A flight bar chain break detection probe and a manufacturing method thereof

Abstract

The application relates to a scraper machine chain breakage detection probe, which comprises a shell, an amorphous wire and a capillary glass tube arranged in the shell, the amorphous wire being connected with a circuit board, the capillary glass tube being fixed in the shell through two annular elastic clamps, the two elastic clamps being clamped in the shell, an inner support being arranged in the inner ring of the elastic clamp, the two ends of the capillary glass tube being supported on the inner support, an epoxy resin filling layer being arranged between the inner support and the elastic clamp, the amorphous wire being arranged in the capillary glass tube, the amorphous wire and the capillary glass tube being coaxially arranged, the capillary glass tube being coaxial with the shell, and a varnished wire coil being arranged outside the capillary glass tube. The application improves the sensitivity and environmental adaptability of the chain breakage detection.

Description

Technical Field

[0001] This invention relates to a chain breakage detection probe and its manufacturing method, belonging to the technical field of chain breakage detection equipment. Background Technology

[0002] Scraper conveyors are conveying devices that use open chutes as load-bearing components. A chain drives scrapers to circulate within the chutes, utilizing the friction between the material and the scrapers and chutes to continuously push bulk materials. They are core equipment for material handling in industries such as coal mining and metallurgy. However, scraper conveyor chains are prone to breakage during operation. Chain breakage can lead to serious production accidents such as equipment downtime, material accumulation, and personnel injuries, directly impacting production safety and efficiency. To reduce losses from chain breakage, current technologies typically employ chain breakage detection technology to continuously monitor chain integrity. Currently, mainstream chain breakage detection equipment includes mechanical contact type, photoelectric type, ordinary magnetic sensor type, and GMI sensor, among others. Mechanical contact type: The chain break signal is triggered by a mechanical structure. The response is delayed, with a response time of ≥5ms. It is easily affected by dust and vibration, which can lead to false alarms. Moreover, the detection accuracy will drop sharply after wear. Photoelectric type: It uses the principle of light blocking to detect chain breakage. It is prone to failure in industrial environments with high dust concentration and complex lighting. The detection distance is limited, generally ≤30mm. Ordinary magnetic sensing type: based on Hall element, magnetoresistive sensor, etc., with low magnetic field detection sensitivity, the detection sensitivity is usually ≥10 mV / Oe, unable to capture the weak magnetic field change at the moment of chain breakage, and has weak anti-electromagnetic interference capability. GMI sensors, also known as giant magnetoresistance sensors, possess natural advantages in weak magnetic field detection due to their pT-level magnetic field detection sensitivity, μs-level response speed, and strong anti-interference characteristics. In recent years, GMI sensors have been gradually applied in industrial inspection fields; however, there is still a technological gap in dedicated probes for scraper conveyor chain breakage detection. Existing general-purpose GMI sensors do not consider harsh industrial environments such as vibration, dust, and extreme temperatures, lack adaptive designs for these environments, and fail to optimize the sensitive structure for the magnetic field characteristics of scraper conveyor chains.

[0003] In summary, existing chain breakage detection equipment has the following core defects: Low sensitivity: Ordinary magnetic sensors cannot capture the weak signal at the moment of chain breakage (magnetic field change of 50~200 Oe), resulting in a high false negative rate; Slow response speed: Traditional solutions have a response time of ≥5ms, which can easily cause detection delays for high-speed scraper conveyors; Poor environmental adaptability: Not resistant to vibration, dust, high and low temperatures, and has a short trouble-free working time in industrial sites (≤1000h). Low installation compatibility: Existing probes are too large to fit the narrow installation space of scraper conveyors, and lack standardized installation interfaces; Weak anti-interference ability: It is easily affected by industrial electromagnetic interference and magnetic field noise caused by chain vibration, resulting in a high false alarm rate. Summary of the Invention

[0004] The purpose of this invention is to provide a scraper conveyor chain breakage detection probe to solve the problems of low sensitivity and poor environmental adaptability of existing scraper conveyor chain breakage detection equipment.

