A fault analysis method for a rock drill

Abstract

The application provides a kind of excavator fault analysis method, comprising the following steps: according to the preset sampling frequency, the no-load current value of excavator under no-load running state is collected;The average value of the no-load current value of the excavator in the first preset time period under normal no-load running state is taken as the historical reference value;According to the preset calculation formula, at least one of the average value of the no-load current value in the second preset time period, the average growth rate of the average value of the no-load current value in the second preset time period, the moving average growth rate of the no-load current value in the third preset time period and the fluctuation rate of the no-load current value in the fourth preset time period is calculated;Determine the cause of the failure of the excavator;Output the cause of the failure of the excavator.This method greatly improves the ability to identify the cause of the failure;Reduce the dependence on fixed threshold set by artificial experience, and reduce false alarm and missed alarm;Realize the integration of prediction and early warning;Improve the accuracy of excavator fault analysis.

Description

Technical Field

[0001] This invention relates to the field of roadheader technology, and in particular to a roadheader fault analysis method. Background Technology

[0002] Roadheader-anchor (BAR) machines are core equipment for integrated tunneling and support operations in coal mines, and their operating status directly affects mine production efficiency and operational safety. During operation, BAR machines operate under heavy loads, vibration, humidity, and dusty environments, making them prone to malfunctions such as motor abnormalities, mechanical jamming, poor electrical contact, insulation aging, and power device damage.

[0003] Current methods for analyzing roadheader / anchor machine (BOOM) faults mainly rely on overcurrent alarms, periodic inspections, or reactive maintenance. Overcurrent alarms typically use fixed thresholds set based on human experience, leading to inaccurate fault analysis results. Periodic inspections or reactive maintenance methods cannot promptly identify early-stage, latent faults based on the BOOM's operating parameters. Summary of the Invention

[0004] This invention provides a method for analyzing the failure of a roadheader and anchor machine, in order to solve the technical problem that existing roadheader and anchor machine failure analysis methods cannot accurately or timely identify the cause of failure.

[0005] To address the aforementioned technical problems, this invention provides a method for analyzing the failure of a roadheader / anchor machine, comprising the following steps:

[0006] S1. Collect the no-load current value of the tunneling and anchoring machine under no-load operation according to the preset sampling frequency;

[0007] S2. The average value of the no-load current during the first preset time period when the tunneling and anchoring machine is in normal no-load operation is used as the historical benchmark value.

[0008] S3. According to the preset calculation formula, calculate at least one of the following: the average value of the no-load current value in the second preset time period, the average growth rate of the average value of the no-load current value in the second preset time period, the moving average growth rate of the no-load current value in the third preset time period, and the volatility of the no-load current value in the fourth preset time period, wherein the time corresponding to the first preset time period is earlier than the time corresponding to the second preset time period, the third preset time period, and the fourth preset time period, and the duration of the third preset time period, the second preset time period, and the fourth preset time period gradually decreases;

[0009] S4. Determine the cause of the failure of the anchor-drilling machine based on the average value of the no-load current value in the second preset time period, the average growth rate of the average value of the no-load current value in the second preset time period, the moving average growth rate of the no-load current value in the third preset time period, the fluctuation rate of the no-load current value in the fourth preset time period, and the preset judgment rules.

[0010] S5. Output the cause of the failure of the tunneling and anchoring machine.

[0011] Preferably, the first preset time period is 20 to 30 days.

[0012] Preferably, the second preset time period is 1 day, and the average growth rate of the average value of the no-load current value within the second preset time period is calculated by the following formula: Where g represents the average daily growth rate of no-load current. This represents the average value of the no-load current for that day. This represents the historical baseline value.

[0013] Preferably, the third preset time period is 5 to 7 days, and the moving average growth rate of the no-load current value within the third preset time period is calculated using the following formula: Where G represents the moving average growth rate of the no-load current value over N days, and N represents the number of days corresponding to the third preset time period. This represents the average growth rate of the daily no-load current on day i.

[0014] Preferably, the fourth preset time period is 1 day or 2 days, and the fluctuation rate of the no-load current value within the fourth preset time period is calculated by the following formula: ,in, Indicates volatility. This indicates the maximum no-load current value within the fourth preset time period. This represents the minimum no-load current value within the fourth preset time period. This represents the average value of all no-load current values ​​within the fourth preset time period.

[0015] Preferably, step S4 includes the following steps: if the average daily no-load current growth rate is ≥10% for 3 consecutive days, the cause of the fault is determined to be at least one of the following: power supply voltage fluctuation, three-phase imbalance, capacitor aging and initial bearing wear.

[0016] If the average daily no-load current is ≥1.04× If the cause of the fault is determined to be at least one of impeller blockage, lubrication failure, or abnormal inverter output, then the fault can be identified as being caused by at least one of the following:

[0017] If the 7-day moving average growth rate is greater than 30%, the cause of the fault is determined to be at least one of the following: winding short circuit, mechanical jamming, and power device breakdown.

