Energy-saving mechanical transport device and method for mine operation

Abstract

The present application relates to the technical field of mine machinery equipment, and discloses an energy-saving mechanical transport device and method for mine operation, which comprises a main body frame and a hoisting mechanism arranged on the main body frame; the hoisting mechanism is used for hoisting heavy objects onto the main body frame, and comprises a swing arm, a driving module for driving the swing arm to rotate and pitch, and a traction module arranged on the swing arm; the traction module comprises a pulley block, a traction chain, a length adjusting unit, a pulley adjusting unit, a sensing unit and a control unit. By adopting the highest point pulley capable of being axially intelligently adjusted, cooperating with the real-time sensing of multiple sensors and the self-adaptive control algorithm, the dynamic tension closed-loop control system is constructed, the imbalance of the chain tension caused by the change of the angle and the load of the traditional cantilever crane is solved, and the risk of chain disengagement, tooth skipping and falling is reduced by reducing the tension fluctuation of the chain.

Description

Technical Field

[0001] This invention relates to the field of mining machinery and equipment technology, and more specifically, to an energy-saving mechanical transportation device and method for mining operations. Background Technology

[0002] In mining operations, tracked transport vehicles are a new type of transport vehicle designed and manufactured for the relocation and transportation of hydraulic supports in underground coal mines. They can travel on unpaved surfaces, improving production efficiency, reducing production costs, alleviating labor intensity for workers, and lowering safety risks. These transport vehicles are typically equipped with cantilever lifting devices to monitor the loading and unloading of materials. Such equipment usually includes a swing arm that can rotate and pitch on the chassis, and a lifting mechanism consisting of pulley blocks and a traction chain. In actual operation, when the swing arm pitches or the load fluctuates, the effective working length and tension of the traction chain dynamically change, leading to problems such as the chain becoming too tight or too loose.

[0003] In existing technologies, static compensation is mostly achieved using fixed pulley blocks supplemented by mechanical tensioners. However, this compensation method cannot adapt to dynamically changing working conditions in real time, resulting in low adjustment accuracy and sluggish response. An overly tight chain increases transmission resistance and exacerbates wear on the sprockets and chain; an overly loose chain can easily cause tooth skipping, chain slippage, and even swaying of the load or falling objects from heights, potentially threatening operational safety and efficiency.

[0004] Therefore, there is an urgent need for a mining transportation device that can intelligently and in real time adjust the chain tension to adapt to complex dynamic working conditions, while also being energy-saving and highly reliable. Summary of the Invention

[0005] The purpose of this invention is to provide an energy-saving mechanical transportation device and method for mining operations to solve the aforementioned technical problems.

[0006] The present invention solves the above-mentioned technical problems through the following technical solutions: This invention provides an energy-saving mechanical transportation device for mining operations, comprising: a main frame and a hoisting mechanism mounted on the main frame; The lifting mechanism is used to lift heavy objects onto the main frame, and includes: a swing arm, a drive module for driving the swing arm to rotate and pitch, and a traction module disposed on the swing arm; The traction module includes: A pulley system, located at the end of the swing arm, comprises at least three pulleys; A traction chain, which is wound around a pulley block, has a hook attached to its bottom end; The length adjustment unit is fixedly mounted on the swing arm and connected to the top of the traction chain, and is used to adjust the height of the hook by retracting or extending the traction chain. The pulley adjustment unit is used to drive the pulley in the pulley block that is at the highest position when the swing arm is in the horizontal reference state to move along the swing arm axis. The sensing unit is used to collect working condition parameters related to chain tension in real time, including at least a tension sensor for detecting the real-time tension of the chain, an angle sensor for detecting the pitch angle of the swing arm, and a load sensor for detecting the weight of the hoisted load. The control unit is connected to the sensing unit and the pulley adjustment unit via signals, and is configured as follows: Receive real-time data from the sensing unit; Based on the pitch angle of the boom and the weight of the load being hoisted, the target tension of the traction chain under the current working conditions is determined through a preset dynamic target tension calculation model. Compare the real-time tension of the traction chain with the target tension, and calculate the tension deviation; When the tension deviation exceeds the preset threshold, the required axial adjustment of the pulley at the highest point is calculated based on the deviation. Output control commands to the pulley adjustment unit to drive the highest point pulley to move the adjustment amount along the swing arm axis, so as to adjust the tension of the traction chain to the target range.

[0007] Preferably, the pulley adjustment unit includes a linear guide rail arranged along the axial direction of the swing arm, a slider that slides with the linear guide rail, and a servo drive for driving the slider to slide, wherein the highest point pulley is mounted on the slider.

