An explosion-proof motor bearing temperature on-line monitoring and fault early warning system

Abstract

This application discloses an explosion-proof online temperature monitoring and fault early warning system for motor bearings, relating to the field of motor bearing condition monitoring technology. The system includes: an explosion-proof temperature sensing module, a signal processing and communication module, a monitoring terminal, and a fault early warning module connected in sequence. The explosion-proof temperature sensing module collects temperature data from the bearings of motors used in coal mine transportation. It is fixed to the bearing housing using a magnetic or flange-type mounting structure, and its outer shell is explosion-proof and meets the explosion-proof standards for underground coal mines. The signal processing and communication module receives and processes the data and wirelessly transmits it to the monitoring terminal. The monitoring terminal displays, stores, and analyzes the data. The fault early warning module triggers an early warning signal based on the analysis results. This system ensures safe operation in the flammable and explosive environment of coal mines, achieving stable real-time online monitoring of motor bearing temperature and timely fault early warning, thus guaranteeing the safe production of coal mine transportation systems.

Description

Technical Field

[0001] This application relates to the field of motor bearing condition monitoring technology, and in particular to an explosion-proof motor bearing temperature online monitoring and fault early warning system. Background Technology

[0002] The underground environment of coal mines contains flammable and explosive substances such as methane and coal dust, imposing mandatory requirements on the explosion-proof performance of electrical equipment. As the core power source for coal mine transportation systems such as belt conveyors, the bearings of motors are among the most prone to failure. Under heavy loads and high-speed operation, bearings are susceptible to abnormal temperature increases due to wear and poor lubrication. If not detected and addressed promptly, this can easily lead to bearing burnout, motor stalling, and the generation of high-temperature sparks, posing a significant safety hazard underground. Existing general-purpose motor bearing temperature monitoring equipment is not specifically designed for the explosion-proof environment of underground coal mines. The equipment casing lacks explosion-proof performance, and the power supply method does not meet coal mine explosion-proof standards, posing a safety risk of electrical sparks igniting flammable gases. Furthermore, the existing equipment has poor installation adaptability and is prone to loosening and detachment under long-term motor vibration conditions, making it impossible to achieve stable and reliable real-time temperature data acquisition. This makes it difficult to meet the needs of long-term online safety monitoring and timely fault warning for motor bearings in underground coal mine transportation systems. Summary of the Invention

[0003] This application provides an explosion-proof online monitoring and fault early warning system for motor bearing temperature. It solves the problems in related technologies where general-purpose motor bearing temperature monitoring equipment is not specifically designed for the explosion-proof environment of underground coal mines, its housing lacks explosion-proof performance, posing a safety hazard, and its mounting structure is prone to loosening and detachment under motor vibration conditions, resulting in unstable temperature data collection.

[0004] According to a first aspect of this application, an explosion-proof motor bearing temperature online monitoring and fault early warning system is provided, comprising:

[0005] An explosion-proof temperature sensing module is used to collect temperature data of the bearings of coal mine transport motors in real time. The signal processing and communication module is connected to the explosion-proof temperature sensing module and is used to receive and process temperature data and wirelessly transmit the data to the monitoring terminal. The monitoring terminal is used to receive data sent by the signal processing and communication module, and to display, store and analyze temperature data. A fault early warning module, connected to the monitoring terminal, is used to trigger an early warning signal based on the analysis results; The explosion-proof temperature sensing module is fixed to the motor bearing seat using a magnetic or flange mounting structure, and its outer shell adopts an explosion-proof design and meets the explosion-proof standards for underground coal mines.

[0006] Optionally, the explosion-proof temperature sensing module includes a platinum resistance temperature sensor and / or an infrared temperature sensor. The sensor is covered with a high-temperature resistant and corrosion-resistant protective layer, and the sensing module has a built-in microprocessor for local temperature data buffering and processing.

