Mining cable with fault early warning function and early warning method

Abstract

The invention discloses a mining cable with a fault early warning function and an early warning method, and relates to the technical field of cables. The mine underground power transmission and signal transmission cable comprises a cable main body, the cable main body is used for mine underground power transmission and signal transmission, and the cable main body is sequentially and coaxially provided with a conductor, an insulating layer and a sheath from inside to outside. Through the integrated design of the distributed micro sensing units and the cable main body, the problem that a traditional mining cable lacks real-time state monitoring capability is solved, the micro sensing units are embedded between the cable insulating layer and the sheath at intervals, multi-dimensional operation parameters such as temperature, strain and partial discharge can be synchronously acquired, and the real-time state monitoring capability of the mining cable is improved. The real-time sensing of potential faults such as cable insulation aging, local overheating and mechanical damage is realized, a traditional passive mode of troubleshooting after faults is broken, an early warning signal is sent in advance, safety accidents caused by sudden faults such as short circuit and electric leakage are effectively avoided, and a powerful guarantee is provided for life safety and production order of mine underground operating personnel.

Description

Technical Field

[0001] This invention belongs to the field of cable technology, and in particular relates to a mining cable with fault early warning function and an early warning method. Background Technology

[0002] Mining cables, as core supporting equipment in coal mines and various metal and non-metal mining industries, undertake critical tasks such as power transmission, signal transmission, equipment control, and safety monitoring. The underground mining environment is extremely complex, presenting challenges such as high humidity, high dust levels, strong mechanical friction, and acid / alkali corrosion, as well as electromagnetic interference, confined spaces, and potential fire risks. This necessitates that mining cables possess stringent special properties. In addition to core flame-retardant characteristics, they must also meet requirements for wear resistance, corrosion resistance, electromagnetic interference resistance, and mechanical impact resistance. Furthermore, all products must pass rigorous certification from the national mine safety supervision department to ensure operational stability and safety in harsh environments.

[0003] Mining cables are prone to short circuits and leakage due to insulation aging, local overheating, and mechanical damage in the underground environment of high humidity, dust, mechanical impact, and strong electromagnetic interference. Traditional cables lack real-time status monitoring capabilities, and faults often occur suddenly and are difficult to locate in time, which may lead to production stoppages or even safety accidents.

[0004] To address these issues, we provide a mining cable with fault early warning functionality and an early warning method. Summary of the Invention

[0005] The purpose of this invention is to provide a mining cable with fault early warning function and an early warning method. By combining the cable body and the micro sensing unit, it solves the problem that mining cables in the prior art lack real-time status monitoring capabilities, and faults often occur suddenly and are difficult to locate in time, which may lead to production stoppages or even safety accidents.

[0006] To solve the above-mentioned technical problems, the present invention is achieved through the following technical solution.

[0007] This invention relates to a mining cable with fault early warning function, comprising a cable body, The cable body is used for power and signal transmission in underground mines. The cable body consists of a conductor, an insulation layer, and a sheath arranged coaxially from the inside to the outside. Miniature sensing units are distributed and embedded between the insulation layer and the sheath, and are spaced apart along the length of the cable body to collect cable operating status information in real time. The miniature sensing unit uses a flexible encapsulation material that is compatible with the cable body to ensure the cable's original flexibility and mechanical strength. The miniature sensing unit is electrically or signal connected to a data transmission module to transmit the collected status information to a remote monitoring terminal.

[0008] The present invention is further configured such that the micro sensing unit includes at least one set of functional sensors, wherein the functional sensors are selected from one or more combinations of fiber optic grating sensors and nanocomposite sensors.

[0009] The present invention is further configured such that, when the functional sensor in the micro-sensing unit includes a fiber optic grating sensor, the fiber optic grating sensor is used to collect temperature parameters and strain parameters of the cable body; and when the functional sensor includes a nanocomposite sensor, the nanocomposite sensor is used to collect partial discharge parameters of the cable body.

[0010] The present invention is further configured such that the micro-sensing units are arranged at intervals of 50-60cm along the length of the cable body, and all micro-sensing units are pre-stored with unique position identification information.