[0008] Preferably, the servo drive includes a servo motor and a ball screw assembly connected to the output end of the servo motor, and the slider is fixedly connected to the nut of the ball screw assembly.

[0009] Preferably, the tension sensor is installed on the traction chain segment between the highest point pulley and the length adjustment unit, the angle sensor is installed at the hinge joint between the swing arm and the drive module, and the load sensor is installed at the connection between the hook and the traction chain.

[0010] Preferably, the sensing unit further includes a position sensor for detecting the real-time position of the slider; The control unit is also configured to: receive feedback signals from the position sensor after the drive slider moves to perform position closed-loop verification; and / or, acquire the real-time tension of the traction chain again to perform tension closed-loop verification.

[0011] Preferably, the length adjustment unit is a servo electric cylinder fixedly installed on the swing arm, and its telescopic end is connected to the top of the traction chain.

[0012] Preferably, the drive module includes a rotating base hinged to the swing arm and a servo hydraulic cylinder mounted between the rotating base and the swing arm.

[0013] Preferably, the pulley system consists of three pulleys arranged in a triangle, with the highest pulley located at the apex of the triangle.

[0014] Preferably, the dynamic target tension calculation model is a functional relationship with the boom pitch angle and the load weight as independent variables and the target tension as the dependent variable.

[0015] A hoisting method for an energy-saving mechanical transport device used in mining operations includes the following steps: S100: Start the transport device, adjust the swing arm to the working position through the drive module, and lower the traction chain and hook through the length adjustment unit; S200: After lifting the load, the sensing unit collects the real-time data on the boom pitch angle, the weight of the lifted load, and the real-time tension of the traction chain. S300: The control unit determines the target tension of the traction chain based on the pitch angle and load weight through a dynamic target tension calculation model; S400: The control unit calculates the deviation between the real-time tension and the target tension, and determines whether the deviation exceeds the allowable range; S500: If the deviation is exceeded, the control unit calculates the pulley adjustment amount based on the deviation and controls the pulley adjustment unit to drive the highest point pulley to move along the swing arm axis to adjust the tension of the traction chain. S600: After adjustment, the tension is checked by the sensing unit. If the tension does not reach the target range, repeat steps S400-S500 for iterative adjustment until the requirements are met.

[0016] The beneficial effects of this invention are as follows: This invention, by incorporating a traction module and an axially intelligent adjustable highest-point pulley, along with multi-sensor real-time sensing and adaptive control algorithms, constructs a dynamic tension closed-loop control system. This solves the problem of chain tension imbalance caused by angle and load changes in traditional cantilever cranes. By reducing chain tension fluctuations, it lowers the risks of chain derailment, tooth skipping, and falling objects, thereby improving operational safety and reliability. Furthermore, by maintaining optimal tension, it reduces transmission friction and wear, extends component life, reduces maintenance costs, and achieves energy saving and consumption reduction. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the external structure of the overall structure of an energy-saving mechanical transportation device for mining operations according to the present invention; Figure 2This is a top view of the overall structure of an energy-saving mechanical transportation device for mining operations according to the present invention; Figure 3 This is a schematic diagram of the hoisting mechanism in an energy-saving mechanical transportation device for mining operations according to the present invention; Figure 4 This is a schematic diagram of the internal structure of the traction module in an energy-saving mining machinery transportation device of the present invention; Figure 5 This is a schematic diagram of the outer side of the traction module in an energy-saving mechanical transportation device for mining operations according to the present invention; Figure 6 This is a block diagram showing the relationship between the functional units in the traction module of an energy-saving mining machinery transportation device of the present invention; Figure 7 This is a flowchart illustrating the lifting method of an energy-saving mechanical transportation device for mining operations according to the present invention.

[0018] In the diagram: 1. Main frame; 2. Lifting mechanism; 21. Swing arm; 22. Drive module; 221. Rotating base; 222. Servo hydraulic cylinder; 23. Traction module; 231. Pulley block; 232. Traction chain; 233. Hook; 234. Servo electric cylinder; 235. Linear guide rail; 236. Slider; 237. Servo motor; 238. Ball screw pair; 239. Tension sensor; 2310. Angle sensor; 2311. Load sensor; 2312. Position sensor. Detailed Implementation

[0019] The subject matter described herein will now be discussed with reference to exemplary embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and implement the subject matter described herein, and changes may be made to the function and arrangement of the elements discussed without departing from the scope of this specification. Various processes or components may be omitted, substituted, or added as needed in the examples. Furthermore, features described in some examples may be combined in other examples.

