Crusher liner impact force distribution detection method and system integrating pressure sensor

Abstract

The present application relates to the technical field of crusher detection, and discloses a crusher liner impact force distribution detection method and system integrated with a pressure sensor, the method comprising: based on an impact energy space distribution prior model, implementing a non-uniform variable density sensor array layout on a liner working surface; using a full parallel synchronous acquisition architecture, real-time acquisition of impact force response signals of the non-uniform variable density sensor array layout; according to the position coordinates and impact force amplitude in the impact force response signals, constructing a synchronous impact force space distribution matrix of the liner working surface; performing impact energy space-time mapping calculation on the synchronous impact force space distribution matrix to obtain an impact energy density distribution graph; based on the impact energy density distribution graph and a pre-stored liner material wear rate-impact energy density mapping curve, evaluating the wear state and residual life of each region of the liner; the present application can improve the accuracy of crusher liner impact force distribution detection.

Description

Technical Field

[0001] This invention relates to the field of crusher testing technology, and in particular to a method and system for detecting the impact force distribution of crusher liners using an integrated pressure sensor. Background Technology

[0002] Existing crusher liner wear monitoring technologies mainly employ two approaches: one is to embed matrix-type wear detection rods or ultrasonic thickness gauges into the liner to measure the liner thickness changes and wear distribution in real time; the other is to establish a crushing force distribution model on the liner surface based on liner wear theory and combined with extrusion crushing simulation experiments, and then use ultrasonic sensors to measure the wear amount to recursively deduce the stress state of the liner. The implementation of these schemes relies on discretizing the liner working surface using a uniform grid and treating the impact force distribution as a quasi-static field quantity that can be indirectly derived from the wear amount. This indirect measurement and uniform sampling architecture necessitates the simultaneous deployment of multiple types of sensors and reliance on a complex wear-force conversion model, increasing the system's hardware complexity and signal processing difficulty.

[0003] Under actual crusher operating conditions, material impact exhibits millisecond-level transient characteristics and significant spatial non-uniformity. Uniform grid sampling struggles to capture the spatial gradient changes of impact force in local high-energy regions, and indirect derivation methods cannot accurately reflect the real-time causal relationship between impact force and wear. Furthermore, the lack of a unified time base among the measuring points and the temporal misalignment of impact response signals from different sampling channels prevent the spatial reconstruction of the stress state at each measuring point at the same moment within a unified time coordinate system. This leads to problems such as: difficulty in reconstructing the true spatial distribution of transient impact force on the liner's working surface; and the significant time lag and cumulative error inherent in methods that infer stress state based on wear, making it difficult to support a refined assessment of the wear state in different areas of the liner. Summary of the Invention

[0004] This invention provides a method and system for detecting the impact force distribution of crusher liners using an integrated pressure sensor, in order to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides a method for detecting the impact force distribution of a crusher liner using an integrated pressure sensor, comprising: S1: Based on the prior model of spatial distribution of impact energy, a non-uniform variable density sensor array layout is implemented on the working surface of the liner. S2: It adopts a fully parallel synchronous acquisition architecture to acquire the impact force response signal of the non-uniform variable density sensor array layout in real time; S3: Construct the synchronous impact force spatial distribution matrix of the working surface of the liner plate based on the position coordinates and impact force amplitude in the impact force response signal; S4: Perform spatiotemporal mapping calculation of impact energy on the spatial distribution matrix of synchronous impact force to obtain the impact energy density distribution map; S5: Based on the impact energy density distribution map and the pre-stored liner material wear rate-impact energy density mapping curve, evaluate the wear status and remaining life of each area of ​​the liner.

[0006] To address the aforementioned problems, the present invention also provides a crusher liner impact force distribution detection system integrating a pressure sensor, the system comprising: The arrangement module is used to implement a non-uniform variable density sensor array layout on the working surface of the liner plate based on a prior model of the spatial distribution of impact energy. The impact acquisition module is used to acquire impact force response signals in real time using a fully parallel synchronous acquisition architecture with a non-uniform variable density sensor array layout. The spatial distribution analysis module is used to construct the synchronous impact force spatial distribution matrix of the liner working surface based on the position coordinates and impact force amplitude in the impact force response signal. The energy density calculation module is used to perform spatiotemporal mapping calculations of impact energy on the spatial distribution matrix of synchronous impact force to obtain an impact energy density distribution map. The condition assessment module is used to assess the wear status and remaining life of each region of the liner based on the impact energy density distribution map and the pre-stored liner material wear rate-impact energy density mapping curve.

