F1 = k1F, k1 = COSA, where F1 represents the tension, F represents the pressure at the transition groove, and COSA is between 0 and 1. Thus, the tension on the scraper chain can be obtained.

[0039] It is worth noting that the embodiments of the present invention can also be installed at the head transition trough or tail transition trough of the scraper conveyor.

[0040] Furthermore, such as Figure 3 As shown, Figure 3 This is a flowchart illustrating a method for monitoring chain tension in a scraper conveyor according to an embodiment of the present invention. The method is based on the chain tension monitoring device for the scraper conveyor mentioned in the above embodiment. The method includes:

[0041] Step S301: Obtain the capacitance value output by the capacitance sensor composed of the first capacitor plate and the second capacitor plate.

[0042] Specifically, in this embodiment of the invention, the capacitance value is obtained through the chain tension monitoring device described in the above embodiments.

[0043] Step S302: Based on the correlation between the capacitance value and the deformation of the elastic component of the chain tension monitoring device and the pressure on the wear-resistant plate, determine the pressure on the wear-resistant plate, wherein the pressure on the wear-resistant plate is the pressure applied to the transition groove by the scraper chain.

[0044] Specifically, according to an optional embodiment of the present invention, determining the pressure on the wear-resistant plate based on the correlation between the capacitance value and the deformation of the elastic component of the chain tension monitoring device and the applied external force includes: determining a first equation relationship between the deformation of the elastic component and the pressure on the wear-resistant plate according to Hooke's Law; determining a second equation relationship between the relative areas of the first capacitor plate and the second capacitor plate, the change in spacing between the first capacitor plate and the second capacitor plate, the relative permittivity of the first capacitor plate and the second capacitor plate, and the capacitance value, wherein the change in spacing between the first capacitor plate and the second capacitor plate is consistent with the deformation of the elastic component; and determining the pressure on the wear-resistant plate based on the first equation relationship and the second equation relationship.

[0045] Specifically, the embodiments of the present invention establish the following first equation relationship:

[0046] In the above formula, This represents the pressure applied by the scraper chain to the transition groove. x represents the deformation of the elastic component.

[0047] Furthermore, embodiments of the present invention establish the following second equation relationship:

[0048] In the above formula, This indicates the capacitance value. This represents the relative permittivity between the first capacitor plate and the second capacitor plate. This represents the area of ​​the first capacitor plate and the second capacitor plate. The distance between the first capacitor plate and the second capacitor plate is the difference between the original distance d0 between the first capacitor plate 103 and the second capacitor plate 104 and the deformation x of the elastic component.

[0049] Based on the first and second equations mentioned above, the following equations are established: ;

[0050] In the above formula, This indicates the pressure applied by the scraper chain to the transition groove. This represents the elasticity coefficient. This represents the relative permittivity between the first capacitor plate and the second capacitor plate. This represents the area of ​​the first capacitor plate and the second capacitor plate. This indicates the capacitance value.

[0051] Thus, in the above formula, , , , , Since all parameters are known, the solution can be obtained. .

[0052] Step S303: Based on the correlation between the pressure and the tension of the scraper chain, determine the tension on the scraper chain.

[0053] Specifically, as an optional embodiment of the present invention, determining the tension on the scraper chain based on the correlation between the pressure and the tension of the scraper chain includes: establishing a linear equation relationship between the pressure and the tension of the scraper chain based on the linear correlation between the pressure and the tension of the scraper chain; and solving for the tension on the scraper chain based on the linear equation relationship.

[0054] Specifically, as above Figure 2 As shown, there is a linear relationship between the tension on the scraper chain and the pressure applied by the scraper chain to the transition groove. By decomposing the pressure applied by the scraper chain to the transition groove, the horizontal component is the force with the same magnitude but opposite direction to the tension. Therefore, an equation can be established between the tension on the scraper chain and the pressure applied by the scraper chain to the transition groove: F1 = k1F, k1 = COSA, where F1 represents the tension, F represents the pressure at the transition groove, and COSA is between 0 and 1. Thus, the tension on the scraper chain can be obtained.

