Lime kiln feeding system and method for preventing hopper crane accidents of lime kiln feeding system

Abstract

The invention relates to a lime kiln feeding system and a method for preventing accidents of a cableway of the lime kiln feeding system.The system is composed of a winch and a feeding mechanism, the feeding mechanism is composed of a cableway, a driving wheel, a first driven wheel, a second driven wheel, a balance weight, a track on which the cableway moves, and a steel wire rope for pulling the cableway; wherein a tensioning wheel is arranged between the first driven wheel and the driving wheel, and a tension sensor used for monitoring tension on the tensioning wheel in real time is installed on the tensioning wheel. According to the lime kiln feeding system and method, an alarm can be given in advance, and accidents are reduced.

Description

Technical Field

[0001] This invention relates to a lime kiln feeding system and a method for preventing accidents involving the bucket truck in the lime kiln feeding system. Background Technology

[0002] The lime workshop in the factory needs to feed lime every day. The large amount of material fed poses a significant challenge to the long-term steady-state operation of the trolley. Over time, the lime kiln feeding system may develop many safety hazards, leading to safety accidents in the factory.

[0003] The feeding system mainly consists of two parts: a winch and a feeding mechanism. The winch consists of a motor, a reducer, a base, a brake, a rope hub, and a mechanical stroke control device. The feeding mechanism mainly consists of a hoist trolley, a buffer device, a counterweight, a track, a bucket wheel, and a counterweight wheel.

[0004] The lime kiln is fed by placing a metered mixture of limestone and coke into a crane trolley. The trolley is suspended by a wire rope passing over a top pulley. Driven by the rotation of a winch hub, the mixture is transported via an 8° inclined overhead track to the kiln top feed bell. From there, a distributor spreads the mixture into the kiln. (The counterweight, suspended by a wire rope passing over a top pulley, moves along the track via the rotation of the winch hub, primarily serving as a counterweight.) The trolley's travel distance is controlled by a control box, which controls the winch's forward and reverse rotation and its start and stop.

[0005] The feeding system has problems, including instances of cable hub breakage or detachment. When the upward distance is too large, the crane needs to tilt to unload the material. However, if the winch tension is too high, the upward distance of the crane tilting linkage mechanism will be excessive, leading to over-tilting and potential jamming. This reduces transportation efficiency and poses a safety hazard. (See [link / reference]). Figure 1 As shown.

[0006] Current technology only addresses the issue of rope hub swaying or breaking in the feeding system by replacing the rope hub, but it cannot provide a timely solution for major accidents caused by hopper jamming.

[0007] A simplified diagram of a normal working scenario is shown below. Figure 2 As shown, only the driving and driven wheels propel the bucket car upwards, with the counterweight providing balance. When the bucket car reaches the top, there is a possibility it will jam, preventing the car from being lowered, resulting in... Figure 3 An accident of the pattern shown. Summary of the Invention

[0008] In view of the problems in the prior art, the present invention provides a lime kiln feeding system and a method for preventing accidents of the hoist trolley in the lime kiln feeding system. By adding a tensioning wheel between the driven wheel and the driving wheel, and adding a tension sensor on the tensioning wheel to monitor the tension in real time, an alarm is issued when the force on the sensor exceeds the threshold by setting a threshold, and then the driving wheel is stopped in time to prevent or reduce the occurrence of accidents.

[0009] The technical solution of the present invention is as follows:

[0010] A lime kiln feeding system consists of two parts: a winch and a feeding mechanism. The winch comprises a motor, a reducer, a base, a brake, a rope hub, and a mechanical stroke control device. The feeding mechanism comprises a hoist trolley, a drive wheel, a first driven wheel, a second driven wheel, a counterweight, a track on which the hoist trolley moves, and a wire rope that pulls the hoist trolley.

[0011] A tensioning wheel is set between the first driven wheel and the driving wheel, and a tension sensor is installed on the tensioning wheel to monitor the tension in real time.

[0012] Furthermore, the tension sensor is mounted on the tensioning wheel via a support, which is connected to the tensioning wheel by a bearing. The supports are symmetrically distributed on both sides of the tensioning wheel to reduce the tension on the sensor. This symmetrical distribution also facilitates the fixed installation of the tensioning wheel and prevents it from shifting. One tension sensor is installed on each side of the tensioning wheel. Because the tension sensors are symmetrically distributed, their tension error is not significant, thus providing a large margin of error for the sensors. The system will stop operating regardless of whether only one sensor alarms or both alarms.

