Underground coal mine explosion-proof drum brake braking system

Abstract

The invention provides a coal mine underground explosion-proof drum brake braking system, which relates to the technical field of coal mine braking systems and comprises an explosion-proof driving module, a dual-redundancy braking execution module, a self-adaptive heat dissipation module, a failure safety control module, a multi-working-condition self-adaptive adjusting unit and an explosion-proof emergency standby power supply, the anti-explosion driving module provides anti-explosion power output and sealing protection functions; the dual-redundancy brake execution module is used for dual-insurance brake execution and brake clearance automatic compensation; a full-link explosion-proof system of power output, friction braking and electrical protection is constructed through an explosion-proof power element, a stainless steel explosion-proof pipeline and a cast aluminum explosion-proof control box of the explosion-proof driving module and a low-spark enhancing lining of the dual-redundancy braking execution module, a spark generation and gas contact path is effectively blocked, the friction spark amount is reduced, and the safety of a gas engine is improved. And dust and humid environment erosion is resisted, potential safety hazards under the high-gas working condition are thoroughly eliminated, and dual guarantee is provided for underground personnel and equipment.

Description

Technical Field

[0001] This invention relates to the field of coal mine braking system technology, and in particular to an explosion-proof drum brake system for underground coal mines. Background Technology

[0002] The braking system of underground coal mine transportation equipment is a core component ensuring the safety of underground operations. Among them, drum brake systems have become the mainstream choice for medium and heavy-duty underground transportation equipment due to their advantages such as large braking torque, compact structure, and controllable cost. Its core working principle is to output power through a hydraulic or pneumatic drive mechanism to push the brake shoes against the brake drum to generate friction, thereby slowing down or stopping the equipment. It mainly consists of a power drive mechanism, braking actuators, a control unit, and a heat dissipation structure, and is widely adaptable to complex underground transportation scenarios.

[0003] Existing drum brake systems exhibit numerous technical shortcomings in the unique environments of underground mines, characterized by high methane levels, high dust levels, and variable operating conditions: their explosion-proof design is flawed, and the high-temperature sparks generated by braking friction and insufficient sealing of electrical components easily lead to gas explosions; their operating condition adaptation mechanism is simplistic, relying solely on fixed braking torque output and failing to adjust parameters dynamically based on slope, load, and speed, resulting in significant braking accuracy deviations and frequent runaway and impact accidents; maintenance processes are cumbersome, requiring over 30 minutes to disassemble and assemble key components in confined spaces, leading to prolonged equipment downtime and high maintenance costs; and their reliability under extreme conditions is insufficient, with the braking system prone to failure after main power loss, and continuous braking causing thermal fade resulting in a significant drop in braking torque, failing to meet stringent requirements such as parking under full load on steep slopes. Therefore, this invention proposes an explosion-proof drum brake system for underground coal mines to address the problems existing in the prior art. Summary of the Invention

[0004] To address the aforementioned problems, this invention proposes an explosion-proof drum brake system for underground coal mines. This system utilizes explosion-proof drive modules with explosion-proof power components, stainless steel explosion-proof pipelines, and cast aluminum explosion-proof control boxes, along with low-spark-enhanced linings in dual-redundant brake actuator modules. This constructs a complete explosion-proof system encompassing power output, friction braking, and electrical protection. It effectively blocks the path of spark generation and gas contact, reduces the amount of frictional sparks, and resists corrosion from dust and humid environments, completely eliminating safety hazards under high-gas conditions and providing dual protection for underground personnel and equipment.

[0005] To achieve the objectives of this invention, the following technical solution is provided: an explosion-proof drum brake system for underground coal mines, comprising an explosion-proof drive module, a dual-redundant brake execution module, an adaptive heat dissipation module, a fail-safe control module, a multi-condition adaptive adjustment unit, and an explosion-proof emergency backup power supply. The explosion-proof drive module provides explosion-proof power output and sealing protection. The dual-redundant brake execution module is used for dual-insurance brake execution and automatic brake gap compensation. The adaptive heat dissipation module is used for intelligent heat dissipation control and dust prevention. The fail-safe control module integrates multiple emergency brake triggers and remote monitoring of component status. The multi-condition adaptive adjustment unit dynamically matches the braking torque based on operating parameters. The explosion-proof emergency backup power supply provides continuous power after the main power supply fails.

[0006] The modules work together to ensure safe braking, adaptive operation, intelligent early warning of component status, rapid maintenance, and braking protection under extreme conditions for underground transportation equipment in coal mines.