[0055] According to the technical solution disclosed in this invention, the chain tension monitoring device senses the pressure applied by the scraper chain to the transition groove through a wear-resistant plate, and then reflects the tension change through the deformation of the elastic component and the change in the distance between the first and second capacitor plates. This method avoids interference from debris such as coal lumps and gangue on the detection results, because only when the actual tension change of the scraper chain causes a change in the pressure of the wear-resistant plate will it lead to a change in the capacitance value, thereby improving the accuracy of the detection results. Furthermore, the wear-resistant plate of this monitoring device is opposite to the scraper, and the first and second capacitor plates do not directly contact the scraper chain. The wear-resistant plate can withstand the compression and friction of the chain, protecting the capacitor plates, reducing wear, and thus ensuring the accuracy and stability of the tension detection. The fixed bracket adopts an inverted U-shaped structure, with the U-shaped opening aligned with the scraper chain and fixed to the upper edge of the transition groove, facilitating installation and positioning. The two ends of the wear-resistant plate are slidably connected to the inner wall of the fixed bracket, and the elastic component is set at both ends between the wear-resistant plate and the top of the fixed bracket, allowing the wear-resistant plate to slide smoothly relative to the fixed bracket under force, while the elastic component can effectively convert the pressure on the wear-resistant plate into its own deformation. By observing minute changes in the spacing between capacitor plates, the variations in scraper chain tension can be accurately reflected. Furthermore, by establishing the correlation between capacitance value, elastic component deformation, pressure on the wear-resistant plate, and scraper chain tension, precise monitoring of scraper chain tension can be achieved.

[0056] It is worth noting that the chain tension monitoring method of the scraper conveyor in the embodiments of the present invention has the same or similar implementation and beneficial effects as the chain tension monitoring device of the scraper conveyor described above, and they can be referred to each other. The embodiments of the present invention will not be described again here.

[0057] It should be noted that the order of the above embodiments of the present invention is merely for descriptive purposes and does not represent the superiority or inferiority of the embodiments. The processes depicted in the accompanying drawings do not necessarily require a specific or sequential order to achieve the desired result. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

[0058] The various embodiments in this specification are described in a progressive manner. The same or similar parts between the various embodiments can be referred to each other. Each embodiment focuses on describing the differences from other embodiments.

Claims

1. A chain tension monitoring device for a scraper conveyor, characterized in that, The chain tension monitoring device for the scraper conveyor includes: a fixed bracket, a wear-resistant plate, a first capacitor plate, a second capacitor plate, an elastic component, and a guide column; The fixed bracket is inverted U-shaped, with the U-shaped opening of the fixed bracket aligned with the scraper of the scraper conveyor and fixed to the upper edge of the transition groove of the scraper conveyor. The two ends of the wear-resistant plate are slidably connected to the inner wall of the fixed bracket and the wear-resistant plate is opposite to the scraper. The elastic component is disposed at both ends between the top of the wear-resistant plate and the top of the fixed bracket. The top of the fixed bracket is provided with a mounting part. The first capacitor plate and the second capacitor plate are spaced apart in the mounting part. One end of the guide post is connected to the wear-resistant plate, and the other end of the guide post is connected to the first capacitor plate. Both ends of the first capacitor plate are slidably connected to the inner wall of the mounting part. The second capacitor plate is fixed above the first capacitor plate. When the scraper chain passes by and squeezes the wear-resistant plate, the wear-resistant plate slides relative to the inner wall of the fixed bracket and squeezes the elastic component. The guide post pushes the first capacitor plate to slide on the inner wall of the mounting part, so that the distance between the first capacitor plate and the second capacitor plate changes and outputs a capacitance value. The capacitance value and the deformation of the elastic component are related to the pressure on the wear-resistant plate. The pressure is related to the tension of the scraper chain. The pressure on the wear-resistant plate is the pressure applied by the scraper chain to the transition groove.

