Real-time chain breakage detection and emergency locking device for scraper conveyor

Abstract

The invention relates to the technical field of safety monitoring and automatic control of fully-mechanized coal mining equipment, in particular to a real-time chain breakage detection and emergency locking device of a scraper conveyor, which comprises a double-chain group A and a double-chain group B which are respectively sleeved at two ends of a power shaft and a driven shaft, the double-chain group A and the double-chain group B are rotatably mounted on the inner side of a conveying frame, and a speed reduction motor group is arranged outside the frame to drive the power shaft. The double-chain group A and the double-chain group B comprise parallel chains A and B, are buckled by vertical buckles and flat buckles in a staggered manner and are detachably connected with a cross rod, and a scraping plate is arranged at the bottom of the cross rod. A double-channel shell is arranged on the tops of the two sides of the conveying frame, double channels are arranged in the double-channel shell and horizontally aligned with the chain vertical buckles, and a counting sensor is arranged on the top of the inner wall. A double-chain set is additionally arranged on the basis of a traditional double-chain scraper conveyor, when one chain is broken on one side, the chain cannot be broken, and safety is improved. The counting sensor is matched with the PLC to monitor the chain, the PLC controls the speed reduction motor set to stop according to the abnormal numerical value when the chain is broken, and larger loss is avoided.

Description

Technical Field

[0001] This invention relates to the field of safety monitoring and automated control technology for fully mechanized coal mining equipment, specifically to a real-time detection and emergency interlocking device for chain breakage of scraper conveyors. Background Technology

[0002] In the operation of traditional double-chain scraper conveyors, chain breakage has always been a key hidden danger affecting the safety and stability of the equipment. Traditional structures are equipped with only one set of double chains. When one chain on one side breaks, the remaining chain is subjected to uneven stress, easily leading to chain collapse. Chain collapse not only causes the conveyor to stop suddenly, interrupting material transport, but can also cause scrapers, chains, and other components to fly off, posing a serious safety threat to surrounding equipment and operators, and potentially causing major accidents such as equipment damage and personal injury.

[0003] Meanwhile, traditional detection methods mostly rely on manual inspections or simple tension monitoring devices. Manual inspections are lagging and difficult to detect early signs of chain breakage in a timely manner; while tension monitoring devices are easily affected by environmental factors and load fluctuations, resulting in insufficient detection accuracy, false alarms or missed alarms occur frequently, and cannot provide reliable safety assurance for the equipment.

[0004] In view of this, this application proposes a real-time chain breakage detection and emergency interlocking device for scraper conveyors. By adding a double-chain group to the traditional double-chain scraper conveyor, the device's resistance to chain breakage is enhanced, avoiding the risk of chain collapse. Furthermore, by utilizing a counting sensor in conjunction with a PLC controller, the device accurately monitors the chain's operating status and promptly controls the geared motor unit to stop in the event of a chain breakage, effectively improving the operational safety of the scraper conveyor and reducing accident losses. Summary of the Invention

[0005] In view of the above-mentioned technical problems in related technologies, the present invention provides a real-time detection and emergency interlocking device for chain breakage of scraper conveyors, which can solve the above problems.

[0006] To achieve the above-mentioned technical objectives, the technical solution of the present invention is implemented as follows: The scraper conveyor chain breakage real-time detection and emergency interlocking device includes a double chain group A and a double chain group B. The double chain group A and double chain group B are respectively fitted onto the ends of the drive shaft and driven shaft. Both the drive shaft and driven shaft are rotatably mounted inside the conveyor frame. A geared motor unit for driving the drive shaft rotation is fixedly installed on the outside of the conveyor frame by bolts. Both double chain group A and double chain group B include two parallel chains A and B. Chains A and B each include staggered vertical and horizontal buckles. Both double chain group A and double chain group B are detachably connected to a crossbar. A scraper is fixedly installed at the bottom of the crossbar. Double-channel housings are fixedly installed on the top of both sides of the conveyor frame. The double-channel housings have double channels inside, and the double-channel housings are horizontally aligned with the vertical buckles of chains A and B. A counting sensor is fixedly installed on the top of the inner wall of the double-channel housing.

[0007] Furthermore, a U-shaped frame is fixedly installed inside the dual channels of the dual-channel housing by bolts, and a cleaning brush is fixedly installed inside the U-shaped frame.