[0007] Optionally, the monitoring terminal integrates a data analysis unit, which is configured as follows: Perform real-time trend analysis on the received temperature data; Compare the temperature data with preset temperature thresholds and temperature rise rate thresholds; The health status of the motor bearings is determined based on the comparison results.

[0008] Optionally, the fault early warning module includes a multi-level early warning unit, which is configured as follows: When the temperature exceeds the first threshold or the rate of temperature rise exceeds the preset rate, a primary warning is triggered. When the temperature value continues to exceed the first threshold and reaches the second higher threshold, a medium-level warning is triggered. An emergency warning is triggered when the temperature value approaches or reaches the shutdown threshold.

[0009] Optionally, the system also includes a re-inspection mechanism unit. When a primary or intermediate warning is triggered and manual intervention is performed, the system will pause the warning within a preset delay period and automatically enter the re-inspection state after the delay ends. If the warning condition is detected again within the re-inspection interval, a higher-level warning or alarm will be triggered.

[0010] Optionally, the system also includes a bearing vibration monitoring module for collecting vibration signal data of the motor bearing; The data analysis unit of the monitoring terminal is also configured to combine temperature data and vibration signal data for fusion analysis to comprehensively determine the bearing condition.

[0011] Optionally, the monitoring terminal is also connected to an underground audible and visual alarm and / or a ground remote monitoring center. The warning signal triggered by the fault warning module can synchronously drive the underground audible and visual alarm to operate and upload the warning information to the ground remote monitoring center.

[0012] Optionally, the monitoring terminal has a built-in historical data storage unit that can store historical temperature data and generate temperature change curves, and supports historical data query and export functions.

[0013] Optionally, the power supply module of the system adopts an intrinsically safe power supply or an explosion-proof power supply to provide power to each module.

[0014] This application addresses the challenges of conventional technologies where general-purpose motor bearing temperature monitoring equipment is not specifically designed for the explosion-proof environment of coal mines, lacks explosion-proof housing, and is easily loosened and detached under motor vibration conditions, resulting in unstable temperature data acquisition. This system architecture incorporates an explosion-proof temperature sensing module, a signal processing and communication module, a monitoring terminal, and a fault early warning module. Furthermore, the explosion-proof temperature sensing module utilizes a flameproof housing design that meets coal mine explosion-proof standards and is fixed to the motor bearing housing via magnetic or flange-type mounting structures. This achieves the technical goal of ensuring safe operation of the system in the flammable and explosive environment of coal mines, enabling stable real-time online monitoring of motor bearing temperature and timely fault early warning, thus guaranteeing safe production in coal mine transportation systems.

[0015] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of this application, nor is it intended to limit the scope of this application. Other features of this application will become readily apparent from the following description. Attached Figure Description

[0016] To more clearly illustrate the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the structure of an explosion-proof motor bearing temperature online monitoring and fault early warning system provided in an embodiment of this application. Detailed Implementation

[0018] The following description, in conjunction with the accompanying drawings, illustrates exemplary embodiments of this application, including various details to aid understanding. These should be considered merely exemplary. Therefore, those skilled in the art will recognize that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of this application. Similarly, for clarity and brevity, descriptions of well-known functions and structures are omitted in the following description.

[0019] The following description, with reference to the accompanying drawings, describes an embodiment of the explosion-proof motor bearing temperature online monitoring and fault early warning system of this application.

[0020] Figure 1 This is a schematic diagram of the structure of an explosion-proof motor bearing temperature online monitoring and fault early warning system provided in an embodiment of this application.

[0021] like Figure 1 As shown, the system includes: Explosion-proof temperature sensing module 1 is used to collect temperature data of bearings in coal mine transport motors in real time. The signal processing and communication module 2 is connected to the explosion-proof temperature sensing module 1 and is used to receive and process temperature data and wirelessly transmit the data to the monitoring terminal 3. The monitoring terminal 3 is used to receive data sent by the signal processing and communication module 2, and to display, store and analyze temperature data. Fault warning module 4 is connected to the monitoring terminal 3 and is used to trigger a warning signal based on the analysis results; The explosion-proof temperature sensing module 1 is fixed to the motor bearing seat using a magnetic or flange mounting structure. Its outer shell is designed to be explosion-proof and meets the explosion-proof standards for underground coal mines.