[0007] Further improvements include: the explosion-proof drive module comprises a mining explosion-proof power component, stainless steel explosion-proof pipelines, and a cast aluminum explosion-proof control box; the mining explosion-proof power component is an explosion-proof gear pump or an explosion-proof piston pump, equipped with an explosion-proof three-phase asynchronous motor, and the enclosure protection level is not lower than IP65; the cast aluminum explosion-proof control box has a wall thickness ≥10mm, a built-in explosion-proof cooling fan, and controls the internal component operating temperature to ≤60℃; the stainless steel explosion-proof pipeline uses a compression fitting, has a built-in copper sealing ring, and the pipeline outer diameter is 10-16mm and the wall thickness is 2-3mm.

[0008] Further improvements are made in the following aspects: the dual-redundant braking execution module includes a brake drum, brake shoes, low-spark linings, and an automatic clearance adjustment mechanism; the brake drum is equipped with composite heat dissipation fins optimized by CFD flow field simulation; the low-spark linings are made of nano-silicon carbide reinforced material and are fixed by clips and explosion-proof bolts; the automatic clearance adjustment mechanism consists of a push rod, an adjusting sleeve, and a return spring, maintaining a braking clearance of 0.2-0.5mm; the brake shoes are made of forged steel, and the guide sleeve is a composite material of polytetrafluoroethylene and bronze powder.

[0009] Further improvements include: the brake drum diameter of the dual redundant braking actuator module is 200-400mm, and the drum wall thickness is 15-30mm; after 15 consecutive braking cycles, the brake drum temperature is ≤150℃.

[0010] Further improvements include: the adaptive heat dissipation module comprises a segmented explosion-proof cover, a stainless steel sintered dust filter, a temperature sensor, and a PLC controller; the segmented explosion-proof cover has a 2-3 segment structure, connected by explosion-proof hinges, allowing direct cleaning of the filter and heat dissipation fins after opening; the stainless steel sintered dust filter has a pore size of 0.3-0.5mm, is fixed by explosion-proof clips, and has a cleaning cycle of ≥30 days; the temperature sensor has a range of 0-300℃, and when the detected temperature exceeds 160℃, the PLC controller triggers an alarm and activates a retarder to suppress thermal decay; the retarder is a hydraulic retarder with a braking torque... .

[0011] Further improvements include: the fail-safe control module includes a triple-trigger emergency braking unit and a mining-grade intrinsically safe wireless monitoring module; the triple-trigger emergency braking unit includes automatic triggering by a pressure sensor, manual triggering by a steel tie rod, and wireless remote triggering, wherein the pulling force of the manual triggering by the steel tie rod is ≤800N, and the transmission distance of the wireless remote triggering is ≥500m; the mining-grade intrinsically safe wireless monitoring module transmits brake drum temperature and lining wear data to the ground monitoring center through the mining ring network, generates trend curves, and predicts maintenance cycles.

[0012] A further improvement is that the intrinsically safe wireless monitoring module for mining is used to predict the replacement cycle of the lining 15-18 days in advance, and triggers a maintenance prompt when the wear of the lining reaches 1.0mm.

[0013] Further improvements are made in the following aspects: the multi-condition adaptive adjustment unit includes a slope sensor, a load sensor, and a braking torque matching algorithm; the slope sensor is installed in the middle of the transport equipment frame, with a horizontal accuracy of ±0.1°; the load sensor is a strain gauge type, installed between the wheel axle and the frame, with a range of 0-20t; the braking torque matching algorithm expression is as follows:

[0014] ,

[0015] Where: T is the target braking torque, in N. m; The slope influence coefficient, ranging from 1.0 to 1.2, increases linearly with the slope and is used to compensate for the influence of gravity on braking; m is the actual load of the transport equipment, which is collected in real time by the load sensor. The acceleration due to gravity is taken as 9.8 m / s², which is a constant physical parameter. The actual slope angle, in degrees, is collected in real time by a slope sensor; This is the friction correction coefficient, ranging from 0.8 to 1.0, which decreases linearly with increasing liner wear. It is used to compensate for the decrease in frictional performance caused by liner wear. The coefficient of friction between the low-spark lining and the brake drum is set to 0.35-0.45 and remains constant under normal operating conditions. is the speed correction coefficient, ranging from 0.5 to 1.5, which increases linearly with increasing travel speed and is used to compensate for the influence of travel speed on braking distance; v is the travel speed of the transport equipment, in km / h, which is synchronously collected by the equipment speed sensor.