[0005] To solve the above problems, the scraper conveyor chain breakage detection probe involved in this invention adopts the following technical solution: A scraper conveyor chain breakage detection probe includes a housing, an amorphous wire and a capillary glass tube are disposed inside the housing, the amorphous wire is connected to a circuit board, the capillary glass tube is fixed inside the housing by two annular elastic clamps, the two elastic clamps are clamped inside the housing, the inner ring of the elastic clamps has an internal support, the two ends of the capillary glass tube are supported on the internal support, there is an epoxy resin potting layer between the internal support and the elastic clamps, the amorphous wire is disposed inside the capillary glass tube, the amorphous wire and the capillary glass tube are coaxially arranged, the capillary glass tube is coaxial with the housing, and an enameled wire coil is wound around the outside of the capillary glass tube.

[0006] The coaxiality between the amorphous wire and the capillary glass tube is ≤0.02mm.

[0007] The coaxiality between the amorphous wire and the shell is ≤0.05mm.

[0008] The elastic clamp is a polytetrafluoroethylene elastic clamp.

[0009] The inner diameter of the elastic clamp and the diameter of the amorphous wire form an interference fit of 0.001 mm.

[0010] A silicone rubber buffer pad is also provided between the outer side of the epoxy resin potting layer and the shell.

[0011] Another objective of this invention is to provide a method for manufacturing a scraper conveyor chain breakage detection probe, comprising: amorphous wire insertion: slowly threading a CoFeSiB amorphous wire through a capillary glass tube, ensuring that both ends protrude, and observing with an optical microscope to confirm that the amorphous wire is free from bending or damage; centering and fixing: fitting polytetrafluoroethylene clamps onto both ends of the amorphous wire, fixing the clamps to the end face of the capillary glass tube with epoxy resin, placing it in an oven for curing, and calibrating it with a coaxiality tester after curing to ensure that the coaxiality between the amorphous wire and the capillary glass tube is ≤0.02mm; the enameled wire coil is wound on the outside of the capillary glass tube with constant tension using a CNC fully automatic winding machine, and the winding spacing is uniform.

[0012] The cladding of the enameled wire coil is a polyimide enameled layer, and the diameter of the enameled wire coil is 50 μm.

[0013] The ends of the enameled wire coils are tin-plated after the enamel is stripped.

[0014] The thickness of the tin plating layer is ≥5μm.

[0015] The present invention comprises an amorphous wire and a capillary glass tube within its housing. The amorphous wire serves as the core sensing element, converting magnetic field changes into impedance changes based on the GMI effect. The capillary glass tube acts as a coil frame, used to fix the amorphous wire and prevent it from being subjected to mechanical stress. The amorphous wire is connected to a circuit board, which integrates driving, acquisition, amplification, and temperature drift compensation circuits. The capillary glass tube is fixed within the housing by two annular elastic clamps. The two elastic clamps are engaged within the housing, and an internal support is located within the inner ring of each elastic clamp. Both ends of the capillary glass tube are supported on the internal support. An epoxy resin potting layer exists between the internal support and the elastic clamps, serving as a moisture-proof, shock-proof, and fixation layer for the internal support. The amorphous wire is positioned within the capillary glass tube. Inside the tube, the amorphous wire is coaxially arranged with the capillary glass tube, which in turn is coaxial with the shell. This ensures the amorphous wire is centrally fixed, completely resolving the problem of uneven magnetic field coupling caused by radial offset of the amorphous wire, reducing the consistency error of the measurement sensitivity. Simultaneously, the buffering characteristics of the elastic clamp absorb minor vibrations, reducing the impact of mechanical stress on the magnetic permeability of the amorphous wire. An enameled wire coil is wound around the outside of the capillary glass tube. This coil generates an excitation magnetic field, enhancing the GMI effect of the amorphous wire. The coil excitation improves the uniformity of the magnetic field, reduces the difference in magnetic field distribution on the amorphous wire surface, and significantly improves the response consistency of the GMI effect. The synergistic effect of the amorphous wire and enameled wire coil in this invention improves the sensitivity of chain breakage detection; the shockproof function of the epoxy resin potting layer enhances environmental adaptability. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly described below: Figure 1 This is an axial sectional view of an embodiment of the present invention; Figure 2 This is an exploded view of an embodiment of the present invention.