[0022] In this embodiment, the explosion-proof motor bearing temperature online monitoring and fault early warning system disclosed in this invention is specifically designed for bearing condition monitoring of underground coal mine transport motors. The system consists of an explosion-proof temperature sensing module 1, a signal processing and communication module 2, a monitoring terminal 3, and a fault early warning module 4, which are sequentially connected. The system primarily targets the drive motors of transport equipment such as coal mine belt conveyors. Through a modular architecture, it achieves real-time online monitoring and fault early warning of motor bearing temperature. Data exchange between modules is conducted using connection methods that comply with coal mine safety regulations.

[0023] The explosion-proof temperature sensing module 1, serving as the system's data acquisition front-end, is directly fixed to the motor bearing housing. Its outer casing adopts an explosion-proof design, meeting the explosion-proof standards for underground coal mines. This effectively isolates potential electrical sparks generated inside the module from the external flammable and explosive environment, preventing safety accidents. The module offers two installation options: magnetic and flange-mounted. The magnetic force for magnetic mounting is ≥50N, while the flange-mounted version uses M8 bolts with a preload of 30N. Both installation methods ensure stability under long-term motor vibration conditions, preventing loosening and detachment, and guaranteeing the continuity and stability of temperature data acquisition.

[0024] Signal processing and communication module 2 is directly connected to explosion-proof temperature sensing module 1. It receives the raw temperature data collected by explosion-proof temperature sensing module 1, performs preliminary data processing, and then transmits the data wirelessly to monitoring terminal 3. Monitoring terminal 3 is deployed in the underground control room or surface management area. After receiving the wirelessly transmitted temperature data, it performs data visualization, secure storage, and basic analysis. Fault early warning module 4 is connected to monitoring terminal 3 and can promptly trigger corresponding early warning signals based on the data analysis results output by monitoring terminal 3, reminding maintenance personnel to pay attention to the operating status of the motor bearings.

[0025] This application utilizes an explosion-proof temperature sensing module 1, which includes an explosion-proof housing and a magnetic or flange-type mounting structure, to form a complete monitoring and early warning system in conjunction with a signal processing and communication terminal 3 and a fault early warning module 4. This solves the problems of insufficient explosion-proof performance and unstable installation of general monitoring equipment in related technologies, preventing safe and stable operation in coal mines. It achieves the technical effect of ensuring long-term reliable operation of the system in flammable and explosive environments, and realizing real-time online monitoring of motor bearing temperature and timely fault early warning.

[0026] Compared with related technologies, in this embodiment, an explosion-proof temperature sensing module 1 is used to collect temperature data of the bearing of the coal mine transport motor in real time; a signal processing and communication module 2 is connected to the explosion-proof temperature sensing module 1 to receive and process the temperature data and wirelessly transmit the data to the monitoring terminal 3; the monitoring terminal 3 is used to receive the data sent by the signal processing and communication module 2 and realize the display, storage and analysis of the temperature data; a fault early warning module 4 is connected to the monitoring terminal 3 to trigger an early warning signal based on the analysis results; the explosion-proof temperature sensing module 1 is fixed to the motor bearing seat using a magnetic or flange mounting structure, and its outer shell adopts an explosion-proof design and meets the explosion-proof standards for underground coal mines. This technology can solve the problems in related technologies where general-purpose motor bearing temperature monitoring equipment is not specifically designed for the explosion-proof environment of underground coal mines, the outer shell lacks explosion-proof performance, posing safety hazards, and the installation structure is prone to loosening and falling off under motor vibration conditions, making it impossible to stably collect temperature data. It achieves the technical effect of ensuring the safe operation of the system in the flammable and explosive environment of coal mines, realizing stable real-time online monitoring of motor bearing temperature and timely fault early warning, and ensuring the safe production of coal mine transportation systems.