[0020] Please refer to the following: Figures 1 to 5 An energy-saving mechanical transportation device for mining operations mainly includes a movable main frame 1 and a hoisting mechanism 2 installed on the top of the rear of the main frame 1. In this embodiment, two symmetrically distributed hoisting mechanisms 2 are provided.

[0021] The hoisting mechanism 2 includes a swing arm 21, a drive module 22, and a traction module 23. The drive module 22 is used to drive the swing arm 21 to achieve rotation in the horizontal plane and pitch swing in the vertical plane. In a specific embodiment, the drive module 22 includes a rotating base 221 fixed on the main frame 1 (the rotating base 221 includes a rotary drive mechanism that drives its rotation, enabling the rotating base 221 to rotate on its own axis) and a servo hydraulic cylinder 222 hinged between the rotating base 221 and the swing arm 21, the extension and retraction of which can precisely control the pitch angle of the swing arm 21.

[0022] The traction module 23 is the core for performing hoisting and realizing intelligent adjustment, and all its components are integrated on the swing arm 21. The traction module 23 includes a pulley block 231, a traction chain 232, a hook 233, a length adjustment unit, a pulley adjustment unit, a sensing unit, and a control unit.

[0023] The pulley block 231 is located at the end of the swing arm 21. In this embodiment, the pulley block 231 consists of three pulleys arranged in a stable triangle. The pulley located at the apex of the triangle is defined as the highest point pulley. This definition is based on the fact that when the swing arm 21 is in a horizontal reference state, this pulley is at its highest position in the vertical direction. This arrangement provides clear force distribution and a compact structure.

[0024] The traction chain 232 winds through the pulley block 231, with its bottom end connected to the hook 233 for lifting materials and its top end connected to the length adjustment unit.

[0025] The length adjustment unit is used to achieve a wide range of adjustment for the lifting and lowering of the hook 233. In this embodiment, it is a servo cylinder 234 fixedly mounted on the swing arm 21. The cylinder body of the servo cylinder 234 is fixed at a suitable position on the swing arm 21, and the end of its telescopic rod is connected to the top of the traction chain 232. By extending and retracting the servo cylinder 234, the traction chain 232 can be quickly extended and retracted, achieving the initial positioning of the hook 233's height to adapt to different suspension points of heavy objects.

[0026] The pulley adjustment unit is used for high-precision fine-tuning of the tension of the traction chain 232. It includes a linear guide rail 235 mounted on the top of the swing arm 21, a slider 236 that slides precisely with the linear guide rail 235, and a servo drive unit that drives the slider 236. The highest point pulley is mounted on the slider 236 via a bearing housing. The servo drive unit specifically includes a servo motor 237 and a ball screw pair 238. The servo motor 237 is connected to the lead screw of the ball screw pair 238 via a coupling, and the nut of the ball screw pair 238 is fixed to the slider 236. When the control unit issues a command, the servo motor 237 rotates according to the calculated number of pulses, converting the rotational motion into high-precision linear displacement of the slider 236 and the highest point pulley along the axial direction of the swing arm 21 via the ball screw pair 238. The axial movement range can be set to 300-500mm according to design requirements.

[0027] The sensing unit is responsible for providing real-time and accurate input signals for intelligent control. It includes: tension sensor 239, angle sensor 2310, load sensor 2311, and position sensor 2312.

[0028] The tension sensor 239 is installed on the traction chain 232 segment between the highest pulley and the length adjustment unit. This position allows for the most direct measurement of the real-time tension of the working chain, and its output signal directly reflects the current tension.

[0029] An angle sensor 2310 is installed at the hinge joint between the swing arm 21 and the drive module 22 to accurately measure the pitch angle θ of the swing arm 21 relative to the horizontal plane.

[0030] The load sensor 2311 is installed at the connection between the hook 233 and the traction chain 232 to measure the weight G of the hoisted load in real time.

[0031] Position sensor 2312 may be mounted at the end of linear guide 235, for example, using a grating ruler, to provide real-time feedback on the precise position of slider 236 (i.e., the highest point pulley).

[0032] The control unit is the intelligent central hub of the entire system and can be constructed using an industrial PLC combined with an edge computing module. For example... Figure 6 As shown, the control unit communicates at high speed with the sensors of the sensing unit, the servo driver of the pulley adjustment unit, the length adjustment unit, and the controller of the drive module 22 via the industrial bus.

[0033] The core control logic operating within the control unit is as follows: Data Acquisition and Filtering: Real-time data is received from tension, angle, and load sensors, and preprocessed using algorithms such as Kalman filtering to remove noise interference and obtain reliable real-time tension T. real Angle θ and load G.