[0011] The present invention is further configured such that the conductor is made of multiple strands of copper conductor twisted together, the insulation layer is made of flame-retardant cross-linked polyethylene, and the sheath is made of neoprene rubber.

[0012] The present invention is further configured such that the data transmission module is integrated into the end of the cable body or an external supporting device, and the transmission process is processed by an encryption protocol to ensure the security of data transmission.

[0013] A fault warning method for mining cables includes the following steps: S1: Operation status information acquisition. The miniature sensing unit collects one or more operational status information of the cable body, such as temperature, strain, and partial discharge, in real time according to a preset cycle. S2: Data preprocessing involves noise reduction, filtering, and standardization of the collected operational status information to improve data accuracy; S3: Data transmission, the pre-processed information is encrypted and transmitted to the remote monitoring terminal through the data transmission module; S4: Anomaly analysis: The remote monitoring terminal compares the received information with a preset threshold to determine whether the data exceeds the threshold range. S5: Early warning and positioning. If an anomaly is detected, the system calculates and determines the precise location of the fault point by combining the location identification information of the micro-sensor unit corresponding to the abnormal data. S6: Early warning output, generates fault warning information and fault location results, and pushes them to the designated terminal.

[0014] The present invention is further configured such that the preset period in step S1 is 1-30 minutes, which can be adaptively adjusted according to the complexity of the downhole environment and the cable load.

[0015] The present invention is further configured such that the preset thresholds in step S4 include a temperature threshold, a strain threshold, and a partial discharge threshold. Each threshold is pre-calibrated and stored in a remote monitoring terminal according to the cable type, rated parameters, and downhole environmental parameters.

[0016] The present invention is further configured such that, in step S6, while the early warning information is pushed to the remote monitoring terminal, it is simultaneously pushed to the downhole operation terminal, clearly indicating the fault type, risk level and fault location, to guide the staff to carry out timely repairs.

[0017] The present invention has the following beneficial effects.

[0018] 1. This invention solves the problem of traditional mining cables lacking real-time status monitoring capabilities through the integrated design of distributed micro-sensing units and the cable body. The micro-sensing units are intermittently embedded between the cable insulation layer and the sheath, and can simultaneously collect multi-dimensional operating parameters such as temperature, strain, and partial discharge. This enables real-time perception of potential faults such as cable insulation aging, local overheating, and mechanical damage, breaking the passive mode of traditional fault diagnosis and issuing early warning signals in advance. This effectively avoids safety accidents caused by sudden faults such as short circuits and leakage, and provides strong protection for the life safety of miners and production order in underground mines.

[0019] 2. The early warning method of this invention has a complete process and precise positioning, taking into account both data reliability and practicality. Data preprocessing improves monitoring accuracy, encrypted transmission ensures information security, and the combination of micro-sensor unit location identification enables precise fault location, significantly shortening fault investigation time. Early warning information is simultaneously pushed to the monitoring center and underground operation terminals, clearly identifying the fault type and location, guiding staff to quickly repair and reducing production downtime losses. Furthermore, the micro-sensor unit uses flexible packaging, which does not affect the original flexibility and mechanical strength of the cable, adapting to the complex underground laying environment. It can be put into use without additional modifications, improving the overall use value and safety of mining cables. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below.

[0021] Figure 1 This is a three-dimensional diagram of a mining cable with fault early warning function and the early warning method.

[0022] Figure 2 This is an exploded schematic diagram of a mining cable with fault early warning function and the early warning method.

[0023] Figure 3 This is a side sectional view of a mining cable with fault early warning function and an early warning method.

[0024] Figure 4 This is a flowchart of a mining cable with fault early warning function and an early warning method.

[0025] In the attached diagram: 1. Cable body; 11. Conductor; 12. Insulation layer; 13. Sheath; 14. Miniature sensing unit. Detailed Implementation

[0026] The technical solutions of the present invention will be described below with reference to the accompanying drawings. The described embodiments are only some embodiments of the present invention, and not all embodiments.