[0016] Further improvements include: the multi-condition adaptive adjustment unit is equipped with an electromagnetic proportional valve, which dynamically adjusts the hydraulic pressure through the output signal of the PLC controller, with an adjustment accuracy of ±0.1MPa, and controls the braking distance deviation under different conditions to ≤1m.

[0017] Further improvements are made in the following aspects: the explosion-proof emergency backup power supply is a 12V increased safety type lead-acid battery, which is installed in the explosion-proof electrical box and linked to the main power supply through an explosion-proof contactor; under normal working conditions, the main power supply charges the backup power supply with a charging current ≤5A and a charging voltage of 13.8V; when the main power supply fails, the explosion-proof contactor completes the power supply switching within 0.5s, and the power supply time is ≥2h.

[0018] The beneficial effects of this invention are as follows:

[0019] 1. This invention constructs a full-link explosion-proof system encompassing power output, friction braking, and electrical protection through explosion-proof drive module explosion-proof power components, stainless steel explosion-proof pipelines, and cast aluminum explosion-proof control box, and low-spark-enhanced lining of dual-redundant braking actuator module. This effectively blocks the path of spark generation and gas contact, reduces the amount of friction sparks, and resists corrosion from dust and humid environments, completely eliminating safety hazards under high-gas conditions and providing dual protection for underground personnel and equipment.

[0020] 2. This invention relies on the slope, load, and speed multi-dimensional sensors of the multi-condition adaptive adjustment unit, combined with a dedicated braking torque matching algorithm, to dynamically calculate the optimal braking torque and precisely control the hydraulic pressure through an electromagnetic proportional valve. This achieves full-condition adaptive adaptation within the range of 0°-30° slope and 0-20t load, with small braking distance deviation and high stability. It solves the problems of equipment slippage and impact caused by braking torque mismatch in traditional systems, and greatly improves the stability and controllability of transportation.

[0021] 3. The adaptive heat dissipation module's segmented protective cover and the quick-release liner structure of the dual redundant braking execution module reduce the replacement time of key components. Combined with the remote status monitoring and maintenance cycle prediction function of the fail-safe control module, it allows for planning operations 15-18 days in advance, reducing annual maintenance costs. The triple emergency braking mechanism, explosion-proof emergency backup power supply, and heat dissipation-retarder collaborative heat dissipation design comprehensively resist the risks of extreme working conditions such as power outages, continuous braking thermal fade, and steep slope parking, ensuring braking reliability in complex environments. Attached Figure Description

[0022] Figure 1 This is the front view of the present invention. Detailed Implementation

[0023] To enhance understanding of the present invention, the present invention will be further described in detail below with reference to embodiments. These embodiments are only used to explain the present invention and do not constitute a limitation on the scope of protection of the present invention.

[0024] Example 1

[0025] according to Figure 1 As shown in the figure, this embodiment proposes an explosion-proof drum brake system for underground coal mines, including an explosion-proof drive module, a dual-redundant brake execution module, an adaptive heat dissipation module, a fail-safe control module, a multi-condition adaptive adjustment unit, and an explosion-proof emergency backup power supply. The explosion-proof drive module provides explosion-proof power output and sealing protection functions; the dual-redundant brake execution module is used for dual-insurance brake execution and automatic brake gap compensation; the adaptive heat dissipation module is used for intelligent heat dissipation regulation and dust prevention and cleaning; the fail-safe control module integrates multiple emergency brake triggers and remote monitoring of component status; the multi-condition adaptive adjustment unit dynamically matches the braking torque based on the operating parameters; and the explosion-proof emergency backup power supply is used to continuously supply power after the main power supply fails.

[0026] The modules work collaboratively to ensure safe braking, adaptive operation, intelligent early warning of component status, rapid maintenance, and braking protection under extreme conditions for underground coal mine transportation equipment. This achieves precise linkage between functional modules, preventing system-wide failure due to a single module malfunction; it comprehensively covers core underground braking requirements, providing all-scenario, comprehensive safety assurance for different types of transportation equipment.

[0027] The explosion-proof drive module includes a mining explosion-proof power component, stainless steel explosion-proof piping, and a cast aluminum explosion-proof control box. The mining explosion-proof power component is an explosion-proof gear pump or an explosion-proof piston pump, equipped with an explosion-proof three-phase asynchronous motor, and its enclosure protection rating is not lower than IP65. The cast aluminum explosion-proof control box has a wall thickness ≥10mm, a built-in explosion-proof cooling fan, and controls the internal component operating temperature to ≤60℃. The stainless steel explosion-proof piping uses compression fittings, has a built-in copper sealing ring, and its outer diameter is 10-16mm and wall thickness is 2-3mm. The explosion-proof structure and sealing design form double protection, effectively blocking the contact path between gas, dust, and electrical components and power parts; it precisely controls the component operating temperature and piping pressure stability, significantly extending the service life and operational reliability of the drive module.