[0034] Target tension calculation: Call the preset dynamic target tension calculation model:

[0035] The coefficients k1 (N / °), k2 (N / kg), and T0 (N) have been obtained and stored through previous equipment calibration experiments. The model shows that the target tension increases linearly with the upward movement of the swing arm 21 (θ increases) to compensate for the geometric slack of the chain, and increases linearly with the increase of the load (G) to provide sufficient gripping force; and the model establishes a mapping relationship between the target tension and the angle of the swing arm 21 and the load weight.

[0036] Deviation judgment: Calculate the absolute deviation ΔT between the current tension and the target tension = |T real -T target | and determine ΔT>5%×T target Is it true? If it is true, then adjustment is triggered.

[0037] Adjustment amount calculation: Calculate the distance the slider needs to move (adjustment amount ΔL) based on the deviation. The calculation formula is as follows:

[0038] Wherein, k3 is the transmission stiffness coefficient (N / mm), representing the change in chain tension caused by a unit distance of axial movement of the pulley, which is also obtained through experimental calibration. When ΔL is positive, it means that the pulley needs to be driven to move towards the end of the swing arm 21 to tighten the chain; when it is negative, it moves in the opposite direction to loosen the chain.

[0039] Command output and execution: The calculated ΔL is converted into the number of pulses required by the servo motor 237 and sent to the servo driver via the bus to start the motor and drive the slider 236 to move.

[0040] Closed-loop verification: During and after the slider's movement, position information fed back by position sensor 2312 is used for closed-loop position verification to ensure it has moved into position. Subsequently, data from tension sensor 239 is read again for tension closed-loop verification. If the verification fails (tension still not within the target range), iterative fine-tuning is repeated until the requirements are met.

[0041] like Figure 7 As shown, the hoisting method based on the above-mentioned device includes the following steps: S100: Start the device, operate the drive module 22 to rotate the swing arm 21 and tilt it to the vicinity of the target working area, and operate the length adjustment unit to lower the traction chain 232 and hook 233 to a suitable height.

[0042] S200: After the load is lifted, the sensing unit starts working continuously, collecting angle θ, load G, and tension T in real time. real.

[0043] S300: The control unit calculates the current target tension T in real time based on θ and G using the dynamic model. target .

[0044] S400: Control unit calculates T real With T target The deviation is measured and it is determined whether it exceeds the allowable range (e.g., ±5%).

[0045] S500: If the value is exceeded, the control unit calculates the precise adjustment amount ΔL and immediately controls the pulley adjustment unit to drive the highest pulley to move axially, quickly adjusting the chain tension.

[0046] S600: After the adjustment is completed, the system automatically performs a closed-loop check. If the check is successful, it will proceed to stable hoisting or the next action. If it fails, it will automatically return to S400 for a new round of sensing and adjustment, forming a dynamic and adaptive intelligent control loop to ensure that the chain tension is always kept in the optimal range during the entire hoisting, moving and placing process.

[0047] This invention utilizes a traction module with deeply integrated electromechanical-hydraulic and intelligent control features to achieve intelligent closed-loop regulation of the chain, reducing the fluctuation range of chain tension and thus mitigating potential malfunctions such as chain derailment, tooth skipping, and load swaying caused by uneven tension. Simultaneously, it enables mining transportation equipment to achieve self-sensing, self-decision-making, and self-adjustment under dynamic operating conditions, improving operational safety, stability, efficiency, and economy, aligning with the development trend of intelligent, green, and energy-saving mining equipment. Furthermore, it possesses the following advantages: Energy saving and low maintenance costs: By keeping the chain in optimal tension at all times, this invention can reduce frictional resistance and ineffective power loss during transmission. At the same time, the significant reduction in equipment failure rate reduces energy consumption caused by frequent start-stop and maintenance, extends the service life of key components (such as sprockets, chains, and bearings), achieves comprehensive energy saving, and reduces maintenance material and labor costs.

[0048] Intelligent and adaptive: This invention is fully automatic, requiring no manual intervention for tension adjustment. The system can sense changes in working conditions in real time and make adjustment decisions in advance, with a fast response speed, and can adapt to continuous dynamic changes in cantilever angle and load.

[0049] Good installation adaptability: The improvement scheme of this invention is mainly focused on the end of the swing arm 21, which requires little modification to the main structure of the equipment, is easy to modify, has controllable cost, and is easy to upgrade and implement on existing equipment.

[0050] The embodiments of the present invention have been described above, but the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention, all of which are within the protection scope of the present invention.