[0027] Please see Figures 1-4 This invention relates to a mining cable with fault early warning function and an early warning method. Each component preferably adopts special materials and structural design adapted to the harsh underground mining environment to ensure stability and safety.

[0028] The cable body 1 is a multi-layer coaxial composite structure, consisting of conductor 11, insulation layer 12 and sheath 13 from the inside out.

[0029] Conductor 11 is made of multiple strands of copper conductors, which combines excellent conductivity with mechanical flexibility and can withstand frequent mechanical pulling and bending downhole.

[0030] The insulation layer 12 is made of flame-retardant cross-linked polyethylene, which has high insulation, flame retardancy and aging resistance, and effectively blocks current leakage.

[0031] The sheath 13 is made of neoprene rubber, which can resist high humidity, dust erosion and acid and alkali corrosion in the well, while also having wear resistance and mechanical impact resistance, ensuring the overall structural integrity of the cable.

[0032] The miniature sensing unit 14 is the core component for fault early warning. It is distributed and embedded between the insulation layer 12 and the sheath 13 at intervals of 50-60cm along the length of the cable body 1. This arrangement can achieve the optimal balance between monitoring accuracy and cost. Each miniature sensing unit 14 is made of flexible high-temperature resistant encapsulation material, which is compatible with the flexibility of the cable body 1 and will not affect the bending and laying of the cable or its daily use. Moreover, the encapsulation layer has waterproof, dustproof and anti-electromagnetic interference capabilities, ensuring stable operation in complex underground environments.

[0033] The miniature sensing unit 14 can be selected from one or more combinations of fiber optic grating sensors and nanocomposite sensors according to actual monitoring needs.

[0034] Fiber Bragg grating sensors accurately collect cable temperature parameters to reflect local overheating and strain parameters to reflect mechanical damage or deformation.

[0035] Nanocomposite sensors focus on collecting partial discharge parameters to reflect insulation aging or damage.

[0036] Each miniature sensing unit 14 pre-stores unique location identification information, providing a basis for subsequent fault location.

[0037] The data transmission module is electrically or signal-connected to all miniature sensing units 14. It can be integrated into the junction box at the end of the cable or set up as an external accessory device. The transmission process adopts an industrial-grade encryption protocol to prevent data from being interfered with or tampered with, ensuring that the operating status information is transmitted securely and stably to the remote monitoring terminal.

[0038] The fault early warning method of this invention is implemented through a six-step closed-loop process, and its specific working principle is as follows: S1: Operation status information acquisition. The miniature sensing unit 14 can adaptively adjust according to the downhole environment and load according to the preset cycle of 1-30 minutes to collect the operating status information of the cable such as temperature, strain, and partial discharge in real time, so as to realize uninterrupted monitoring at all times.

[0039] S2: Data preprocessing. The collected raw data undergoes noise reduction, filtering, and standardization processing by the built-in processing chip to eliminate invalid data caused by environmental interference, thereby improving the accuracy and reliability of the data and providing a precise basis for subsequent analysis.

[0040] S3: Data transmission. The pre-processed valid data is encrypted and transmitted to the remote monitoring terminal through the data transmission module. The transmission process is adapted to the complex electromagnetic environment downhole to ensure that the data is not lost or leaked.

[0041] S4: Anomaly Analysis. The remote monitoring terminal calls the pre-stored threshold parameters, including temperature threshold, strain threshold, and partial discharge threshold. All of these are pre-calibrated according to the cable type, rated parameters, and downhole environment. The received real-time data is compared with the thresholds one by one to determine whether the data is within the normal range.

[0042] S5: Early warning and positioning. If the data transmitted by a certain micro-sensor unit 14 exceeds the threshold range, it is judged as abnormal. The terminal combines the pre-stored location identification information of the unit and accurately locates the fault point through the distance calculation algorithm. The positioning error can be controlled within ±5cm.

[0043] S6: Early warning output. The terminal immediately generates early warning information including the fault type (overheating / mechanical damage / insulation aging, etc.), risk level, and precise location of the fault point. This information is simultaneously pushed to the remote monitoring center and the mobile terminals of the downhole workers, guiding them to quickly go to the fault point for repair, forming a closed-loop management of "monitoring-analysis-early warning-repair".