[0027] Optionally, the explosion-proof temperature sensing module 1 includes a platinum resistance temperature sensor and / or an infrared temperature sensor. The sensor is covered with a high-temperature resistant and corrosion-resistant protective layer, and the sensing module has a built-in microprocessor for local temperature data buffering and processing.

[0028] In this embodiment, the explosion-proof temperature sensing module 1 integrates a platinum resistance temperature sensor and / or an infrared temperature sensor, which can be flexibly selected according to the structural characteristics and installation space of different motor bearings. The platinum resistance temperature sensor is suitable for contact temperature measurement, and can directly contact the bearing housing surface to obtain accurate temperature values, while the infrared temperature sensor is suitable for bearing parts that cannot be directly contacted, realizing non-contact temperature acquisition.

[0029] The sensor is uniformly covered with a high-temperature resistant and corrosion-resistant protective layer. The protective layer is made of ceramic or 316L stainless steel and is 2mm thick. It can withstand a temperature range of -40℃ to 200℃, effectively resisting the corrosion of coal dust, moisture and various chemicals in the underground environment, extending the service life of the sensor and ensuring the accuracy of long-term measurements.

[0030] The sensing module also incorporates a microprocessor for buffering and preliminary processing of local temperature data. The microprocessor can be an STM32F4 series chip, equipped with 128KB of local data buffer space. It can perform a moving average filtering algorithm on the acquired raw temperature data to filter out noise signals caused by environmental vibration and electromagnetic interference. The module's sampling frequency is set to 1Hz. The pre-processed temperature data is transmitted to the signal processing and communication module 2 via a shielded cable to reduce interference during data transmission.

[0031] The above structural design improves the accuracy and anti-interference capability of temperature acquisition, enabling the sensing module to adapt to the harsh working environment in coal mines and ensuring the reliability and continuity of temperature data.

[0032] Optionally, the monitoring terminal 3 integrates a data analysis unit, which is configured as follows: Perform real-time trend analysis on the received temperature data; Compare the temperature data with preset temperature thresholds and temperature rise rate thresholds; The health status of the motor bearings is determined based on the comparison results.

[0033] In this embodiment, the monitoring terminal 3 integrates a data analysis unit, which serves as the core data processing component of the system and is responsible for in-depth analysis and status assessment of the received temperature data.

[0034] The data analysis unit first performs real-time trend analysis on the received temperature data. Using an exponentially weighted moving average algorithm with a 10-minute sliding window, the continuously collected temperature data is smoothed, effectively filtering out instantaneous interference signals, accurately identifying long-term temperature trends, and detecting slow, abnormal increases in bearing temperature in advance.

[0035] The data analysis unit compares the processed temperature data with preset temperature thresholds and temperature rise rate thresholds. The preset temperature thresholds are divided into three levels: the first threshold is 80℃, the second threshold is 90℃, and the shutdown threshold is 100℃. The temperature rise rate threshold is set to 5℃ / min. The unit compares the current temperature value with each threshold level in real time and calculates the temperature change per unit time to determine if there is a sudden temperature rise.

[0036] Based on the above comparison results, the data analysis unit comprehensively judges the health status of the motor bearings and classifies the bearing operating status into four levels: normal, caution, warning, and danger. Different levels correspond to different bearing operating conditions, providing accurate data for subsequent fault early warning and maintenance decisions.

[0037] The above configuration enables precise analysis and condition classification of motor bearing temperature, improving the accuracy and timeliness of fault identification and providing reliable support for the early detection of bearing faults.

[0038] Optionally, the fault early warning module 4 includes a multi-level early warning unit, which is configured as follows: When the temperature exceeds the first threshold or the rate of temperature rise exceeds the preset rate, a primary warning is triggered. When the temperature value continues to exceed the first threshold and reaches the second higher threshold, a medium-level warning is triggered. An emergency warning is triggered when the temperature value approaches or reaches the shutdown threshold.