Claims

1. An energy-saving mechanical transport device for mining operations, characterized in that, include: The main frame and the hoisting mechanism mounted on the main frame; The lifting mechanism is used to lift heavy objects onto the main frame, and includes: a swing arm, a drive module for driving the swing arm to rotate and pitch, and a traction module disposed on the swing arm; The traction module includes: A pulley system, located at the end of the swing arm, comprises at least three pulleys; A traction chain, which is wound around a pulley block, has a hook attached to its bottom end; The length adjustment unit is fixedly mounted on the swing arm and connected to the top of the traction chain, and is used to adjust the height of the hook by retracting or extending the traction chain. The pulley adjustment unit is used to drive the pulley in the pulley block that is at the highest position when the swing arm is in the horizontal reference state to move along the swing arm axis. The sensing unit is used to collect working condition parameters related to chain tension in real time, including at least a tension sensor for detecting the real-time tension of the chain, an angle sensor for detecting the pitch angle of the swing arm, and a load sensor for detecting the weight of the hoisted load. The control unit is connected to the sensing unit and the pulley adjustment unit via signals, and is configured as follows: Receive real-time data from the sensing unit; Based on the pitch angle of the boom and the weight of the load being hoisted, the target tension of the traction chain under the current working conditions is determined through a preset dynamic target tension calculation model. Compare the real-time tension of the traction chain with the target tension, and calculate the tension deviation; When the tension deviation exceeds the preset threshold, the required axial adjustment of the pulley at the highest point is calculated based on the deviation. Output control commands to the pulley adjustment unit to drive the highest point pulley to move the adjustment amount along the swing arm axis, so as to adjust the tension of the traction chain to the target range.

2. The energy-saving mechanical transportation device for mining operations according to claim 1, characterized in that, The pulley adjustment unit includes a linear guide rail arranged along the axial direction of the swing arm, a slider that slides with the linear guide rail, and a servo drive for driving the slider to slide. The highest point pulley is mounted on the slider.

3. The energy-saving mechanical transportation device for mining operations according to claim 2, characterized in that, The servo drive includes a servo motor and a ball screw assembly connected to the output end of the servo motor, and the slider is fixedly connected to the nut of the ball screw assembly.

4. The energy-saving mechanical transportation device for mining operations according to claim 1, characterized in that, The tension sensor is installed on the traction chain segment between the highest pulley and the length adjustment unit, the angle sensor is installed at the hinge joint between the swing arm and the drive module, and the load sensor is installed at the connection between the hook and the traction chain.

5. The energy-saving mechanical transportation device for mining operations according to claim 2, characterized in that, The sensing unit also includes a position sensor for detecting the real-time position of the slider; The control unit is also configured to: receive feedback signals from the position sensor after the drive slider moves to perform position closed-loop verification; and / or, acquire the real-time tension of the traction chain again to perform tension closed-loop verification.

6. The energy-saving mechanical transportation device for mining operations according to claim 1, characterized in that, The length adjustment unit is a servo electric cylinder fixedly installed on the swing arm, and its telescopic end is connected to the top of the traction chain.

7. The energy-saving mechanical transportation device for mining operations according to claim 1, characterized in that, The drive module includes a rotating base hinged to the swing arm and a servo hydraulic cylinder installed between the rotating base and the swing arm.

8. The energy-saving mechanical transportation device for mining operations according to claim 1, characterized in that, The pulley system consists of three pulleys arranged in a triangle, with the highest pulley located at the apex of the triangle.

9. The energy-saving mechanical transportation device for mining operations according to claim 1, characterized in that, The dynamic target tension calculation model is a functional relationship with the boom pitch angle and the load weight as independent variables and the target tension as the dependent variable.

10. A method for hoisting an energy-saving mechanical transport device for mining operations, using the energy-saving mechanical transport device for mining operations as described in any one of claims 1-9, characterized in that, The following steps are included: S100: Start the transport device, adjust the swing arm to the working position through the drive module, and lower the traction chain and hook through the length adjustment unit; S200: After lifting the load, the sensing unit collects the real-time data on the boom pitch angle, the weight of the lifted load, and the real-time tension of the traction chain. S300: The control unit determines the target tension of the traction chain based on the pitch angle and load weight through a dynamic target tension calculation model; S400: The control unit calculates the deviation between the real-time tension and the target tension, and determines whether the deviation exceeds the allowable range; S500: If the deviation is exceeded, the control unit calculates the pulley adjustment amount based on the deviation and controls the pulley adjustment unit to drive the highest point pulley to move along the swing arm axis to adjust the tension of the traction chain. S600: After adjustment, the tension is checked by the sensing unit. If the tension does not reach the target range, repeat steps S400-S500 for iterative adjustment until the requirements are met.

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