[0013] Furthermore, the support is I-shaped, including a base fixed to a platform, a vertical beam fixed to the base, and a horizontal beam pivotally connected to the upper part of the vertical beam (i.e., the horizontal beam can rotate around a pin set at the upper end of the vertical beam). One end of the horizontal beam is connected to a tension wheel via a shaft, and the other end is connected to the upper end of a tension sensor. The lower end of the tension sensor is connected to the base on one side of the vertical beam. The distances from the sensor and the tension wheel to the horizontal midpoint of the support are equal, ensuring that the vertical force on the tension wheel is equal to the tension force on the sensor. The base must be fixed to a platform because the tension wheel is in mid-air. A fixed platform is set in mid-air on site, and the base can be fixedly connected to it by corresponding bolt holes. A groove can be provided on the upper part of the vertical beam of the support. The horizontal beam passes through this groove and is connected by a pin. The height of the groove is greater than the height of the horizontal beam. A certain amount of space is left between the top and bottom of the groove and the upper and lower parts of the horizontal beam, allowing the horizontal beam to rotate a certain range around the pin.

[0014] The tension sensor structure includes an elastic body, a strain gauge, and a threaded mounting hole; it is also called a resistance strain gauge sensor. The sensor is bolted to the top of the support (i.e., the lower part of the other end of the crossbeam), while a spherical bearing is installed inside the bottom of the support, and the sensor and the spherical bearing are bolted together. The tension force on the tension wheel is determined by detecting changes in the strain gauge resistance, allowing for real-time monitoring. If the trolley gets stuck and the winch reverses, the force on the tension wheel decreases significantly, triggering an alarm and allowing the winch to be powered off to stop operation and prevent accidents. The support and tension wheel are connected by a bearing, and the supports are symmetrically distributed on both sides of the tension wheel to reduce the tension force on the sensor. This symmetrical distribution also facilitates the fixed installation of the tension wheel and prevents it from shifting. At both ends of the top of the support, one end connects to the tension wheel, and the other end connects to the sensor. Ideally, the distances from the sensor and the tension wheel to the horizontal midpoint of the support should be equal or substantially equal to ensure that the vertical force on the tension wheel is equal to the tension force on the sensor.

[0015] The tension sensor used here can be the TE FN3060 S-type cantilever beam force sensor, which has overload protection, a full-scale output of ±5V, and a tensile range of 2500N, but is not limited to these.

[0016] The elastomer is the core mechanical structure of the sensor. Through precise calculation and processing, it will produce a small deformation in a specific area when subjected to tensile force, which is proportional to the external force.

[0017] Strain gauges are key components that convert mechanical quantities into electrical quantities. They are devices whose resistance changes with their geometry. When an elastic body deforms, the strain gauge is stretched or compressed, and the minute change in its resistance causes the sensor to emit different signal amplitudes.

[0018] In this application, the winches commonly used in the art can be employed, and will not be described in detail here.

[0019] The mounting threaded hole provides a mechanical interface. The upper end of the tension sensor is bolted to the crossbeam on the support, and the lower end of the tension sensor is connected to the base of the support, with a spherical bearing installed inside the bottom of the support. The sensor and the spherical bearing are bolted together to prevent damage to the sensor from lateral forces or bending moments.

[0020] The present invention further provides a method for preventing accidents (such as jamming, belt slippage, overload, etc.) in the hoist trolley of the lime kiln feeding system, the method comprising:

[0021] Static tension calculation

[0022] (1) Calculate the total lifting load F 总 :

[0023] Considering mechanical efficiency and belt weight:

[0024] F 总 =M·(g+a)

[0025] Where the gravitational acceleration g = 9.81, M is the mass of the limestone load in kg, and a is the acceleration in m / s². 2 The value is typically 0.1;

[0026] (2) Calculate the driving tension of the active wheel (T1)

[0027] Considering mechanical efficiency η and belt weight:

[0028]

[0029] Among them, F 总 To increase the total load capacity, η is the mechanical efficiency. When the winch applies tension, it will do extra work. There is no machine with a mechanical efficiency of 1. It is usually taken as 0.85.