[0028] The dual-redundant braking execution module includes a brake drum, brake shoes, low-spark linings, and an automatic clearance adjustment mechanism. The brake drum is equipped with composite heat dissipation fins optimized by CFD flow field simulation. The low-spark linings are made of nano-silicon carbide reinforced material and are fixed by clips and explosion-proof bolts. The automatic clearance adjustment mechanism consists of a push rod, adjusting sleeve, and return spring, maintaining a braking clearance of 0.2-0.5mm. The brake shoes are made of forged steel, and the guide sleeve is a composite material of polytetrafluoroethylene and bronze powder. The dual-redundant braking design, in conjunction with the automatic clearance compensation function, ensures a stable and controllable braking process, avoiding braking lag or failure caused by abnormal clearance. The low-spark reinforced linings, combined with the wear-resistant guide sleeve, reduce frictional loss and eliminate the potential spark hazards generated by braking friction, making it suitable for high-gas downhole environments.

[0029] The dual-redundant braking actuator module has a brake drum diameter of 200-400mm and a drum wall thickness of 15-30mm; after 15 consecutive braking cycles, the brake drum temperature is ≤150℃. The graded and adaptable brake drum size can meet the braking force requirements of 10-20t downhole equipment, balancing structural compactness and braking torque; the temperature control capability after continuous braking effectively suppresses thermal fade, ensuring stable braking performance under high-intensity, high-frequency braking scenarios.

[0030] The adaptive heat dissipation module includes a segmented explosion-proof cover, a stainless steel sintered dust filter, a temperature sensor, and a PLC controller. The segmented explosion-proof cover has a 2-3 segment structure connected by explosion-proof hinges, allowing direct cleaning of the filter and heat dissipation fins after opening. The stainless steel sintered dust filter has a pore size of 0.3-0.5mm, is fixed by explosion-proof clips, and has a cleaning cycle of ≥30 days. The temperature sensor has a range of 0-300℃. When the detected temperature exceeds 160℃, the PLC controller triggers an alarm and activates a retarder to suppress thermal decay. The retarder is a hydraulic retarder with a braking torque ≥3000N. The segmented protective cover and quick-release filter design simplify the downhole maintenance process, allowing cleaning to be completed without complete disassembly, thus improving maintenance efficiency; the temperature sensor and hydraulic retarder are intelligently linked to achieve precise response to heat dissipation needs, avoiding overheating that could lead to a decrease in braking efficiency.

[0031] The fail-safe control module includes a triple-trigger emergency braking unit and a mining-grade intrinsically safe wireless monitoring module. The triple-trigger emergency braking unit includes automatic triggering via a pressure sensor, manual triggering via a steel tie rod, and wireless remote triggering. The manual triggering force of the steel tie rod is ≤800N, and the wireless remote triggering transmission distance is ≥500m. The mining-grade intrinsically safe wireless monitoring module transmits brake drum temperature and lining wear data to the ground monitoring center via the mining ring network, generating trend curves and predicting maintenance cycles. The triple emergency triggering mechanism covers all scenarios—equipment failure, manual operation, and remote control—ensuring rapid braking activation in extreme situations. The wireless monitoring module is compatible with the mining ring network, enabling remote visualization of component status and facilitating advance planning of maintenance operations by ground personnel.

[0032] The intrinsically safe wireless monitoring module for mining applications is used to predict the liner replacement cycle 15-18 days in advance, triggering a maintenance prompt when the liner wear reaches 1.0 mm. This advance prediction of the maintenance cycle allows for planned shutdowns, preventing underground safety accidents caused by sudden liner failure. The precise wear threshold ensures braking performance while avoiding costly over-maintenance.

[0033] The multi-condition adaptive adjustment unit includes a slope sensor, a load sensor, and a braking torque matching algorithm; the slope sensor is installed in the middle of the transport equipment frame, with a horizontal accuracy of ±0.1°; the load sensor is a strain gauge type, installed between the wheel axle and the frame, with a range of 0-20t; the braking torque matching algorithm expression is:

[0034] ,

[0035] Where: T is the target braking torque, in N. m; The slope influence coefficient, ranging from 1.0 to 1.2, increases linearly with the slope and is used to compensate for the influence of gravity on braking; m is the actual load of the transport equipment, which is collected in real time by the load sensor. The acceleration due to gravity is taken as 9.8 m / s², which is a constant physical parameter. The actual slope angle, in degrees, is collected in real time by a slope sensor; This is the friction correction coefficient, ranging from 0.8 to 1.0, which decreases linearly with increasing liner wear. It is used to compensate for the decrease in frictional performance caused by liner wear. The coefficient of friction between the low-spark lining and the brake drum is set to 0.35-0.45 and remains constant under normal operating conditions. The speed correction coefficient, ranging from 0.5 to 1.5, increases linearly with increasing travel speed, and is used to compensate for the impact of travel speed on braking distance; v is the travel speed of the transport equipment, in km / h, synchronously collected by the equipment speed sensor. Multi-dimensional sensors accurately capture operating parameters, providing real-time data support for braking torque calculation, adapting to complex scenarios with slopes of 0°-30° and loads of 0-20t; a dedicated algorithm achieves dynamic optimization of braking torque, avoiding equipment impact and slippage risks caused by excessive or insufficient braking.

[0036] The multi-condition adaptive adjustment unit is equipped with an electromagnetic proportional valve, which dynamically adjusts the hydraulic pressure through a PLC controller output signal, with an adjustment accuracy of ±0.1MPa, controlling the braking distance deviation to ≤1m under different operating conditions. High-precision hydraulic adjustment ensures uniform and stable braking force output, improving braking comfort and extending equipment lifespan; strict control of braking distance deviation ensures operational safety and controllability in confined downhole working spaces.

[0037] The explosion-proof emergency backup power supply is a 12V increased-safety lead-acid battery, installed in an explosion-proof electrical box, and linked to the main power supply via an explosion-proof contactor. Under normal operating conditions, the main power supply charges the backup power supply with a charging current ≤5A and a charging voltage of 13.8V. When the main power supply fails, the explosion-proof contactor completes the power supply switch within 0.5s, and the power supply time is ≥2 hours. The second-level power supply switching speed ensures that the braking system does not stop working after the main power supply fails, eliminating the risk of loss of control due to power failure. The long-endurance design meets the needs of emergency braking and fault diagnosis, providing sufficient emergency response time for underground operations.

[0038] Example 2

[0039] according to Figure 1 As shown in the figure, this embodiment proposes an explosion-proof drum brake system for underground coal mines, designed for 15t-class mine cars, and adapted to slope conditions of 0°-30° and load conditions of 0-15t. The specific configuration is as follows:

[0040] Explosion-proof drive module: Selects a mining explosion-proof gear pump (displacement 10mL / r), matched with an explosion-proof three-phase asynchronous motor (power 5.5kW), motor housing protection level IP65; stainless steel pipeline outer diameter 12mm, wall thickness 2.5mm, compression fitting with built-in copper sealing ring; cast aluminum explosion-proof control box with 12mm wall thickness, built-in explosion-proof cooling fan (speed 2800r / min) to ensure that the operating temperature of the components inside the box is ≤58℃.

[0041] Dual-redundant braking actuator module: Brake drum diameter 300mm, wall thickness 20mm, composite heat dissipation fins adopt a spiral + axial combination structure, increasing the heat dissipation area by 42% compared to the traditional structure; brake shoes are forged from No. 45 steel, guide sleeves are made of polytetrafluoroethylene-bronze powder composite material; low spark lining thickness 12mm, nano silicon carbide reinforced particle content 15%, ceramic fiber heat insulation layer thickness 3mm, fixed by "clip + 1 explosion-proof bolt"; automatic gap adjustment mechanism maintains braking gap 0.3-0.4mm.

[0042] Adaptive heat dissipation module: The split-type protective cover has a two-part structure, connected by explosion-proof hinges, with an opening angle ≥90°; the dust filter has a pore size of 0.4mm, is fixed by explosion-proof buckles, and has a cleaning cycle of 35 days; the temperature sensor is installed on the side of the brake drum, with a range of 0-300℃; the PLC controller is model S7-1200, linked to a YH300 hydraulic retarder (braking torque 3200N). When the brake drum temperature exceeds 160℃, the retarder is automatically triggered to work in coordination.

[0043] Fail-safe control module: Pressure sensor with a range of 0-30MPa, automatically triggering emergency braking when hydraulic pressure is abnormal; manual pull rod with a diameter of 12mm and a triggering force of 750N; mining intrinsically safe wireless module with a transmission distance of 550m, allowing the ground monitoring center to receive real-time data on brake drum temperature and lining wear, and generate trend curves.