[0017] The diagram is labeled as follows: 1. Shell, 2. Amorphous wire, 3. Capillary glass tube, 4. Circuit board, 5. Elastic clamp, 6. Internal support, 7. Epoxy resin potting layer, 8. Enamelled wire coil, 9. Silicone rubber buffer pad. Detailed Implementation

[0018] To make the technical objectives, technical solutions, and beneficial effects of the present invention clearer, the technical solutions of the present invention will be further described below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only for explaining the present invention and are not intended to limit the present invention; that is, the described embodiments are merely some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0019] Specific embodiments of the scraper conveyor chain breakage detection probe involved in this invention are as follows: Figures 1-2The device includes a housing 1, within which an amorphous wire 2 and a capillary glass tube 3 are housed. The amorphous wire 2 converts magnetic field changes into impedance changes based on the GMI effect. The amorphous wire 2 is connected to a circuit board 4 via wires. The circuit board 4 integrates driving, acquisition, amplification, and temperature drift compensation circuits and is made of FR-4 material. The capillary glass tube 3 is fixed inside the housing 1 by two annular elastic clamps 5. The two elastic clamps 5 are locked in place within the housing 1. The inner ring of the elastic clamps 5 has an internal support 6, on which both ends of the capillary glass tube 3 are supported. The internal support 6 is used to fix the capillary glass tube 3 to the circuit board 4. The material is polytetrafluoroethylene. An epoxy resin potting layer 7 is provided between the internal support 6 and the elastic clamps 5 for moisture protection, shockproofing, and impact resistance. 100% The filling is bubble-free, and its model is E-51. The amorphous wire 2 is placed inside the capillary glass tube 3, and the amorphous wire 2 and the capillary glass tube 3 are coaxially arranged. The capillary glass tube 3 is coaxial with the shell 1. An enameled wire coil 8 is wound around the outside of the capillary glass tube 3. The capillary glass tube 3 serves as a skeleton on the one hand and is used to fix the amorphous wire 3 on the other hand to prevent it from being subjected to mechanical stress. The material of the capillary glass tube 3 is borosilicate glass, and it is laid flat. The enameled wire coil 8 is used to generate an excitation magnetic field to enhance the GMI effect of the amorphous wire 2. The amorphous wire 2, the capillary glass tube 3, and the enameled wire coil 8 together constitute the sensitive element unit. The insulation and structural stability of the capillary glass tube 3 can prevent the amorphous wire 2 from being directly subjected to mechanical stress, and at the same time provide a uniform winding carrier for the enameled wire coil 8. After a specific frequency excitation signal is passed to the enameled wire coil 8, a uniform alternating magnetic field is generated, which is superimposed with the constant magnetic field of the magnetic mark of the scraper chain and acts together on the amorphous wire to form a magnetic field coupling closed loop. When the scraper conveyor chain is running normally, the constant magnetic field of the magnetic marker continues to act, keeping the permeability of the amorphous wire 2 stable and its impedance constant. When the chain breaks, the magnetic marker detaches from the detection area, the superimposed magnetic field disappears instantly, and the permeability of the amorphous wire changes drastically, causing a sudden change in impedance. This sudden change signal is the core trigger source for chain break detection. The amorphous wire 2 sends this sudden change signal to the circuit board 4. When the circuit board 4 detects a voltage signal change amplitude ≥ 0.5V and a duration ≥ 100μs, it determines that a chain break fault has occurred and immediately outputs a fault signal to the scraper conveyor control system through the signal pin of the M12 waterproof connector, triggering an alarm and a shutdown command.

[0020] Specifically, the coaxiality between the amorphous wire 2 and the capillary glass tube 3 is ≤0.02mm. During assembly, the elastic clamp 5 is fitted onto both ends of the amorphous wire 2, and epoxy resin is applied to fix the elastic clamp 5 and the end face of the capillary glass tube 3. The assembly is then placed in an 80℃ oven for curing for 1 hour. After curing, a coaxiality tester is used for calibration to ensure that the coaxiality between the amorphous wire 2 and the capillary glass tube 3 is ≤0.02mm.

[0021] Specifically, the coaxiality between the amorphous wire 2 and the housing 1 is ≤0.05mm. This completely solves the problem of uneven magnetic field coupling caused by the radial offset of the amorphous wire 2, making the detection sensitivity consistency error ≤±0.03 mV / Oe.