[0030] ρ is the density of the rope hub, in kg / m; h is the lifting height, in m; g is the acceleration due to gravity, g = 9.81;

[0031] (3) Calculate the tension of the driven wheel (T2)

[0032] When the driven pulley tension belt (T2) passes over the tension pulley, the tension is transmitted due to the friction between the pulley and the belt.

[0033]

[0034] e is the natural constant (e≈2.718), u is the belt friction coefficient, and α is the belt wrap angle on both sides of the tensioner pulley. The wrap angle α refers to the central angle subtended by the contact arc between the belt and the pulley, taking the corresponding radian value. The size of the wrap angle reflects the length of the contact arc between the belt and the pulley's circular surface. This value is determined based on the most common values ​​under actual working conditions.

[0035] The tension wheel is located in the middle and needs to balance the tension on both sides and the downward force. The tension on the tension wheel is equal to the sum of the pulling forces on the two sensors. Therefore, the net force on the tension wheel in the vertical direction is zero.

[0036] (4) Calculate the total force F1 on the tensioner wheel.

[0037] The tension pulley is subjected to the tension of the belts on both sides and its own weight. The angle between the belt tension and the x-axis is... The equilibrium equation is: The net force in the vertical direction is zero.

[0038] F1=T1sin(θ)+T2sin(θ)+mg

[0039] Where m is the mass of the tensioner wheel in kg, g is the gravitational acceleration g = 9.81, and α is taken as an angle value;

[0040] (5) Calculate the force F2 on a single sensor:

[0041]

[0042] (6) Select the sensor range based on the calculated force F2 on the single sensor.

[0043] For sensor range selection, to ensure normal sensor operation, the range is typically at least 1.5 times the applied tension F2. A warning is issued when the belt slips or the wheelbarrow jams and cannot return (tension decreases by 15%). At this point, the minimum tension is F. min =0.85*F2. An alarm will sound when an overload occurs (tension increases by 20%), the tensile overload value F. max =1.2*F2.

[0044] (7) When the sensor output signal displays the actual measured tension value F at the minimum tension F min The following or tensile overload value F max When the above conditions are met, an alarm will be triggered, causing the winch to stop working or its power to be cut off. After stopping the machine, the on-site problems should be investigated, repaired, and the fault diagnosed. If slippage occurs, the position of the tension wheel needs to be adjusted to increase the tension or the belt needs to be replaced. If the bucket car is jammed, manual handling is required. If overload occurs, the weight of the material needs to be reduced. After handling these issues, the winch should be manually restarted to continue working, and sensor data should be recorded every five minutes. After 30 minutes of actual testing to confirm that there is no abnormal data, normal operation can begin.

[0045] Sensor selection parameter verification:

[0046] When the selected sensor parameters are "range 0-2500N, output signal 0-5V":

[0047] F = the actual measured tensile force value;

[0048] F s =Sensor range;

[0049] S1 = Minimum value of the sensor output signal (corresponding to the output signal when the tension is 0);

[0050] S2 = The maximum value of the sensor output signal (corresponding to the output signal when the tension is 2500);

[0051] S max =To be found, corresponding to F max The output signal value of the tension;

[0052] S min =To be found, corresponding to Fmin The output signal value of the tension.

[0053] According to the linear proportion calculation formula:

[0054]

[0055] The tension sensor signal value F2 measured during normal operation can be calculated using the following formula:

[0056]

[0057] The slippage warning (tension decrease of 15%) signal value can be obtained according to the following formula:

[0058]

[0059] The overload alarm (tension increase of 20%) signal value can be obtained according to the following formula:

[0060]

[0061] This invention adds a tensioning wheel and a sensor. The tensioning wheel is responsible for reducing the pressure on the rope hub, while the sensor is responsible for detecting the tension on the rope hub and calculating the tension distribution and vibration mode in real time. It can also detect when the hopper is stuck and take measures to minimize the impact of the accident.

[0062] Advantages of this invention:

[0063] According to the lime kiln feeding system and the method for preventing malfunctions of the bucket truck in the lime kiln feeding system of the present invention, a tensioning wheel is set between the driven wheel and the driving wheel, a tension sensor is added to the tensioning wheel to monitor the tension in real time, and an alarm is issued when the force on the sensor exceeds the threshold by setting a threshold, and then the driving wheel is stopped in time to prevent accidents from occurring. Attached Figure Description

[0064] Figure 1 This is a schematic diagram of the existing lime kiln feeding system, where a is a schematic diagram of the feeding process of the crane trolley, and b is a schematic diagram of the crane trolley overturning and jamming.