[0008] Furthermore, both the drive shaft and the driven shaft have relief grooves in the middle, and the length of the relief grooves is consistent with the length of the scraper.

[0009] Furthermore, a boss is fixedly installed on the top of the flat buckle on the same horizontal line, and the crossbar is fixed to the surface of the boss by bolts.

[0010] Furthermore, a PLC controller is fixedly installed on the side of the conveyor frame near the geared motor unit, and the geared motor unit and the counting sensor are electrically connected to the PLC controller.

[0011] Furthermore, the counting sensor is located directly above the vertical running trajectory.

[0012] The beneficial effects of this invention are as follows: Based on the traditional double-chain scraper conveyor, the device of this application adds a set of double chains. When one chain in the double chain set on one side breaks, the unit will not experience chain collapse, thus improving the operational safety of the scraper conveyor. By using a counting sensor in conjunction with a PLC controller to monitor the chain operation, when a chain breakage occurs, the value of the counting sensor will not increase steadily. This signal is used to determine if the chain has broken, and the PLC controller controls the geared motor unit to stop running in time, avoiding greater losses. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments 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.

[0014] The present invention will now be described in further detail with reference to the accompanying drawings.

[0015] Figure 1 This is a schematic diagram of the structure of the upper half of double chain group A and double chain group B; Figure 2 This is a schematic diagram of the structure of the real-time detection and emergency interlocking device for chain breakage of a scraper conveyor; Figure 3 This is a schematic diagram of the dual-channel shell structure.

[0016] In the picture: 1. Chain A; 2. Chain B; 3. Vertical buckle; 4. Flat buckle; 5. Horizontal bar; 6. Scraper; 7. Boss; 8. Conveyor frame; 9. Drive shaft; 901. Recessed groove; 10. Driven shaft; 11. Gear motor assembly; 12. Dual-channel housing; 13. Counting sensor; 14. U-shaped frame; 15. Cleaning brush body; 16. PLC controller. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0018] Example 1: As Figure 1-3 As shown Overall structure of the device This scraper conveyor real-time chain breakage detection and emergency interlocking device is an improvement on the traditional double-chain scraper conveyor and mainly consists of the following parts: Chain assembly section: Two double chain assemblies, A and B, are provided. Chain assemblies A and B are respectively fitted onto the two ends of the drive shaft 9 and driven shaft 10. Each double chain assembly contains two parallel chains, A1 and B2, each composed of staggered vertical buckles 3 and horizontal buckles 4. This double chain assembly design prevents chain collapse if one chain in a single double chain assembly breaks, effectively improving the operational safety of the scraper conveyor.

[0019] Power and transmission components: Both the drive shaft 9 and the driven shaft 10 are rotatably mounted inside the conveyor frame 8. A geared motor assembly 11 is bolted to the outside of the conveyor frame 8. The geared motor assembly 11 drives the drive shaft 9 to rotate, thereby driving the entire chain assembly to achieve material conveying.

[0020] Scraper and crossbar assembly: Both double chain assembly A and double chain assembly B are detachably connected to crossbar 5. A scraper 6 is fixedly installed at the bottom of crossbar 5, moving with the chain assembly to push materials. Both the drive shaft 9 and driven shaft 10 have a relief groove 901 in the middle, with the length of the relief groove 901 matching the length of the scraper 6, providing space for the scraper 6's operation and preventing interference between the scraper 6 and the shaft. A boss 7 is fixedly installed at the top of the flat buckle 4 on the same horizontal line, and crossbar 5 is bolted to the surface of boss 7, achieving a reliable connection between crossbar 5 and the chain assembly.

[0021] Detection and Cleaning Section: Dual-channel housings 12 are fixedly installed on the top of both sides of the conveyor frame 8. Each housing 12 has two channels, horizontally aligned with the vertical buckles 3 of chains A1 and B2. A counting sensor 13 is fixedly installed on the top of the inner wall of each channel of the dual-channel housing 12, positioned directly above the running trajectory of the vertical buckles 3, for real-time monitoring of the chain's operation. A U-shaped frame 14 is bolted to the inside of each channel of the dual-channel housing 12. A cleaning brush 15 is fixedly installed inside the U-shaped frame 14, cleaning the vertical buckles 3 during chain operation to remove impurities and stabilize the counter's monitoring and counting function.