[0022] Specifically, the elastic clamp 5 is a polytetrafluoroethylene (PTFE) elastic clamp. The buffering characteristics of the elastic clamp 5 can absorb slight vibrations, reduce the impact of mechanical stress on the magnetic permeability of the amorphous wire 2, and ensure that the detection accuracy of the probe decreases by ≤3% during long-term operation (≥10000h).

[0023] Specifically, the inner diameter of the elastic clamp 5 is designed to be 126μm, and the diameter of the amorphous wire 2 is 125μm, forming an interference fit of 0.001mm.

[0024] Specifically, a silicone rubber buffer pad 9 is provided between the outer side of the epoxy resin potting layer 7 and the shell 1. The silicone rubber buffer pad 9 can absorb axial and radial vibration energy, avoid structural displacement and signal distortion caused by vibration, and thus enhance the ability to resist vibration interference.

[0025] A method for manufacturing a scraper conveyor chain breakage detection probe: An enameled wire coil 8 is wound on the outside of a capillary glass tube 3 using a CNC fully automatic winding machine with a constant tension of 0.05N. The winding spacing is uniform, with a winding spacing of 0.05mm / turn. This ensures uniform winding of the enameled wire coil 8 and improves the uniformity of the coil's excitation magnetic field.

[0026] Specifically, the cladding of the enameled wire coil 8 is a polyimide enameled layer, and the diameter of the enameled wire coil 8 is 50μm.

[0027] Specifically, the ends of the enameled wire coil 8 are tin-plated after the enamel is stripped.

[0028] Specifically, the tin plating layer thickness is ≥5μm.

[0029] The scraper conveyor chain breakage detection probe implemented in this embodiment mainly consists of the following components: Sensing element unit: amorphous wire, capillary glass tube, enameled wire coil; Signal processing unit: circuit board, component mounting pads, driver chip (AD9851), acquisition chip (AD9245), differential amplifier chip (AD8628), temperature sensor (DS18B20), main control chip (ZYNQ7020); Protection and fixing unit: epoxy resin potting layer, internal support, M12 waterproof connector, mounting holes, silicone rubber buffer pad; Auxiliary units: pin soldering points, wire end soldering points, and PTFE fixing clamps.

[0030] The amorphous filament is the core sensing element, which converts magnetic field changes into impedance changes based on the GMI effect; the material is CoFeSiB (silver white), with a diameter of 125μm and a length of 5cm.

[0031] The capillary glass tube serves as the coil frame, fixing the amorphous wire and preventing it from being subjected to mechanical stress; it is made of borosilicate glass, laid flat, with a length of 4.8cm and a diameter of 0.2mm.

[0032] The function of the enameled wire coil is to generate an excitation magnetic field and enhance the GMI effect of the amorphous wire; the diameter is 50μm (polyimide enameled layer), the number of turns is 100, the winding length is 4.6cm, and 1cm wire ends are left on both sides.

[0033] The PTFE fixing clamp is used to fix the amorphous wire and ensure its centered placement; the inner diameter is 126μm and the clamp fits the amorphous wire with an interference fit of 0.001mm.

[0034] The circuit board integrates driver, acquisition, amplification, and temperature drift compensation circuits; it measures 40mm×20mm×3mm, is made of FR-4 material, and is encapsulated inside an epoxy resin potting layer.

[0035] The amorphous wire is made of CoFeSiB alloy, whose core characteristic is high magnetic permeability (μ≥1.2×10⁻⁶). 5 The significant giant magnetoresistance (GMI) effect—when the external magnetic field changes, the AC impedance of the amorphous wire undergoes a significant nonlinear change, which is the core basis for achieving highly sensitive magnetic field detection. The capillary glass tube, serving as the coil frame, is arranged horizontally. Its insulation and structural stability prevent the amorphous wire from being directly subjected to mechanical stress, while simultaneously providing a uniform winding carrier for the enameled wire coil. After a specific frequency excitation signal is applied to the enameled wire coil, a uniform alternating magnetic field is generated. This magnetic field, combined with the constant magnetic field of the magnetic marker on the scraper chain, acts on the amorphous wire, forming a magnetic field coupling closed loop.