[0044] Multi-condition adaptive adjustment unit: The slope sensor is installed in the middle of the frame, with a horizontal accuracy of ±0.1°; the load sensor is installed between the wheel axle and the frame, with a range of 0-15t; the PLC has a built-in braking torque matching algorithm. When the vehicle is fully loaded (10t) on a 15° inclined road and traveling at a speed of 8km / h, the following calculations are performed: =1.1、 =0.9、 =1.0、 =0.4, T=1.1×10×9.8×sin15°+0.9×10×9.8×0.4×cos15°+1.0×8≈905N m, the electromagnetic proportional valve adjusts the hydraulic pressure to 11MPa to achieve precise braking.

[0045] Explosion-proof emergency backup power supply: 12V increased safety type lead-acid battery (capacity 100Ah). Under normal working conditions, the main power supply charges at a current of 4.5A and a charging voltage of 13.8V. After the main power supply fails, the power supply switch is completed within 0.5s, and the power supply continues for 2.5 hours.

[0046] Application results: Braking distance deviation ≤0.9m, braking distance stability improved by 32%; after 15 consecutive braking cycles, the brake drum temperature was 145℃, and the heat fade alarm was not triggered; the lining wear rate was 0.09mm / day, and replacement was indicated 16 days in advance when the wear reached 1.0mm; the replacement time for key components was 12min, maintenance efficiency improved by 53%, and annual maintenance costs were reduced by 43%; friction sparks were reduced by 55%, eliminating the risk of gas ignition; there was no slippage when parking under full load on a 30° steep slope.

[0047] Example 3

[0048] according to Figure 1 As shown in the figure, this embodiment proposes an explosion-proof drum brake system for underground coal mines, designed for 20t-class trackless rubber-tired vehicles, and adapted to slope conditions of 0°-25° and load conditions of 0-20t. The specific configuration is as follows:

[0049] Explosion-proof drive module: Utilizes an explosion-proof piston pump (displacement 15mL / r), paired with an explosion-proof three-phase asynchronous motor (power 7.5kW), with an IP65 enclosure protection rating; stainless steel piping with an outer diameter of 16mm and a wall thickness of 3mm, and compression fittings with built-in copper sealing rings; cast aluminum explosion-proof control box with a wall thickness of 15mm, and a built-in explosion-proof cooling fan (speed 3000r / min), ensuring the internal component operating temperature is ≤55℃.

[0050] Dual-redundant braking actuator module: Brake drum diameter 350mm, wall thickness 25mm, composite heat dissipation fins increase heat dissipation area by 45% compared to traditional structures; brake shoes are forged from No. 45 steel, guide sleeves are made of polytetrafluoroethylene-bronze powder composite material; low-spark lining thickness 15mm, nano-silicon carbide reinforcing particle content 18%, ceramic fiber heat insulation layer thickness 4mm; automatic gap adjustment mechanism maintains braking gap 0.2-0.5mm, brake drum temperature 140℃ after 15 consecutive braking cycles.

[0051] Adaptive heat dissipation module: The split-type protective cover has a 3-lobed structure, explosion-proof hinge connection, dust filter with a pore size of 0.3mm, and a cleaning cycle of 40 days; the temperature sensor is linked with the PLC controller, and the hydraulic retarder is automatically activated when the brake drum temperature exceeds 160℃.

[0052] Fail-safe control module: pressure sensor range 0-40MPa, manual lever pulling force 780N, wireless module transmission distance 600m, ground monitoring center generates brake drum temperature trend chart and lining wear curve chart in real time, and predicts maintenance cycle.

[0053] Multi-condition adaptive adjustment unit: slope sensor horizontal accuracy ±0.1°, load sensor range 0-20t; when in a 30° inclined tunnel with a full load (15t) and a travel speed of 10km / h, the following algorithm is applied: =1.2、 =1.0、 =1.2、 =0.45, T=1.2×15×9.8×sin30+1.0×15×9.8×0.45×cos30°+1.2×10≈1920N m, the electromagnetic proportional valve adjusts the hydraulic pressure to 19MPa and activates the retarder for cooperative braking.

[0054] Explosion-proof emergency backup power supply: 12V increased safety type lead-acid battery (capacity 120Ah), which can provide continuous power supply for 3 hours after the main power supply fails, meeting the needs of emergency braking and fault diagnosis.

[0055] Application effects: Braking distance deviation ≤0.8m, braking distance stability improved by 35%; lining cleaning cycle 35 days, key component replacement time 10min, maintenance efficiency improved by 58%, annual maintenance cost reduced by 45%; friction sparks reduced by 58%, fully adaptable to high gas underground environment; emergency braking can be stably completed after main power failure, and there is no slippage when parking fully loaded on a 30° steep slope.