[0018] If the volatility is greater than 15%, the cause of the failure is determined to be at least one of poor contact, insulation breakdown, and battery equalization failure.

[0019] Preferably, step S5 includes the following steps: outputting graded early warning information based on a preset multi-level early warning mechanism and the cause of failure of the tunneling and anchoring machine.

[0020] Preferably, step S5 includes the following steps: if the average daily growth rate of no-load current and the moving average growth rate are between 10% and 20%, a yellow warning is issued, and a reminder is given to strengthen equipment inspection and infrared temperature measurement.

[0021] If the average daily growth rate of no-load current and the moving average growth rate are between 20% and 30%, an orange warning will be issued, and production will be restricted and offline diagnostics will be performed.

[0022] If the daily average growth rate of no-load current and the moving average growth rate are greater than 30%, a red warning will be issued, prompting an immediate shutdown and the commencement of a winding turn withstand voltage test.

[0023] The present invention provides a fault analysis method for roadheader and anchor machine, which has the following technical effects:

[0024] 1. Early latent fault identification is achieved through the multi-dimensional characteristics of no-load current values, which significantly improves the ability to identify fault causes compared to traditional instantaneous value monitoring;

[0025] 2. By using historical benchmark values ​​with adaptive changes as dynamic thresholds, the reliance on fixed thresholds set by human experience is reduced, and false alarms and false negatives are decreased.

[0026] 3. Establish a complete closed loop of fault type, current characteristics, early warning level, and handling measures to achieve integrated prediction and early warning;

[0027] 4. Supports sliding windows and trend judgment, adapts to complex working conditions of roadheader and anchor machine, and improves the accuracy of roadheader and anchor machine fault analysis. Attached Figure Description

[0028] Figure 1 This is a flowchart of a fault analysis method for a tunneling and anchoring machine provided in an embodiment of the present invention. Detailed Implementation

[0029] To make the objectives, advantages, and features of this invention clearer, the following detailed description of a roadheader / anchor machine failure analysis method proposed by this invention is provided in conjunction with the accompanying drawings. It should be noted that the drawings are all in a very simplified form and use non-precise proportions, and are only used to facilitate and clarify the explanation of the embodiments of this invention.

[0030] In the description of this invention, the terms "first," "second," and other qualifiers are added for convenience of description and reference, and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with qualifiers such as "first" and "second" may explicitly or implicitly include one or more of that feature.

[0031] like Figure 1 As shown, the present invention provides a method for analyzing the failure of a roadheader and anchor machine, comprising the following steps:

[0032] S1. Collect the no-load current value of the roadheader under no-load operation according to the preset sampling frequency. The preset sampling frequency can be adjusted according to the sampling cost and fault analysis accuracy. The higher the sampling frequency, the higher the sampling cost and the higher the fault analysis accuracy.

[0033] S2. The average value of the no-load current during the first preset time period under normal no-load operation of the roadheader is taken as the historical benchmark value. Normal no-load operation of the roadheader means that the roadheader is in no-load operation and the no-load current value is within the preset normal range. When the roadheader is running under no-load, the cutting machine stops and the hydraulic system is in standby mode.

[0034] Preferably, the first preset time period is 20 to 30 days. For example, the first preset time period can be 30 days, in which case the historical benchmark value represents the average value of the no-load current of the roadheader under normal no-load operation over 30 days. The historical benchmark value calculated based on the no-load current value under normal no-load operation over 20 to 30 days has real-time and adaptive properties, which can reduce the dependence on fixed thresholds set by manual experience and reduce false alarms and missed alarms.

[0035] S3. According to the preset calculation formula, calculate at least one of the following: the average value of the no-load current value in the second preset time period, the average growth rate of the average value of the no-load current value in the second preset time period, the moving average growth rate of the no-load current value in the third preset time period, and the volatility of the no-load current value in the fourth preset time period. The time corresponding to the first preset time period is earlier than the time corresponding to the second preset time period, the third preset time period, and the fourth preset time period, and the duration of the third preset time period, the second preset time period, and the fourth preset time period gradually decreases.

[0036] Preferably, the second preset time period is 1 day, and the average growth rate of the average value of the no-load current value within the second preset time period is calculated by the following formula: Where g represents the average daily growth rate of no-load current. This represents the average value of the no-load current for that day. This represents the historical baseline value. This formula uses one day as a dividing line for the no-load current value, and by analyzing the no-load current value of that day, it determines whether the roadheader experienced a malfunction that day.