[0039] In this embodiment, the fault early warning module 4 is directly connected to the data analysis unit of the monitoring terminal 3. Its core is a multi-level early warning unit, which can trigger the corresponding level of early warning signal according to the bearing health status judgment result output by the data analysis unit, so as to realize the graded response of bearing fault.

[0040] The multi-level early warning unit first executes the primary early warning logic. When the data analysis unit detects that the bearing temperature exceeds the first threshold of 80℃, or the temperature rise rate per unit time exceeds the preset 5℃ / min, the primary early warning is immediately triggered. The primary early warning is a suggestive warning, used to remind maintenance personnel that the bearing has experienced early temperature anomalies and requires closer attention.

[0041] When the temperature exceeds the first threshold for 5 minutes and further rises to the second threshold of 90°C, the multi-level early warning unit triggers an intermediate warning. The intermediate warning is a cautionary warning, indicating that the abnormal bearing temperature has worsened and there is a risk of further failure, requiring timely on-site inspection and handling by maintenance personnel.

[0042] When the bearing temperature approaches or reaches the shutdown threshold of 100°C, the multi-level early warning unit triggers an emergency warning. The emergency warning is the highest level alarm signal, indicating that the bearing is in a serious fault state and may seize up or burn out at any time, requiring immediate emergency measures such as shutdown.

[0043] By setting up a three-level progressive early warning mechanism, the system can respond in stages according to the severity of bearing temperature anomalies, avoiding false alarms and missed alarms caused by single threshold early warnings. At the same time, it allows maintenance personnel sufficient time to handle faults, improving the reliability and security of the system's early warning.

[0044] Optionally, the system also includes a re-inspection mechanism unit. When a primary or intermediate warning is triggered and manual intervention is performed, the system will pause the warning within a preset delay period and automatically enter the re-inspection state after the delay ends. If the warning condition is detected again within the re-inspection interval, a higher-level warning or alarm will be triggered.

[0045] In this embodiment, the system also includes a re-inspection mechanism unit, which is integrated inside the fault early warning module 4 and works in conjunction with the multi-level early warning unit to verify the actual effect of manual intervention and avoid unnecessary downtime and excessive maintenance caused by false alarms or temporary anomalies.

[0046] The re-inspection mechanism is triggered when the system issues a primary or intermediate alert, and maintenance personnel complete manual intervention and confirm the operation. In emergency alert situations, the re-inspection mechanism is not activated; instead, the highest-level emergency response procedure is executed directly. When the triggering conditions are met, the system will pause the output of the current level alert signal for a preset delay period of 30 minutes to allow sufficient time for the bearing status to recover after manual intervention.

[0047] After the delay period, the system automatically enters a re-inspection state, adjusting the temperature data sampling interval to 1 minute to increase data acquisition density and accurately monitor bearing temperature changes. The re-inspection interval remains consistent with the delay period, also 30 minutes. During the re-inspection interval, the data analysis unit continuously analyzes and judges the temperature data. If no corresponding level of warning condition is detected again, it indicates that manual intervention was effective, and the system automatically returns to normal monitoring status. If a warning condition is detected again, a higher-level warning or alarm signal is directly triggered without needing to go through the original level's duration determination.

[0048] By setting up a re-inspection mechanism unit, it is possible to effectively distinguish between temporary anomalies and persistent faults, reduce unplanned downtime caused by false alarms or minor anomalies, and ensure that faults that have not been completely resolved can be detected and escalated in a timely manner, thus ensuring production continuity while taking into account the safety of equipment operation.

[0049] Optionally, the system also includes a bearing vibration monitoring module for collecting vibration signal data of the motor bearing; The data analysis unit of the monitoring terminal 3 is also configured to combine temperature data and vibration signal data for fusion analysis to comprehensively determine the bearing condition.