[0022] Control section: A PLC controller 16 is fixedly installed on the side of the conveyor frame 8 near the geared motor assembly 11. The geared motor assembly 11 and the counting sensor 13 are both electrically connected to the PLC controller 16. The PLC controller 16 receives the signal from the counting sensor 13 and determines the running status of the chain based on the signal, thereby controlling the operation of the geared motor assembly 11.

[0023] Device installation steps Shaft installation: Rotate the drive shaft 9 and driven shaft 10 to the predetermined positions inside the conveyor frame 8 to ensure that the shafts are firmly installed and rotate flexibly.

[0024] Chain assembly installation: Install double chain assembly A and double chain assembly B on both ends of the drive shaft 9 and driven shaft 10 respectively, and adjust the chain tension to ensure they are in a suitable operating condition.

[0025] Crossbar and scraper installation: Fix the boss 7 at the top of the flat buckle 4 on each horizontal line, then fix the crossbar 5 to the surface of the boss 7 with bolts, and then fix the scraper 6 to the bottom of the crossbar 5, ensuring that the scraper 6 is installed firmly and in the correct position.

[0026] Dual-channel housing installation: Fix the dual-channel housing 12 to the top of both sides of the conveyor frame 8, so that the dual channels are horizontally aligned with the vertical buckles 3 of chains A1 and B2.

[0027] Counting sensor installation: The counting sensor 13 is fixedly installed on the top of the dual-channel inner wall of the dual-channel housing 12, ensuring that the counting sensor 13 is located directly above the running trajectory of the vertical buckle 3, so as to accurately monitor the number of vertical buckles 3 passing through.

[0028] Installation of U-shaped frame and cleaning brush: The U-shaped frame 14 is fixedly installed inside the dual channel of the dual channel housing 12 with bolts. Then, the cleaning brush 15 is fixedly installed inside the U-shaped frame 14 so that the cleaning brush 15 contacts the chain and can effectively clean the chain.

[0029] Gear motor assembly installation: Fix the gear motor assembly 11 to the outside of the conveyor frame 8 near the power shaft 9 with bolts to ensure that the connection between the gear motor assembly 11 and the power shaft 9 is reliable and can drive the power shaft 9 to rotate normally.

[0030] PLC controller installation: Fix the PLC controller 16 on the side of the conveyor frame 8 near the geared motor assembly 11, and then electrically connect the geared motor assembly 11 and the counting sensor 13 to the PLC controller 16 respectively, ensuring that the wiring is correct and the signal transmission is stable.

[0031] Operating principle and monitoring process of the device Normal operation: The geared motor assembly 11 is started, driving the power shaft 9 to rotate. The power shaft 9 drives the double chain assembly A and double chain assembly B, causing the crossbar 5 and scraper 6 to move along with the chain assembly, thus conveying the material. During chain operation, the vertical buckles 3 sequentially pass through the dual channels of the dual-channel housing 12. The counting sensor 13 counts the number of vertical buckles 3 passing through in real time and transmits the counting signal to the PLC controller 16. As the chain operates normally, the value of the counting sensor 13 increases steadily. After receiving a stable counting signal, the PLC controller 16 determines that the chain is operating normally and will not issue a stop command to the geared motor assembly 11. The geared motor assembly 11 continues to drive the chain assembly.

[0032] The counting sensor 13 generates pulse signals by detecting the number of times the vertical buckles 3 pass through. During normal operation, the vertical buckles 3 pass through the sensor at fixed intervals, forming a stable pulse sequence. When the chain breaks, the pulse frequency becomes abnormal or interrupted. When a vertical buckle 3 passes through the sensor's detection area, it blocks or triggers the photoelectric / electromagnetic components inside the sensor, generating an electrical pulse signal. Each pass of a vertical buckle 3 generates one pulse, which is transmitted to the PLC controller 16 via a cable. Digital signal transmission is used between the sensor and the PLC, providing strong anti-interference capabilities and ensuring signal accuracy. The PLC continuously receives pulse signals and calculates the number of pulses per unit time (i.e., the frequency of the vertical buckles 3 passing through). During normal operation, the pulse frequency is stable and matches the designed chain speed.

[0033] Chain breakage fault detection Frequency threshold setting: PLC presets the lower limit of pulse frequency (e.g., 80% of the normal frequency).

[0034] Anomaly detection: When the actual pulse frequency is lower than the threshold or interrupted, the PLC determines that the chain is broken or the chain is jammed.

[0035] Signal processing: The PLC immediately triggers an emergency interlock command to stop the operation of the geared motor unit 11 and prevent the fault from escalating.