[0036] When the scraper conveyor chain is running normally, the constant magnetic field of the magnetic marker continues to act, the permeability of the amorphous wire remains stable, and the impedance value is constant. When the chain breaks, the magnetic marker leaves the detection area, the superimposed magnetic field disappears instantly, the permeability of the amorphous wire changes drastically, causing a sudden change in the impedance value (the change amplitude is ≥5%). This sudden change signal is the core trigger source for chain break detection.

[0037] Operating principles and technical effects of key structures (1) Amorphous wire centrally fixed structure Operating principle: Polytetrafluoroethylene (PTFE) elastic clamps are used to fix both ends of the amorphous wire. The inner diameter of the clamps is designed to be 126μm, forming a 0.001mm interference fit with the diameter of the amorphous wire (125μm). This ensures the stability of the fixation while avoiding mechanical stress caused by excessive clamping. At the same time, the capillary glass tube is calibrated through the positioning groove of the internal support (tolerance ±0.01mm) to ensure that the coaxiality between the amorphous wire and the capillary glass tube is ≤0.02mm and the coaxiality with the overall axis of the probe is ≤0.05mm.

[0038] Technical effects: It completely solves the problem of uneven magnetic field coupling caused by radial offset of amorphous wire, making the detection sensitivity consistency error ≤ ±0.03 mV / Oe; the buffer characteristics of the elastic clamp can absorb slight vibrations and reduce the influence of mechanical stress on the magnetic permeability of amorphous wire, so that the detection accuracy of the probe decreases by ≤3% during long-term operation (≥10000h).

[0039] (2) Enamelled wire coil winding structure Operating principle: A fully automatic CNC winding machine is used to wind enameled wire (polyimide enameled layer, diameter 50μm) on the outside of a capillary glass tube with a constant tension of 0.05N. The number of turns is precisely controlled to 100 turns, and the winding length is 4.6cm (to match the total length of the capillary glass tube of 4.8cm, with space reserved at both ends for fixing). The winding spacing is uniform (0.05mm / turn), with no overlap or crossing. 10mm is reserved on each side of the wire end. After peeling off 3mm of enamel, tin plating is performed (plating thickness ≥5μm), and then it is soldered to the lead solder joint. The solder joint is sealed and fixed with epoxy resin.

[0040] Technical effects: The uniformity of the excitation magnetic field of the coil is ≥95%, and the difference in magnetic field distribution on the surface of the amorphous wire is ≤±2%, which significantly improves the response consistency of the GMI effect; the contact resistance of the tin-plated solder joint is ≤5mΩ, which reduces signal transmission loss and ensures the integrity of the excitation signal and the acquisition signal. Ultimately, the magnetic field detection sensitivity of the probe reaches ≥0.5 mV / Oe, which is 16 times higher than that of existing Hall elements.

[0041] (3) Epoxy resin potting and buffer composite structure Operating principle: The internal support and external space (without stainless steel shell design) are filled and potted with 100% E-51 epoxy resin. Vacuum degassing treatment is performed before potting to ensure no air bubbles or voids. A 3mm thick silicone rubber buffer pad (Shore hardness 50°) is wrapped between the internal support and the potting layer, forming a composite protective structure of "rigid fixation + elastic buffer" - the potting layer provides moisture-proof, dust-proof and impact-proof protection, and the buffer pad absorbs axial and radial vibration energy.

[0042] Technical benefits: The potting layer enables the probe to achieve an IP65 protection rating, resisting the intrusion of industrial dust with a particle size ≤10μm and short-term spraying at ≤0.3MPa; the silicone rubber buffer pad can effectively absorb vibration energy of 5~50Hz and acceleration ≤5g, ensuring that the vibration displacement of the sensitive element unit is ≤0.05mm, avoiding structural displacement and signal distortion caused by vibration, and the probe's fault-free working time is ≥10000h, which is 10 times better than existing products.