[0056] In summary, through the coordinated design of six core modules, the system achieves simultaneous improvements in four core performance aspects: explosion-proof safety, operational condition adaptability, maintenance efficiency, and extreme protection. Applications were conducted on 15t mining cars and 20t trackless rubber-tired vehicles, verifying the system's stability and reliability under varying loads and gradients. Key indicators such as braking accuracy, explosion-proof performance, and maintenance efficiency all outperform existing technologies. The braking system features a rational structural design and strong versatility. The brake drum diameter, power component parameters, and sensor range can be flexibly adjusted according to the load and size requirements of different underground transportation equipment. It is compatible with various underground transportation equipment such as mining cars, trackless rubber-tired vehicles, and winches, requiring no large-scale modification of existing equipment for installation and use, thus demonstrating broad application prospects.

[0057] This explosion-proof drum brake system for underground coal mines utilizes explosion-proof drive modules with explosion-proof power components, stainless steel explosion-proof pipelines, and cast aluminum explosion-proof control boxes. The dual-redundant brake actuator module features low-spark-enhanced linings, constructing a complete explosion-proof system encompassing power output, friction braking, and electrical protection. This effectively blocks the path between spark generation and gas contact, reduces frictional sparks, and resists corrosion from dust and humid environments, completely eliminating safety hazards under high-gas conditions and providing dual protection for underground personnel and equipment. Simultaneously, relying on multi-dimensional sensors for slope, load, and speed in the multi-condition adaptive adjustment unit, combined with a proprietary braking torque matching algorithm, this invention can dynamically calculate the optimal braking torque and precisely control the hydraulic pressure via an electromagnetic proportional valve. This achieves full-condition adaptive adaptation within a 0°-30° slope and 0-20t load range, resulting in small braking distance deviations and high stability. It solves problems such as equipment slippage and impact caused by braking torque mismatch in traditional systems, significantly improving transportation stability and controllability. In addition, the segmented protective cover of the adaptive heat dissipation module and the quick-release liner structure of the dual redundant braking execution module reduce the replacement time of key components. Combined with the remote status monitoring and maintenance cycle prediction function of the fail-safe control module, the operation can be planned 15-18 days in advance, reducing annual maintenance costs. The triple emergency braking mechanism, explosion-proof emergency backup power supply, and heat dissipation-retarder collaborative heat dissipation design comprehensively resist the risks of extreme working conditions such as power outages, continuous braking thermal fade, and parking on steep slopes, ensuring braking reliability in complex environments.

[0058] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A coal mine explosion-proof drum brake system, comprising an explosion-proof drive module, a dual-redundant brake execution module, an adaptive heat dissipation module, a fail-safe control module, a multi-condition adaptive adjustment unit, and an explosion-proof emergency backup power supply, characterized in that: The explosion-proof drive module provides explosion-proof power output and sealing protection; the dual-redundant braking execution module is used for dual-insurance braking execution and automatic compensation of braking gap; the adaptive heat dissipation module is used for intelligent heat dissipation regulation and dust prevention and cleaning. The fail-safe control module integrates multiple emergency braking triggers and remote monitoring of component status; the multi-condition adaptive adjustment unit dynamically matches the braking torque based on the condition parameters; and the explosion-proof emergency backup power supply is used to provide continuous power after the main power supply fails. The modules work together to ensure safe braking, adaptive operation, intelligent early warning of component status, rapid maintenance, and braking protection under extreme conditions for underground transportation equipment in coal mines.

2. The explosion-proof drum brake system for underground coal mines according to claim 1, characterized in that: The explosion-proof drive module includes a mining explosion-proof power component, stainless steel explosion-proof pipelines, and a cast aluminum explosion-proof control box. The mining explosion-proof power component is an explosion-proof gear pump or an explosion-proof piston pump, equipped with an explosion-proof three-phase asynchronous motor, and the enclosure protection level is not lower than IP65. The cast aluminum explosion-proof control box has a wall thickness of ≥10mm, a built-in explosion-proof cooling fan, and controls the internal component operating temperature to ≤60℃. The stainless steel explosion-proof pipeline uses a compression fitting, has a built-in copper sealing ring, and has an outer diameter of 10-16mm and a wall thickness of 2-3mm.

3. The explosion-proof drum brake system for underground coal mines according to claim 1, characterized in that: The dual-redundant braking actuator module includes a brake drum, brake shoes, low-spark linings, and an automatic clearance adjustment mechanism. The brake drum is equipped with composite heat dissipation fins optimized by CFD flow field simulation. The low-spark linings are made of nano-silicon carbide reinforced material and are fixed by clips and explosion-proof bolts. The automatic clearance adjustment mechanism consists of a push rod, an adjusting screw sleeve, and a return spring, maintaining a braking clearance of 0.2-0.5 mm. The brake shoes are made of forged steel, and the guide sleeve is a composite material of polytetrafluoroethylene and bronze powder.