[0050] In this embodiment, the system also includes a bearing vibration monitoring module, which is installed alongside the explosion-proof temperature sensing module 1 at the corresponding position in the motor bearing housing. This module is used to collect vibration signal data of the motor bearing during operation in real time. Bearing vibration is an important indicator reflecting the mechanical condition of the bearing, directly reflecting mechanical fault characteristics such as wear, cracks, loosening, and poor lubrication within the bearing. It complements the temperature data, enhancing the comprehensiveness of condition monitoring.

[0051] The bearing vibration monitoring module uses a piezoelectric accelerometer as its core sensing element, which can accurately acquire the acceleration signal of bearing vibration and convert it into a corresponding electrical signal output. The module's sampling frequency is set to 10kHz, which can cover the commonly used range of bearing fault characteristic frequencies, ensuring the capture of high-frequency vibration signals generated by early minor faults. After the acquired vibration signal is filtered and amplified by the signal conditioning circuit inside the module, it is transmitted to the data analysis unit of monitoring terminal 3 for processing.

[0052] The data analysis unit of monitoring terminal 3, based on the original temperature data analysis, has added vibration signal analysis and multi-source data fusion analysis functions. The data analysis unit first performs time-domain and frequency-domain analysis on the vibration signal, extracting time-domain characteristic parameters such as peak value, effective value, and kurtosis of the vibration signal, as well as frequency-domain characteristic parameters such as harmonic frequencies and sidebands, to identify fault characteristics of different parts of the bearing.

[0053] Based on this, the data analysis unit integrates the extracted vibration characteristic parameters with the synchronously acquired temperature data for analysis. When the temperature data shows an abnormal increase, accompanied by vibration characteristic parameters exceeding the normal range, it is determined that the bearing has a high risk of failure. When the temperature data is normal but the vibration characteristics show specific fault frequency components, early latent failures of the bearing can be detected in advance. When a single parameter shows a slight abnormality, it is combined with the status of another parameter for comprehensive verification, effectively reducing the probability of false alarms.

[0054] By adding a bearing vibration monitoring module and realizing the fusion analysis of temperature and vibration data, the operating status characteristics of motor bearings can be fully captured, significantly improving the accuracy of fault identification and early warning capability, avoiding the problems of missed and false alarms caused by single parameter monitoring, and providing more comprehensive and reliable data support for predictive maintenance of bearings.

[0055] Optionally, the monitoring terminal 3 is also connected to an underground audible and visual alarm and / or a ground remote monitoring center. The warning signal triggered by the fault warning module 4 can synchronously drive the underground audible and visual alarm to operate and upload the warning information to the ground remote monitoring center.

[0056] In this embodiment, the monitoring terminal 3 serves as the system's early warning response hub, and simultaneously establishes signal connections with the downhole audible and visual alarm and the ground remote monitoring center. Any level of early warning signal triggered by the fault early warning module 4 will be synchronously distributed to the downhole audible and visual alarm and the ground remote monitoring center, thus constructing an integrated early warning system that combines local response and remote collaboration.

[0057] The underground audible and visual alarm adopts a coal mine-specific explosion-proof design, meeting underground explosion-proof standards and achieving an IP65 protection level, enabling it to adapt to the harsh environment of dampness and dust underground. Different levels of warning signals correspond to different audible and visual output modes. When a primary warning is triggered, the alarm emits a flashing yellow light accompanied by intermittent buzzing; when a medium warning is triggered, it switches to a flashing red light accompanied by a high-frequency intermittent buzzing; when an emergency warning is triggered, it maintains a constant red light and emits a continuous high-frequency buzzing, allowing on-site maintenance personnel to quickly identify the warning level through visual and auditory means and take timely corresponding measures.

[0058] Monitoring terminal 3 transmits data with the ground-based remote monitoring center via industrial Ethernet, with bandwidth sufficient to meet the requirements for simultaneous data upload from multiple monitoring points. After the early warning information is uploaded to the ground-based remote monitoring center, it will be displayed in real-time on the center's large monitoring screen, including key information such as the faulty motor's number, installation location, warning level, real-time temperature data, and the time the warning occurred. The ground-based remote monitoring center will also permanently store all early warning information and generate early warning statistical reports, providing data support for subsequent equipment failure analysis and maintenance plan development.