[0037] Preferably, the third preset time period is 5 to 7 days, and the moving average growth rate of the no-load current value within the third preset time period is calculated using the following formula: Where G represents the moving average growth rate of the no-load current value over N days, and N represents the number of days corresponding to the third preset time period. This represents the average daily growth rate of the no-load current on day i. N can be 5, 6, or 7 days. By analyzing the average daily growth rate of the no-load current over multiple days, short-term random fluctuations can be eliminated and trend anomalies can be identified.

[0038] Preferably, the fourth preset time period is 1 day or 2 days, and the fluctuation rate of the no-load current value within the fourth preset time period is calculated by the following formula: ,in, Indicates volatility. This indicates the maximum no-load current value within the fourth preset time period. This represents the minimum no-load current value within the fourth preset time period. This represents the average value of all no-load current values ​​within the fourth preset time period. The fourth preset time period is a user-selected time frame, essentially a moving time window that can be 1 day, 2 days, or other durations. By analyzing the fluctuation rate of the no-load current values, it is possible to determine whether the roadheader has malfunctioned.

[0039] S4. Based on the average value of the no-load current during the second preset time period, the average growth rate of the average value of the no-load current during the second preset time period, the moving average growth rate of the no-load current during the third preset time period, the fluctuation rate of the no-load current during the fourth preset time period, and the preset judgment rules, determine the cause of the failure of the tunneling and anchoring machine. Preferably, step S4 includes the following steps: if the average daily growth rate of the no-load current for three consecutive days is ≥10%, then the cause of the failure is determined to include at least one of the following: power supply voltage fluctuation, three-phase imbalance, capacitor aging, and initial bearing wear;

[0040] If the average daily no-load current is ≥1.04× If the cause of the fault is determined to be at least one of impeller blockage, lubrication failure, or abnormal inverter output, then the fault can be identified as being caused by at least one of the following:

[0041] If the 7-day moving average growth rate is greater than 30%, the cause of the fault is determined to be at least one of the following: winding short circuit, mechanical jamming, and power device breakdown.

[0042] If the volatility is greater than 15%, the cause of the failure is determined to be at least one of poor contact, insulation breakdown, and battery equalization failure.

[0043] By statistically analyzing the relationship between changes in different parameters and the causes of roadheader failures, the causes of roadheader failures can be inferred based on changes in parameters.

[0044] S5. Output the cause of the failure of the tunneling and anchoring machine. Preferably, step S5 includes the following steps: if the average daily growth rate of no-load current and the moving average growth rate are between 10% and 20%, a yellow warning is output, and a suggestion is made to strengthen equipment inspection and infrared temperature measurement;

[0045] If the average daily growth rate of no-load current and the moving average growth rate are between 20% and 30%, an orange warning will be issued, and production will be restricted and offline diagnostics will be performed.

[0046] If the daily average growth rate of no-load current and the moving average growth rate are greater than 30%, a red warning will be issued, prompting an immediate shutdown and the commencement of a winding turn withstand voltage test.

[0047] The three-level early warning mechanism can distinguish the cause and severity of faults, facilitating maintenance personnel to take appropriate maintenance actions based on the warnings. After step S5 is executed, the collected no-load current value, calculated values, fault cause, and prompt information can be stored for updating historical reference values. .

[0048] The specific implementation examples are as follows:

[0049] Example 1: Early Warning of Initial Bearing Wear

[0050] Historical benchmark value of roadheader =85A, the daily average current for three consecutive days is 94A, 95A and 95A respectively, and the calculated average growth rate g of the daily average no-load current is 10.6%, 11.8% and 11.8% respectively, which meets the requirement of a continuous three-day growth of ≥10%; the vibration value can be monitored simultaneously >100μm, the system judges it as the initial wear of the bearing; triggers a yellow warning, prompting to strengthen inspection and infrared temperature measurement, and track the current trend change.

[0051] Example 2: Pump Blockage Early Warning

[0052] The daily average no-load current of the tunneling and anchoring machine rose to 89A, which meets the requirement of I≥1.04×85=88.4A; the system determined that the inlet filter was clogged or the lubrication failed; an orange alert was triggered, production was restricted and offline investigation was carried out.

[0053] Example 3: Winding Short Circuit / Mechanical Locked Rotor Protection

[0054] The 7-day moving average growth rate of the tunneling and anchoring machine reached 32%, and the instantaneous current value exceeded 130% of the rated value and lasted for 120ms; the system judged it to be a short circuit in the motor winding or mechanical stall; a red warning was triggered, the power was cut off within 0.5 seconds, and the shutdown protection was activated.

[0055] In summary, the fault analysis method for roadheader provided by this invention has the following technical effects:

[0056] 1. Early latent fault identification is achieved through the multi-dimensional characteristics of no-load current values, which significantly improves the ability to identify fault causes compared to traditional instantaneous value monitoring;

[0057] 2. By using historical benchmark values ​​with adaptive changes as dynamic thresholds, the reliance on fixed thresholds set by human experience is reduced, and false alarms and false negatives are decreased.