[0065] Figure 2 This is a schematic diagram illustrating the working principle of an existing lime kiln feeding system.

[0066] Figure 3 This is a schematic diagram of a jammed feeding system in an existing lime kiln.

[0067] Figure 4 A schematic diagram for improving the operation of the device.

[0068] Figure 5 A schematic diagram illustrating the process of improving a stuck device.

[0069] Figure 6 This is a schematic diagram of the winch conveyor belt detection device of the present invention.

[0070] Figure 7 This is a schematic diagram of a tension sensor structure.

[0071] Figure 8 This is a schematic diagram of the installation of a tension sensor.

[0072] Figure 9 This is a schematic diagram showing the installation relationship at the bottom of the tension sensor support.

[0073] Figure 10 This is a schematic diagram of the tensioner installation.

[0074] Figure 11 This is a schematic flowchart illustrating the typical working principle of a tension sensor.

[0075] Explanation of reference numerals in the attached figures:

[0076] 1-First driven wheel; 2-Driving wheel; 3-Second driven wheel; 4-Balance weight; 5-Hoisting trolley; 6-Tensioning wheel; 601-Bearing; 602-Shaft; 7-Support; 701-Base; 702-Vertical beam; 703-Horizontal beam; 704-Pin; 705-Fixing bolt hole; 8-Force sensor; 801-Mounting threaded hole; 802-Strain gauge; 803-Elastic body; 804-First fixing bolt; 805-Spherical bearing; 806-Second fixing bolt; 9-Rope. Detailed Implementation

[0077] The present invention will be further illustrated below with reference to the accompanying drawings and embodiments.

[0078] A simplified schematic diagram of the normal working scenario of a lime kiln feeding system in the prior art is shown below. Figure 2 As shown, only the drive and driven wheels move the bucket car upwards, with the counterweight providing balance. When the bucket car reaches the top, there is a possibility it will get stuck, preventing the car from being lowered, resulting in... Figure 3 The accident is as shown in the image. Therefore, to address this problem, a tensioning wheel is added as follows: Figure 4 As shown, a tension sensor is added to the tension wheel to monitor the tension in real time, and a threshold is set to trigger a response when the force on the sensor exceeds the threshold. Figure 5 If the wheelbarrow gets stuck, an alarm will sound, and the drive wheel will be stopped in time to reduce the occurrence of accidents.

[0079] like Figure 6-10As shown, the present invention provides a lime kiln feeding system, which consists of a winch and a feeding mechanism. The winch consists of a motor, a reducer, a base, a brake, a rope hub, and a mechanical stroke control device. The feeding mechanism consists of a hoist 5, a drive wheel 2, a first driven wheel 1, a second driven wheel 3, a counterweight 4, a track on which the hoist 5 moves, and a rope 9 (steel wire rope) that pulls the hoist 5. A tension wheel 6 is set between the first driven wheel 1 and the drive wheel 2. The rope passes through the tension wheel 6. A tension sensor 8 is installed on the tension wheel 6 to monitor the tension force on the tension wheel in real time.

[0080] The tension sensor 8 is mounted on the tension wheel 6 via a support 7. The support 7 and the tension wheel 6 are connected by a shaft 602 (the shaft 602 is connected to the tension wheel 6 via a bearing 601). The supports 7 are symmetrically distributed on both sides of the tension wheel 6 to reduce the tension force on the tension sensor. The symmetrical distribution of the supports 7 also facilitates the fixed installation of the tension wheel 6 and prevents it from shifting. One tension sensor 8 is mounted on each side of the tension wheel 6. Because the tension sensors are symmetrically distributed, their tension error is not large, thus providing a large tolerance margin. The system will stop operating if either sensor triggers an alarm or both trigger alarms.