[0059] Through the above-mentioned connection and synchronous drive design, it is possible to achieve rapid on-site response to early warning signals and remote synchronous monitoring on the ground, forming a complete emergency response closed loop. This ensures that both the underground site and the ground management department can simultaneously grasp the equipment failure status, greatly improving the timeliness and coordination of failure handling and effectively reducing the risk of accidents.

[0060] Optionally, the monitoring terminal 3 has a built-in historical data storage unit that can store historical temperature data and generate temperature change curves, and supports historical data query and export functions.

[0061] In this embodiment, the monitoring terminal 3 has a built-in historical data storage unit, which serves as the core of the system's data management and is responsible for long-term storage of the motor bearing's temperature operation data, providing a data foundation for equipment status retrospection and predictive maintenance.

[0062] The historical data storage unit uses a 1TB SSD as the storage medium, featuring high-speed read / write capabilities and excellent shock resistance, making it suitable for industrial operating environments. The unit automatically stores all collected temperature data and adds a precise timestamp to each data point, achieving a time resolution of one minute, thus completely recording the bearing temperature change process over time. The storage unit generates continuous temperature change curves based on the data, visually displaying the fluctuation patterns and long-term trends of the bearing temperature, facilitating maintenance personnel to quickly identify the evolution of temperature anomalies.

[0063] The historical data storage unit supports flexible historical data query functions. Maintenance personnel can quickly retrieve temperature data and temperature change curves for a corresponding time period based on the motor number and a specified time range. The unit also provides a data export function, supporting the export of queried historical data as CSV or Excel files. The exported files contain complete timestamps and corresponding temperature values, facilitating offline in-depth data analysis and fault tracing.

[0064] By setting up historical data storage units, the temperature operation records of motor bearings can be completely preserved, providing reliable data support for post-failure analysis of bearing failures and the formulation of equipment maintenance plans. This helps maintenance personnel to grasp the long-term operating patterns of bearings and realize the transformation from passive maintenance to proactive predictive maintenance.

[0065] Optionally, the power supply module of the system adopts an intrinsically safe power supply or an explosion-proof power supply to provide power to each module.

[0066] In this embodiment, the system's power supply module provides stable and reliable power support for the entire monitoring and early warning system. It adopts two optional schemes: intrinsically safe power supply or explosion-proof power supply. Both schemes strictly comply with the GB3836 coal mine explosion-proof standard, eliminating the safety risk of electric sparks igniting flammable gases underground from the source.

[0067] Intrinsically safe power supplies limit the voltage, current, and energy parameters of the circuit to ensure that, under normal operation or specified fault conditions, the electrical sparks and thermal effects generated by the circuit cannot ignite explosive mixtures such as methane and coal dust. This type of power supply is suitable for underground mining faces and surrounding areas with high gas concentrations and extremely stringent explosion-proof requirements, possessing the highest level of safety protection capabilities.

[0068] Explosion-proof power supplies enclose all electrical components that may generate sparks within a high-strength explosion-proof enclosure. The enclosure can withstand the pressure generated by the explosion of the internal explosive mixture while preventing the propagation of internal explosion flames to the external environment. This type of power supply has a stronger power supply capacity and is suitable for most underground transport roadways and electromechanical chambers, meeting the power supply needs of multi-monitoring systems.

[0069] The power supply module outputs 24V DC, a common safety voltage level in underground coal mines. The module's enclosure has an IP65 protection rating, effectively resisting the intrusion of coal dust and moisture, and adapting to harsh industrial environments. The power supply module provides independent power supply circuits for the explosion-proof temperature sensing module 1, signal processing and communication module 2, monitoring terminal 3, and fault early warning module 4, preventing a single circuit failure from affecting the operation of the entire system.