[0058] 3. Establish a complete closed loop of fault type, current characteristics, early warning level, and handling measures to achieve integrated prediction and early warning;

[0059] 4. Supports sliding windows and trend judgment, adapts to complex working conditions of roadheader and anchor machine, and improves the accuracy of roadheader and anchor machine fault analysis.

[0060] The above description is only a description of preferred embodiments of the present invention and is not intended to limit the scope of the present invention in any way. Any changes or modifications made by those skilled in the art based on the above disclosure shall fall within the protection scope of the present invention.

Claims

1. A method for analyzing the failures of a roadheader / anchor operator, characterized in that, Includes the following steps: S1. Collect the no-load current value of the tunneling and anchoring machine under no-load operation according to the preset sampling frequency; S2. The average value of the no-load current during the first preset time period when the tunneling and anchoring machine is in normal no-load operation is used as the historical benchmark value. S3. According to the preset calculation formula, calculate at least one of the following: the average value of the no-load current value in the second preset time period, the average growth rate of the average value of the no-load current value in the second preset time period, the moving average growth rate of the no-load current value in the third preset time period, and the volatility of the no-load current value in the fourth preset time period, wherein the time corresponding to the first preset time period is earlier than the time corresponding to the second preset time period, the third preset time period, and the fourth preset time period, and the duration of the third preset time period, the second preset time period, and the fourth preset time period gradually decreases; S4. Determine the cause of the failure of the anchor-drilling machine based on the average value of the no-load current value in the second preset time period, the average growth rate of the average value of the no-load current value in the second preset time period, the moving average growth rate of the no-load current value in the third preset time period, the fluctuation rate of the no-load current value in the fourth preset time period, and the preset judgment rules. S5. Output the cause of the failure of the tunneling and anchoring machine.

2. The method for analyzing the failure of a roadheader as described in claim 1, characterized in that, The first preset time period is from the 20th to the 30th.

3. The method for analyzing the failure of a roadheader as described in claim 1, characterized in that, The second preset time period is 1 day, and the average growth rate of the average value of the no-load current value within the second preset time period is calculated by the following formula: Where g represents the average daily growth rate of no-load current. This represents the average value of the no-load current for that day. This represents the historical baseline value.

4. The method for analyzing the failure of a roadheader as described in claim 3, characterized in that, The third preset time period is 5 to 7 days, and the moving average growth rate of the no-load current value within the third preset time period is calculated using the following formula: Where G represents the moving average growth rate of the no-load current value over N days, and N represents the number of days corresponding to the third preset time period. This represents the average growth rate of the daily no-load current on day i.

5. The method for analyzing the failure of a roadheader as described in claim 1, characterized in that, The fourth preset time period is 1 day or 2 days, and the fluctuation rate of the no-load current value within the fourth preset time period is calculated by the following formula: ,in, Indicates volatility. This indicates the maximum no-load current value within the fourth preset time period. This represents the minimum no-load current value within the fourth preset time period. This represents the average value of all no-load current values ​​within the fourth preset time period.

6. The method for analyzing the failure of a roadheader as described in claim 3, characterized in that, Step S4 includes the following steps: If the average daily no-load current growth rate is ≥10% for 3 consecutive days, the cause of the fault is determined to be at least one of the following: power supply voltage fluctuation, three-phase imbalance, capacitor aging, and initial bearing wear. If the average daily no-load current is ≥1.04× If the cause of the fault is determined to be at least one of impeller blockage, lubrication failure, or abnormal inverter output, then the fault can be identified as being caused by at least one of the following: If the 7-day moving average growth rate is greater than 30%, the cause of the fault is determined to be at least one of the following: winding short circuit, mechanical jamming, and power device breakdown. If the volatility is greater than 15%, the cause of the failure is determined to be at least one of poor contact, insulation breakdown, and battery equalization failure.

7. The method for analyzing the failure of a roadheader as described in claim 6, characterized in that, Step S5 includes the following steps: outputting graded early warning information based on the preset multi-level early warning mechanism and the cause of the tunneling and anchoring machine failure.

8. The method for analyzing the failure of a roadheader as described in claim 7, characterized in that, Step S5 includes the following steps: If the average daily growth rate of no-load current and the moving average growth rate are between 10% and 20%, a yellow warning will be issued, and a reminder will be given to strengthen equipment inspection and infrared temperature measurement. If the average daily growth rate of no-load current and the moving average growth rate are between 20% and 30%, an orange warning will be issued, and production will be restricted and offline diagnostics will be performed. If the daily average growth rate of no-load current and the moving average growth rate are greater than 30%, a red warning will be issued, prompting an immediate shutdown and the commencement of a winding turn withstand voltage test.

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