[0081] Furthermore, the support 7 is I-shaped, including a base 701 fixed to the platform, a vertical beam 702 fixed to the base, and a horizontal beam 703 pivotally connected to the upper part of the vertical beam (i.e., the horizontal beam 703 can rotate around a pin 704 located at the upper end of the vertical beam 702). One end of the horizontal beam 703 is connected to and fixed to the tension wheel 6 via a shaft 602, and the other end is connected to the upper end of the tension sensor 8. The lower end of the tension sensor 8 is connected to the base 701 on one side of the vertical beam. The distances from the tension sensor 8 and the tension wheel 6 (center) to the horizontal midpoint (pin) of the support are equal, ensuring that the vertical force on the tension wheel is equal to the tension force on the sensor. The base 701 needs to be fixed to a platform because the tension wheel 6 is located in mid-air. A platform is set up in mid-air on site, and the base 701 can be fixedly connected to it by opening corresponding bolt holes 705. A groove can be provided on the upper part of the vertical beam 702 of the support. The crossbeam passes through the groove and is connected by a pin 704. The height of the groove is greater than the height of the crossbeam. The top and bottom of the groove leave a certain space with the upper and lower parts of the crossbeam 703, respectively, so that the crossbeam 703 can rotate around the pin within a certain range.

[0082] The tension sensor 8 includes an elastic body 803 (usually a spring), a strain gauge 802, and a mounting threaded hole 801. Also known as a resistance strain gauge sensor, it contains both an elastic body and a strain gauge. The tension sensor 8 is fixed to the top of the support (i.e., the lower part of the other end of the crossbeam) using a second fixing bolt 806. A spherical bearing 805 is installed inside the bottom of the support, and the sensor and the spherical bearing are fixedly connected by a first fixing bolt 804. The tension force on the tension wheel 6 is determined by detecting changes in the strain gauge resistance, allowing for real-time monitoring. If the trolley gets stuck and the winch reverses, significantly reducing the force on the tension wheel, an alarm can be triggered, allowing the winch to be powered off and stopped to prevent accidents. The support 7 is connected to the tension wheel 6 via a bearing 601, and the supports are symmetrically distributed on both sides of the tension wheel to reduce the tension force on the sensor. This symmetrical distribution also facilitates the fixed installation of the tension wheel and prevents it from shifting. At the top two ends of the support 7, one end is connected to the fixed tension wheel 6, and the other end is connected to the tension sensor 8. Preferably, the distances from the sensor and the tension wheel to the horizontal midpoint of the support are equal or substantially equal, to ensure that the vertical force on the tension wheel is equal to the tension force on the sensor.

[0083] The tension sensor used here can be the TE FN3060 S-type cantilever beam force sensor, which has overload protection, a full-scale output of ±5V, and a tensile range of 2500N.

[0084] The elastomer is the core mechanical structure of the sensor. Through precise calculation and processing, it will produce a small deformation in a specific area when subjected to tensile force, which is proportional to the external force.

[0085] Strain gauges are key components that convert mechanical quantities into electrical quantities. They are devices whose resistance changes with their geometry. When an elastic body deforms, the strain gauge is stretched or compressed, and the minute change in its resistance causes the sensor to emit different signal amplitudes.

[0086] The mounting threaded hole provides a mechanical interface. The upper end of the tension sensor is bolted to the crossbeam 703 on the support, and the lower end of the tension sensor is connected to the base 701 of the support. A spherical bearing is installed inside the bottom of the support, and the sensor and the spherical bearing are bolted together to prevent damage to the sensor by lateral forces or bending moments.

[0087] Example 1

[0088] See Figure 11 Now, by assuming the operating parameters of the enterprise's winch, the specific process parameters for calculating various values ​​of the tension sensor are set.

[0089]

[0090] Static tension calculation

[0091] (1) Calculate the total lifting load.

[0092] Considering mechanical efficiency and belt weight:

[0093] F 总 =M·(g+a)=200×(9.81+0.1)=1982N

[0094] Where the gravitational acceleration g = 9.81, M is the mass of the limestone load in kg, and a is the acceleration in m / s². 2 .

[0095] (2) Calculate the driving tension of the active wheel (T1)

[0096] Considering mechanical efficiency η and belt weight:

[0097]

[0098] η is the mechanical efficiency. When a winch applies a pulling force, it will do extra work. There is no machine with a mechanical efficiency of 1. 0.85 is a commonly used value. h is the lifting height in meters. ρ is the rope density in kg / m. g is the acceleration due to gravity.

[0099] (3) Calculate the tension of the driven wheel (T2)

[0100] When the driven pulley tension (T2) belt passes over the tension pulley, the tension is transmitted due to the friction between the pulley and the belt.