[0043] This invention, through optimized collaborative design of sensitive elements, enhanced industrial-grade protection structure, and innovative signal processing mechanism, achieves the following significant advantages compared to existing scraper conveyor chain breakage detection technologies and products, and all of these advantages are directly derived from the specific technical solution: 1. Breakthrough improvement in detection sensitivity CoFeSiB amorphous wire (μ≥1.2×10⁻⁶) was used. 5 The synergistic design of a 100-turn precision-wound coil achieves a magnetic field detection sensitivity of ≥0.5 mV / Oe, which is 16 times higher than existing Hall elements (≥8 mV / Oe) and 10 times higher than AMR magnetoresistive sensors (≥5 mV / Oe). It can accurately capture the weak magnetic field change of 50~200 Oe at the moment of chain breakage, and reduce the false detection rate to ≤0.01%, completely solving the core pain point of "high false detection rate" in existing technologies. The amorphous wire is centrally fixed (coaxiality ≤0.05mm) to ensure uniform magnetic field coupling, making the detection sensitivity consistency error ≤±0.03 mV / Oe, thus improving the product stability in mass production.

[0044] 2. Response speed meets real-time protection requirements. The 36MHz high sampling rate AD9245 chip, combined with an optimized signal processing link, reduces the overall response time to ≤1ms, a 75% reduction compared to existing technologies (≥4ms). For scraper conveyors with a maximum operating speed of 1.5m / s, the stopping distance after chain breakage is ≤1.5mm, which is far superior to the ≥6mm of existing technologies, effectively preventing the accident from escalating.

[0045] 3. Environmental adaptability suitable for harsh industrial environments Vibration resistance: The silicone rubber buffer composite structure can withstand vibrations of 5~50Hz and acceleration ≤5g, with a vibration displacement of sensitive elements ≤0.05mm and a non-fault working time ≥10000h, which is 10 times better than existing products (≤1000h). Protection rating: E-51 epoxy resin full potting + M12 waterproof joint (fluororubber sealing ring) design, achieving IP65 protection rating, can resist the intrusion of industrial dust with a particle size ≤10μm and short-term spray of ≤0.3MPa, suitable for dusty and humid environments such as coal mines and metallurgical workshops; Temperature drift control: The DS18B20 temperature sensor (accuracy ±0.5℃) + dynamic compensation algorithm ensures that the temperature drift error is ≤0.05 mV / Oe・℃ within the operating temperature range of -20~85℃, which is 75% lower than the existing technology (≥0.2 mV / Oe・℃), ensuring stable detection accuracy in high and low temperature environments.

[0046] 4. Significantly improved installation compatibility and ease of maintenance. Miniaturized structure: The overall size of the probe is optimized to a length ≤95mm and a diameter ≤22mm, which is 37% smaller than the existing general-purpose GMI sensor (length ≥150mm), and can be adapted to the narrow installation gap of scraper conveyor ≥30mm; Standardized interface: radially symmetrical M4 mounting holes (30mm spacing) + L-shaped waist-shaped hole bracket, supporting ±2mm installation distance fine adjustment, on-site installation time ≤30 minutes; M12 waterproof connector (4-pin standardized definition) simplifies wiring, and is easy to plug and unplug during maintenance without the need for professional tools.

[0047] 5. Significantly enhanced anti-interference capability and operational stability. Electromagnetic interference immunity: The AD8628 differential amplifier chip + signal grounding design provides common-mode interference attenuation ≥40dB and a signal-to-noise ratio ≥60dB, effectively resisting electromagnetic interference generated by industrial frequency converters and motors. The false alarm rate is reduced to ≤0.01%, a 98% reduction compared to existing technologies (≥0.5%). Structural stability: The PTFE clamp provides elastic fixation, and the epoxy resin is fully encapsulated to avoid the mechanical stress affecting the amorphous wire. The detection accuracy decay is ≤3% during long-term operation (≥10000h), which is far superior to existing products (≥15%).