[0070] By adopting intrinsically safe or explosion-proof power supplies that meet coal mine explosion-proof standards, the safety hazards of general power supplies in flammable and explosive underground environments can be completely eliminated, providing a continuous and stable power supply for all modules of the system and ensuring the long-term safe and reliable operation of the entire monitoring and early warning system.

[0071] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0072] The above are merely specific embodiments of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to these embodiments, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A system for online monitoring and fault early warning of explosion-proof motor bearing temperature, characterized in that, include: An explosion-proof temperature sensing module is used to collect temperature data of the bearings of coal mine transport motors in real time. The signal processing and communication module is connected to the explosion-proof temperature sensing module and is used to receive and process temperature data and wirelessly transmit the data to the monitoring terminal. The monitoring terminal is used to receive data sent by the signal processing and communication module, and to display, store and analyze temperature data. A fault early warning module, connected to the monitoring terminal, is used to trigger an early warning signal based on the analysis results; The explosion-proof temperature sensing module is fixed to the motor bearing seat using a magnetic or flange mounting structure, and its outer shell adopts an explosion-proof design and meets the explosion-proof standards for underground coal mines.

2. The explosion-proof motor bearing temperature online monitoring and fault early warning system according to claim 1, characterized in that, The explosion-proof temperature sensing module includes a platinum resistance temperature sensor and / or an infrared temperature sensor. The sensor is covered with a high-temperature resistant and corrosion-resistant protective layer, and the sensing module has a built-in microprocessor for local temperature data buffering and processing.

3. The explosion-proof motor bearing temperature online monitoring and fault early warning system according to claim 1, characterized in that, The monitoring terminal integrates a data analysis unit, which is configured as follows: Perform real-time trend analysis on the received temperature data; Compare the temperature data with preset temperature thresholds and temperature rise rate thresholds; The health status of the motor bearings is determined based on the comparison results.

4. The explosion-proof motor bearing temperature online monitoring and fault early warning system according to claim 1, characterized in that, The fault early warning module includes a multi-level early warning unit, which is configured as follows: When the temperature exceeds the first threshold or the rate of temperature rise exceeds the preset rate, a primary warning is triggered. When the temperature value continues to exceed the first threshold and reaches the second higher threshold, a medium-level warning is triggered. An emergency warning is triggered when the temperature value approaches or reaches the shutdown threshold.

5. The explosion-proof motor bearing temperature online monitoring and fault early warning system according to claim 4, characterized in that, The system also includes a re-inspection mechanism unit. When a primary or intermediate warning is triggered and manual intervention is performed, the system will pause the warning within a preset delay period and automatically enter the re-inspection state after the delay ends. If the warning condition is detected again within the re-inspection interval, a higher-level warning or alarm will be triggered.

6. The explosion-proof motor bearing temperature online monitoring and fault early warning system according to claim 1, characterized in that, The system also includes a bearing vibration monitoring module for collecting vibration signal data of the motor bearing; The data analysis unit of the monitoring terminal is also configured to combine temperature data and vibration signal data for fusion analysis to comprehensively determine the bearing condition.

7. The explosion-proof motor bearing temperature online monitoring and fault early warning system according to claim 1, characterized in that, The monitoring terminal is also connected to an underground audible and visual alarm and / or a ground remote monitoring center. The warning signal triggered by the fault warning module can synchronously drive the underground audible and visual alarm to operate and upload the warning information to the ground remote monitoring center.

8. The explosion-proof motor bearing temperature online monitoring and fault early warning system according to claim 1, characterized in that, The monitoring terminal has a built-in historical data storage unit, which can store historical temperature data and generate temperature change curves, and supports historical data query and export functions.

9. The explosion-proof motor bearing temperature online monitoring and fault early warning system according to claim 1, characterized in that, The power supply module of the system adopts intrinsically safe power supply or explosion-proof power supply to provide power to each module.

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