4. The explosion-proof drum brake system for underground coal mines according to claim 3, characterized in that: The brake drum of the dual-redundant braking actuator module has a diameter of 200-400mm and a drum wall thickness of 15-30mm; after 15 consecutive braking cycles, the brake drum temperature is ≤150℃.

5. The explosion-proof drum brake system for underground coal mines according to claim 1, characterized in that: The adaptive heat dissipation module includes a segmented explosion-proof cover, a stainless steel sintered dust filter, a temperature sensor, and a PLC controller. The segmented explosion-proof cover has a 2-3 segment structure connected by explosion-proof hinges, allowing direct cleaning of the filter and heat dissipation fins after opening. The stainless steel sintered dust filter has a pore size of 0.3-0.5mm, is fixed by explosion-proof clips, and has a cleaning cycle of ≥30 days. The temperature sensor has a range of 0-300℃. When the detected temperature exceeds 160℃, the PLC controller triggers an alarm and activates a retarder to suppress thermal decay. The retarder is a hydraulic retarder with a braking torque of [missing information]. .

6. The explosion-proof drum brake system for underground coal mines according to claim 1, characterized in that: The failure safety control module includes a triple-trigger emergency braking unit and a mining-grade intrinsically safe wireless monitoring module. The triple-trigger emergency braking unit includes automatic triggering by a pressure sensor, manual triggering by a steel tie rod, and wireless remote triggering. The pulling force of the manual triggering by the steel tie rod is ≤800N, and the transmission distance of the wireless remote triggering is ≥500m. The mining-grade intrinsically safe wireless monitoring module transmits brake drum temperature and lining wear data to the ground monitoring center through the mining ring network, generates trend curves, and predicts maintenance cycles.

7. The explosion-proof drum brake system for underground coal mines according to claim 6, characterized in that: The intrinsically safe wireless monitoring module for mining is used to predict the lining replacement cycle 15-18 days in advance, and triggers a maintenance prompt when the lining wear reaches 1.0mm.

8. The explosion-proof drum brake system for underground coal mines according to claim 5, characterized in that: The multi-condition adaptive adjustment unit includes a slope sensor, a load sensor, and a braking torque matching algorithm; the slope sensor is installed in the middle of the transport equipment frame, with a horizontal accuracy of ±0.1°; the load sensor is a strain gauge type, installed between the wheel axle and the frame, with a range of 0-20t; the braking torque matching algorithm expression is: ， Where: T is the target braking torque, in N. m; The slope influence coefficient, ranging from 1.0 to 1.2, increases linearly with the slope and is used to compensate for the influence of gravity on braking; m is the actual load of the transport equipment, which is collected in real time by the load sensor. The acceleration due to gravity is taken as 9.8 m / s², which is a constant physical parameter. The actual slope angle, in degrees, is collected in real time by a slope sensor; This is the friction correction coefficient, ranging from 0.8 to 1.0, which decreases linearly with increasing liner wear. It is used to compensate for the decrease in frictional performance caused by liner wear. The coefficient of friction between the low-spark lining and the brake drum is set to 0.35-0.45 and remains constant under normal operating conditions. is the speed correction coefficient, ranging from 0.5 to 1.5, which increases linearly with increasing travel speed and is used to compensate for the influence of travel speed on braking distance; v is the travel speed of the transport equipment, in km / h, which is synchronously collected by the equipment speed sensor.

9. The explosion-proof drum brake system for underground coal mines according to claim 8, characterized in that: The multi-condition adaptive adjustment unit is equipped with an electromagnetic proportional valve, which dynamically adjusts the hydraulic pressure through the output signal of the PLC controller, with an adjustment accuracy of ±0.1MPa, and controls the braking distance deviation to ≤1m under different working conditions.

10. The explosion-proof drum brake system for underground coal mines according to claim 1, characterized in that: The explosion-proof emergency backup power supply is a 12V increased safety lead-acid battery, installed in an explosion-proof electrical box, and linked to the main power supply through an explosion-proof contactor. Under normal operating conditions, the main power supply charges the backup power supply with a charging current ≤5A and a charging voltage of 13.8V. When the main power supply fails, the explosion-proof contactor completes the power supply switch within 0.5s, and the power supply time is ≥2h.

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