[0101]

[0102] e is the natural constant (e≈2.718), u is the coefficient of friction between the belt and the pulley, and the wrap angle α=120° is converted to radians:

[0103]

[0104] The tension wheel is located in the middle and needs to balance the tension on both sides and the downward force. The tension on the tension wheel is equal to the sum of the pulling forces on the two sensors. Therefore, the net force on the tension wheel in the vertical direction is zero.

[0105] (4) Calculate the total force F1 on the tensioner wheel.

[0106] The tension pulley is subjected to the tension of the belts on both sides and its own weight. The wrap angle α = 120°. The angle between the belt tension and the x-axis is... The equilibrium equation is: The net force in the vertical direction is zero.

[0107] F1=T1sin(θ)+T2sin(θ)+mg=2390×0.866+1149×0.866+10×9.81≈3162N.

[0108] m is the mass of the tensioner wheel in kg, g is the acceleration due to gravity g = 9.81, and α is taken as an angle value here;

[0109] (5) Calculate the force on a single sensor:

[0110]

[0111] (6) Select the sensor range based on the calculated force F2 on the single sensor.

[0112] For sensor range selection, to ensure normal operation, the range is typically 1.5 times the applied tension F2. Therefore, the maximum sensor range is approximately 2372N, so a range of 2.5KN is sufficient. A warning will be issued when the belt slips or the wheelbarrow jams and cannot return (tension decreases by 15%). The minimum tension at this time is F. min = 0.85 × 1581 ≈ 1343 N. An alarm will sound when an overload occurs (tension increases by 20%). max =1.2×1581≈1898N.

[0113] (7) When the sensor output signal displays the actual measured tension value F at the minimum tension F min The following or tensile overload value F max When the above conditions are met, an alarm is triggered, causing the winch to stop working or its power to be cut off.

[0114] Sensor selection parameter verification:

[0115] When the selected sensor parameters are "range 0-2500N, output signal 0-5V":

[0116] F = the actual measured tensile force value;

[0117] F s =Sensor range;

[0118] S1 = Minimum value of the sensor output signal (corresponding to the output signal when the tension is 0);

[0119] S2 = The maximum value of the sensor output signal (corresponding to the output signal when the tension is 2500);

[0120] S max = The output signal value corresponding to a tensile force of 1898N to be determined;

[0121] S min = The output signal value corresponding to a tensile force of 1343N to be determined.

[0122] According to the linear proportion calculation formula:

[0123]

[0124] The tension sensor signal value measured during normal operation:

[0125]

[0126] S = 3.162V;

[0127] Slippage warning (tension decrease of 15%) signal value:

[0128]

[0129] S min =2.686V;

[0130] Overload alarm (tension increase of 20%) signal value:

[0131]

[0132] S max =3.796V.

[0133] Substituting specific numerical values ​​reveals the following:

[0134] The sensor should be selected with a range of 2.5kN, and the output signal should be around 3.162V when working normally.

[0135] The alarm thresholds should be set to 1343N (lower limit) and 1898N (upper limit), corresponding to 2.686V and 3.796V output signals from the tension sensor, respectively. When these values ​​are exceeded or fallen below, an alarm will be triggered, causing the winch to stop working or its power to be cut off. If the hoist truck is stuck and the tension wheel experiences a significant decrease in force, the sensor reading will fall below S. min This will trigger an alarm and stop the winch. After stopping, the problem on site should be investigated, repaired, and the fault diagnosed. If slippage occurs, the tension pulley position needs to be adjusted to increase tension or the belt needs to be replaced. If the bucket is jammed, manual handling is required. If overload occurs, the weight of the material needs to be reduced. After handling, the winch should be manually restarted and the sensor data should be recorded every five minutes. After 30 minutes of actual testing to confirm that there is no abnormal data, it can be put into normal operation.

[0136] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A lime kiln feeding system, comprising a winch and a feeding mechanism, wherein the feeding mechanism consists of a hoist (5), a drive wheel (2), a first driven wheel (1), a second driven wheel (3), a counterweight (4), a track on which the hoist moves, and a rope (9) for pulling the hoist. Its features are, A tensioning wheel (6) is set between the first driven wheel (1) and the driving wheel (2), and a tension sensor (8) is installed on the tensioning wheel (6) to monitor the tension in real time.