[0044] The preferred embodiments of the present invention disclosed above are only for the purpose of illustrating the present invention. The preferred embodiments do not describe all the details in detail, nor do they limit the invention to the specific implementation described herein. This specification selects and specifically describes these embodiments in order to better explain the principles and practical applications of the present invention, so that those skilled in the art can better understand and utilize the present invention.

Claims

1. A mining cable with fault early warning function, comprising a cable body (1), characterized in that: The cable body (1) is used for power transmission and signal transmission in underground mines. The cable body (1) is coaxially arranged with conductor (11), insulation layer (12) and sheath (13) from the inside to the outside. Miniature sensing units (14) are distributed and embedded between the insulation layer (12) and the sheath (13), and are arranged at intervals along the length of the cable body (1) to collect cable operating status information in real time; The micro-sensing unit (14) adopts a flexible encapsulation material that is compatible with the cable body (1) to ensure the original flexibility and mechanical strength of the cable. The micro-sensing unit (14) is electrically or signal-connected to a data transmission module for transmitting the collected status information to a remote monitoring terminal.

2. A mining cable with fault early warning function according to claim 1, characterized in that: The micro-sensing unit (14) includes at least one set of functional sensors, which are selected from one or more combinations of fiber optic grating sensors and nanocomposite sensors.

3. A mining cable with fault early warning function according to claim 1, characterized in that: When the functional sensor in the micro-sensing unit (14) includes a fiber optic grating sensor, the fiber optic grating sensor is used to collect the temperature parameters and strain parameters of the cable body (1). When the functional sensor includes a nanocomposite sensor, the nanocomposite sensor is used to collect the partial discharge parameters of the cable body (1).

4. A mining cable with fault early warning function according to claim 1, characterized in that: The micro-sensing units (14) are arranged at intervals of 50-60cm along the length of the cable body (1), and all micro-sensing units (14) have pre-stored unique location identification information.

5. A mining cable with fault early warning function according to claim 1, characterized in that: The conductor (11) is made of multiple strands of copper conductors twisted together, the insulation layer (12) is made of flame-retardant cross-linked polyethylene, and the sheath (13) is made of neoprene rubber.

6. A mining cable with fault early warning function according to claim 1, characterized in that: The data transmission module is integrated into the end of the cable body (1) or an external accessory device. The transmission process is processed using an encryption protocol to ensure data transmission security.

7. A fault warning method for a mining cable with fault warning function according to any one of claims 1-6, characterized in that: Includes the following steps: S1: Operation status information acquisition, the micro sensing unit (14) collects one or more of the operation status information of the cable body (1) in real time according to the preset cycle, including temperature, strain, partial discharge; S2: Data preprocessing involves noise reduction, filtering, and standardization of the collected operational status information to improve data accuracy; S3: Data transmission, the pre-processed information is encrypted and transmitted to the remote monitoring terminal through the data transmission module; S4: Anomaly analysis: The remote monitoring terminal compares the received information with a preset threshold to determine whether the data exceeds the threshold range. S5: Early warning positioning. If an abnormality is determined, the location of the fault point is calculated and determined by combining the location identification information of the micro-sensing unit (14) corresponding to the abnormal data. S6: Early warning output, generates fault warning information and fault location results, and pushes them to the designated terminal.

8. The early warning method for a mining cable with fault early warning function according to claim 7, characterized in that: The preset cycle in step S1 is 1-30 minutes, which can be adaptively adjusted according to the complexity of the downhole environment and the cable load.

9. A method for early warning of faults in mining cables according to claim 7, characterized in that: The preset thresholds in step S4 include temperature threshold, strain threshold and partial discharge threshold. Each threshold is pre-calibrated and stored in the remote monitoring terminal according to the cable type, rated parameters and downhole environmental parameters.

10. A method for early warning of faults in mining cables according to claim 7, characterized in that: In step S6, while the early warning information is pushed to the remote monitoring terminal, it is also pushed to the downhole operation terminal at the same time, clearly marking the fault type, risk level and fault location, to guide the staff to carry out timely repairs.

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