[0036] Chain breakage monitoring and emergency interlocking: When the chain breaks, the chain at the break point stops running, the number of vertical buckles 3 passing through the dual channels no longer increases steadily, and the value detected by the counting sensor 13 changes abnormally and no longer increases steadily. The counting sensor 13 transmits this abnormal signal to the PLC controller 16. After receiving the abnormal signal, the PLC controller 16 determines that the chain has broken and immediately issues a stop command to the geared motor unit 11. The geared motor unit 11 stops running, thereby avoiding greater losses due to chain breakage, such as chain collapse or equipment damage.

[0037] Equipment maintenance and upkeep Regularly inspect the chains: Regularly check the wear of double chain group A and double chain group B, and check if the chain tension is appropriate. If severe wear or improper tension is found, adjust or replace the chains promptly to ensure their proper functioning.

[0038] Chain cleaning and brush cleaning: Regularly remove impurities from the chain and check the wear of the brush 15. If the brush 15 is severely worn, replace it promptly to ensure effective chain cleaning.

[0039] Check the counting sensor and PLC controller: Regularly check the operating status of the counting sensor 13 and the PLC controller 16 to see if the counting sensor 13 can count accurately and if the PLC controller 16 can receive and process signals normally. If any problems are found, repair or replace them in time to ensure that the monitoring and control functions of the device are normal.

[0040] Check the geared motor assembly: Regularly check the operation of the geared motor assembly 11, and check for abnormal noise, overheating, or other phenomena. If any problems are found, repair them promptly to ensure the normal operation of the geared motor assembly 11 and to provide stable power to the chain assembly.

[0041] Through the above specific implementation methods, this scraper conveyor chain breakage real-time detection and emergency interlocking device can realize real-time monitoring of the scraper conveyor chain operation, and stop the equipment operation in time when the chain breaks, effectively improving the operation safety and reliability of the scraper conveyor.

[0042] 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, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A real-time detection and emergency interlocking device for chain breakage in scraper conveyors, characterized in that, The system includes a double chain group A and a double chain group B, which are respectively sleeved and installed at both ends of the drive shaft (9) and the driven shaft (10). The drive shaft (9) and the driven shaft (10) are rotatably installed inside the conveyor frame (8). A geared motor group (11) for driving the drive shaft (9) to rotate is fixedly installed on the outside of the conveyor frame (8) by bolts. Both the double chain group A and the double chain group B include two parallel chains A (1) and B (2). Both chains A (1) and B (2) include interlocking chains. Vertical buckle (3), horizontal buckle (4), the double chain group A and the double chain group B are detachably connected to the crossbar (5), the bottom of the crossbar (5) is fixedly installed with a scraper (6), the top of both sides of the conveyor frame (8) is fixedly installed with a double channel housing (12), the double channel housing (12) is provided with a double channel inside, the double channel housing (12) is horizontally aligned with the vertical buckle (3) of chain A (1) and chain B (2), and a counting sensor (13) is fixedly installed on the top of the double channel inner wall of the double channel housing (12).

2. The real-time chain breakage detection and emergency interlocking device for scraper conveyors according to claim 1, characterized in that, The U-shaped frame (14) is fixedly installed inside the dual channels of the dual-channel housing (12) by bolts, and a cleaning brush (15) is fixedly installed inside the U-shaped frame (14).

3. The scraper conveyor chain breakage real-time detection and emergency interlocking device according to claim 1, characterized in that, Both the drive shaft (9) and the driven shaft (10) have a relief groove (901) in the middle, and the length of the relief groove (901) is consistent with the length of the scraper (6).

4. The scraper conveyor chain breakage real-time detection and emergency interlocking device according to claim 1, characterized in that, A boss (7) is fixedly installed on the top of the flat buckle (4) on the same horizontal line, and the crossbar (5) is fixed to the surface of the boss (7) by bolts.

5. The real-time chain breakage detection and emergency interlocking device for scraper conveyors according to claim 1, characterized in that, The conveyor frame (8) is fixedly installed with a PLC controller (16) on the side close to the geared motor assembly (11). The geared motor assembly (11) and the counting sensor (13) are both electrically connected to the PLC controller (16).

6. The real-time detection and emergency interlocking device for chain breakage of scraper conveyors according to claim 1, characterized in that, The counting sensor (13) is located directly above the running trajectory of the vertical buckle (3).

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