2. The chain tension monitoring device for a scraper conveyor according to claim 1, characterized in that, The wear-resistant plate has a T-shaped structure. The vertical rod of the T-shaped structure is embedded in the transition groove. The two ends of the horizontal rod of the T-shaped structure are slidably connected to the inner wall of the fixed bracket. The guide post is located in the middle of the wear-resistant plate, and the mounting part is opposite to the middle of the wear-resistant plate.

3. The chain tension monitoring device for a scraper conveyor according to claim 1, characterized in that, The mounting part is a rectangular groove formed on the top of the fixed bracket. The inner wall of the rectangular groove is provided with a guide rail in the vertical direction. The two ends of the first capacitor plate are provided with sliding protrusions that are adapted to the guide rail. The sliding protrusions are embedded in the guide rail and are in clearance fit with the inner wall of the rail.

4. The chain tension monitoring device for a scraper conveyor according to claim 1, characterized in that, The elastic component is a helical spring. One end of the helical spring is welded and fixed to the upper surface of the wear-resistant plate, and the other end is welded and fixed to the lower surface of the top of the fixed bracket.

5. The chain tension monitoring device for a scraper conveyor according to claim 1, characterized in that, The inner wall of the fixed bracket is provided with a vertically extending groove, and both ends of the wear-resistant plate are provided with sliders that are adapted to the groove. The sliders are embedded in the groove and slidably connected to the inner wall of the groove. The outer wall of the slider is provided with a polytetrafluoroethylene wear-resistant layer.

6. The chain tension monitoring device for a scraper conveyor according to claim 1, characterized in that, The guide post has a cylindrical structure. One end of the guide post is detachably connected to the upper surface of the wear-resistant plate by bolts, and the other end passes through the through hole at the top of the fixing bracket and is bonded and fixed to the lower surface of the first capacitor plate. The inner diameter of the through hole is 0.2-0.3 mm larger than the outer diameter of the guide post, and a rubber sealing ring is provided on the inner wall of the through hole to prevent dust from entering the installation part and affecting the insulation performance of the first capacitor plate and the second capacitor plate.

7. The chain tension monitoring device for a scraper conveyor according to claim 1, characterized in that, The chain tension monitoring device of the scraper conveyor also includes a guide plate. The two ends of the guide plate are fixed to the mounting part and located below the first capacitor plate. An opening is provided on the guide plate at the position opposite to the guide post. The guide post passes through the opening and connects to the first capacitor plate.

8. A method for monitoring chain tension in a scraper conveyor, characterized in that, The chain tension monitoring device for the scraper conveyor according to any one of claims 1-7 includes: Obtain the capacitance value output by the capacitance sensor composed of the first capacitor plate and the second capacitor plate; Based on the correlation between the capacitance value and the deformation of the elastic component of the chain tension monitoring device and the pressure on the wear-resistant plate, the pressure on the wear-resistant plate is determined, and the pressure on the wear-resistant plate is the pressure applied to the transition groove by the scraper chain; Based on the correlation between the pressure and the tension of the scraper chain, the tension on the scraper chain is determined.

9. The method for monitoring chain tension of a scraper conveyor according to claim 8, characterized in that, The determination of the pressure on the wear-resistant plate based on the correlation between the capacitance value and the deformation of the elastic component of the chain tension monitoring device and the applied external force includes: The first equation relating the deformation of the elastic component to the pressure exerted on the wear-resistant plate is determined according to Hooke's Law. The second equation relationship is determined between the relative areas of the first capacitor plate and the second capacitor plate, the change in the distance between the first capacitor plate and the second capacitor plate, the relative permittivity of the first capacitor plate and the second capacitor plate, and the capacitance value. The change in the distance between the first capacitor plate and the second capacitor plate is consistent with the deformation of the elastic component. The pressure exerted on the wear-resistant plate is determined based on the first equation and the second equation.

10. The method for monitoring chain tension of a scraper conveyor according to claim 8, characterized in that, The determination of the tension on the scraper chain based on the correlation between the pressure and the tension of the scraper chain includes: Based on the linear relationship between the pressure and the tension of the scraper chain, a linear equation is established between the pressure and the tension of the scraper chain. The tension on the scraper chain is determined based on the linear equation relationship.

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