[0048] Assembly steps (perform in sequence) (1) Assembly of sensitive element unit 1. Amorphous wire insertion: Slowly insert the CoFeSiB amorphous wire through the capillary glass tube, ensuring that each end protrudes 1mm. Observe with an optical microscope to confirm that the amorphous wire is free from bending and damage. 2. Centering and fixing: Insert the PTFE clamps into both ends of the amorphous wire, fix the clamps to the end face of the capillary glass tube with epoxy resin, and place them in an 80℃ oven to cure for 1 hour. After curing, use a coaxiality tester to calibrate and ensure that the coaxiality between the amorphous wire and the capillary glass tube is ≤0.02mm. 3. Coil winding: A CNC fully automatic winding machine is used to wind 50μm enameled wire on the outside of the capillary glass tube with a tension of 0.05N. The winding parameters are set as follows: 100 turns, winding length 4.6cm, and spacing 0.05mm. After winding, the two ends of the coil are fixed with tape to prevent loosening. 4. Wire end treatment: Leave 10mm on each side of the coil wire end, peel off 3mm of the enamel layer, tin-plat it with a tin bath (temperature 230℃) (plating thickness ≥5μm), solder it to the pin soldering point, and fix the soldering point with epoxy resin.

[0049] Comparison with existing technologies The present invention is compared with the prior art as follows: Note: The sensor in the comparison document uses ion beam sputtering to fabricate a three-dimensional micro coil. Although it has the advantage of miniaturization, the process is complex (requiring ion beam etching equipment), the mass production cost is high (the cost per unit is about twice that of my solution), and its stability in strong vibration environments (scraper machine working scenario) is slightly inferior to the elastic fixing structure of this solution.

[0050] Finally, it should be noted that the above embodiments are only for illustration and not for limiting the technical solutions of the present invention. Any equivalent substitutions, modifications or partial substitutions that do not depart from the spirit and scope of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. A scraper conveyor chain breakage detection probe, comprising a housing, wherein an amorphous wire and a capillary glass tube are disposed within the housing, the amorphous wire being connected to a circuit board, characterized in that, The capillary glass tube is fixed inside the housing by two annular elastic clamps. The two elastic clamps are locked inside the housing. The inner ring of the elastic clamp has an internal support. The two ends of the capillary glass tube are supported on the internal support. There is an epoxy resin potting layer between the internal support and the elastic clamp. The amorphous wire is arranged inside the capillary glass tube. The amorphous wire is coaxial with the capillary glass tube. The capillary glass tube is coaxial with the housing. The outside of the capillary glass tube is wound with an enameled wire coil.

2. The scraper conveyor chain breakage detection probe according to claim 1, characterized in that, The coaxiality between the amorphous wire and the capillary glass tube is ≤0.02mm.

3. The scraper conveyor chain breakage detection probe according to claim 2, characterized in that, The coaxiality between the amorphous wire and the shell is ≤0.05mm.

4. The scraper conveyor chain breakage detection probe according to claim 3, characterized in that, The elastic clamp is a polytetrafluoroethylene elastic clamp.

5. The scraper conveyor chain breakage detection probe according to claim 4, characterized in that, The inner diameter of the elastic clamp and the diameter of the amorphous wire form an interference fit of 0.001 mm.

6. The scraper conveyor chain breakage detection probe according to any one of claims 1-5, characterized in that, A silicone rubber buffer pad is also provided between the outer side of the epoxy resin potting layer and the shell.

7. A method for manufacturing a scraper conveyor chain breakage detection probe according to any one of claims 1-6, characterized in that: include: Amorphous wire insertion: The CoFeSiB amorphous wire is slowly threaded through the capillary glass tube, ensuring that both ends protrude. Observation is performed using an optical microscope to confirm that the amorphous wire is free from bending and damage. Centering and fixing: The PTFE clamps are fitted onto both ends of the amorphous wire, and epoxy resin is applied to fix the clamps to the end face of the capillary glass tube. The tube is then placed in an oven for curing. After curing, the coaxiality is calibrated using a coaxiality tester to ensure that the coaxiality between the amorphous wire and the capillary glass tube is ≤0.02mm. The enameled wire coil is wound using a CNC fully automatic winding machine with constant tension on the outside of the capillary glass tube, and the winding spacing is uniform.

8. The manufacturing method of the scraper conveyor chain breakage detection probe according to claim 7, characterized in that, The cladding of the enameled wire coil is a polyimide enameled layer, and the diameter of the enameled wire coil is 50 μm.

9. The manufacturing method of the scraper conveyor chain breakage detection probe according to claim 8, characterized in that, The ends of the enameled wire coils are tin-plated after the enamel is stripped.

10. The method for manufacturing the scraper conveyor chain breakage detection probe according to claim 9, characterized in that, The thickness of the tin plating layer is ≥5μm.

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