2. The lime kiln feeding system according to claim 1, characterized in that, The tension sensor (8) is mounted on the tension wheel (6) via a support (7). The support (7) and the tension wheel (6) are connected by a shaft (602). A tension sensor (8) is mounted on each side of the tension wheel (6), and the supports (7) are symmetrically distributed on both sides of the tension wheel (6) to reduce the tension on the tension sensor.

3. The lime kiln feeding system according to claim 2, characterized in that, The support (7) is I-shaped and includes a base (701) fixed on the platform, a vertical beam (702) fixed on the base, and a horizontal beam (703) connected to the upper part of the vertical beam by a pin (704). One end of the horizontal beam (703) is connected to a tension wheel (6) via a shaft (602), and the other end is connected to the upper end of a tension sensor (8). The lower end of the tension sensor (8) is connected to the base (701) on one side of the vertical beam. The tension sensor (8) and the tension wheel (6) are equidistant from the horizontal midpoint of the support.

4. The lime kiln feeding system according to claim 3, characterized in that, A groove is provided on the upper part of the vertical beam (702) of the support (7), and the horizontal beam (703) passes through the groove and is connected by a pin (704). The height of the groove is greater than the height of the horizontal beam. The top and bottom of the groove leave a certain space with the upper and lower parts of the horizontal beam (703) respectively, so that the horizontal beam (703) can rotate around the pin within a certain range.

5. The lime kiln feeding system according to claim 3 or 4, characterized in that, The tension sensor (8) includes an elastomer (803), a strain gauge (802), and a mounting threaded hole (801). The tension sensor (8) is connected and fixed to the top of the support using a second fixing bolt (806), while a spherical bearing (805) is installed inside the bottom of the support. The tension sensor (8) and the spherical bearing (805) are fixedly connected by a first fixing bolt (804).

6. A method for preventing accidents involving the hopper trolley in a lime kiln feeding system, the method using the lime kiln feeding system according to any one of claims 1-6, comprising the following steps: (1) Calculate the total lifting load force F_total: F 总 =M·(g+a), Where the gravitational acceleration g = 9.81, M is the mass of the limestone load in kg, and a is the acceleration with a value of 0.1; (2) Calculate the driving tension of the active wheel (T1) Where η is the mechanical efficiency; ρ is the density of the rope hub, in kg / m; h is the lifting height, in m; g is the acceleration due to gravity, g = 9.81; (3) Calculate the tension of the driven wheel (T2) When the driven pulley tension belt (T2) passes over the tension pulley, the tension is transmitted due to the friction between the pulley and the belt. e is the natural constant, e≈2.718, u is the belt friction coefficient, and α is the belt wrap angle on both sides of the tensioner pulley, taking the corresponding radian value. (4) Calculate the total force F1 on the tensioner wheel. The tension pulley is subjected to the tension of the belts on both sides and its own weight. The angle between the belt tension and the x-axis is... The net force in the vertical direction is zero. The equilibrium equation is: (where α is taken as an angle value). F1=T1sin(θ)+T2sin(θ)+mg, Where m is the mass of the tensioner wheel in kg, and g is the gravitational acceleration g = 9.81; (5) Calculate the force F2 on a single sensor: (6) Select the sensor range based on the calculated force F2 on the single sensor. The sensor range is selected to be at least 1.5 times the applied tension F2. An early warning is issued when the belt slips or the wheelbarrow jams and cannot return; at this point, the minimum tension is F. min =0.85*F2, an alarm will be triggered when an overload occurs, the tensile overload value F max =1.2*F2; (7) When the sensor output signal displays the actual measured tension value F at the minimum tension F min The following or tensile overload value F max When the above conditions are met, an alarm is triggered, causing the winch to stop working or its power to be cut off.

7. The method according to claim 6, characterized in that, After shutdown, the on-site problems are investigated, repaired and diagnosed. If slippage occurs, the position of the tension wheel needs to be adjusted to increase the tension or the belt needs to be replaced. If the wheelbarrow is stuck, it needs to be handled manually. If overload occurs, the weight of the material needs to be reduced.

8. The method according to claim 7, characterized in that, After the problem was resolved, the winch was manually started to continue working, and sensor data was recorded every five minutes. After 30 minutes of testing to confirm that there was no abnormal data, the machine was put into normal operation.

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