[0007] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention constructs a priori model of impact energy spatial distribution based on historical operating data to guide the implementation of a non-uniform variable density sensor array layout on the liner working face. It employs a fully parallel synchronous acquisition architecture to acquire impact force response signals from each measuring point in real time. Furthermore, it correlates the synchronously acquired impact force amplitude with the position coordinates to construct a synchronous impact force spatial distribution matrix. By performing a spatiotemporal mapping of impact energy on this matrix, an impact energy density distribution map is obtained. Finally, the wear state of each region is evaluated by combining the material wear rate-energy density mapping curve. Therefore, this invention fundamentally overcomes the inherent defects of the prior art, such as the difficulty in capturing spatial gradient changes in high-energy regions due to uniform sampling, and the introduction of time delay and cumulative errors by indirect derivation methods. It achieves a direct physical mapping from transient impact force response to wear state assessment, providing a foundation for wear state assessment of crusher liners with in-situ, real-time, and high spatial resolution capabilities.

[0008] 2. In practical implementation, how to convert the impact force response data of discrete measuring points into regionalized physical quantities that can characterize the material wear driving force is a key factor affecting the accuracy of wear assessment. To this end, after constructing a synchronous impact force spatial distribution matrix, this invention further extracts the impact force amplitude time series at each sensor location and determines the duration and representative amplitude value of each impact. The product of the representative amplitude value and duration of each impact at the same location is accumulated to obtain the cumulative impact effect. This cumulative effect is then divided by the corresponding detection area to obtain the impact energy density value of each detection area. This additional processing transforms the discrete measuring point impact data into a regionalized wear driving force index with clear physical dimensions (energy / area). Therefore, based on the synchronous acquisition and spatial distribution reconstruction established in the independent claims, this further improves the accuracy and regional precision of the wear state assessment results in characterizing the material removal mechanism. Attached Figure Description

[0009] Figure 1 This is a schematic flowchart of a crusher liner impact force distribution detection method with an integrated pressure sensor provided in an embodiment of the present invention. Figure 2 This is a functional block diagram of a crusher liner impact force distribution detection system with integrated pressure sensor provided in an embodiment of the present invention.

[0010] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0011] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0012] This application provides a method for detecting the impact force distribution of a crusher liner using an integrated pressure sensor. The execution entity of this method includes, but is not limited to, at least one of the following electronic devices that can be configured to execute the method provided in this application: a server, a terminal, etc. In other words, the method for detecting the impact force distribution of a crusher liner using an integrated pressure sensor can be executed by software or hardware installed on a terminal device or a server device. The server includes, but is not limited to, a single server, a server cluster, a cloud server, or a cloud server cluster. The server can be an independent server or a cloud server that provides basic cloud computing services such as cloud services, cloud databases, cloud computing, cloud functions, cloud storage, network services, cloud communication, middleware services, domain name services, security services, content delivery networks (CDNs), and big data and artificial intelligence platforms.

[0013] Reference Figure 1 The diagram shown is a flowchart illustrating a method for detecting the impact force distribution of a crusher liner using an integrated pressure sensor, according to an embodiment of the present invention. In this embodiment, the method for detecting the impact force distribution of a crusher liner using an integrated pressure sensor includes: S1: Based on the prior model of spatial distribution of impact energy, a non-uniform variable density sensor array layout is implemented on the working surface of the liner. In this embodiment of the invention, the construction process of the prior model for the spatial distribution of impact energy is as follows.

[0014] Acquire impact event records at each detection point of the crusher during its historical operating cycle.

[0015] The data recorded for this impact event includes the time of impact and the magnitude of the impact.

[0016] The historical operation cycle can be set as a continuous time period between thirty and ninety days, such as sixty days.

[0017] The selected time period should cover the complete operating scenarios of the crusher processing different batches of materials, different feed particle sizes, and different operating conditions.

[0018] Based on the impact event record data, the total number of impacts and the cumulative impact amplitude at each detection point within a unit time window are statistically analyzed.

[0019] The unit time window can be set to one hour, four hours, or eight hours. The specific value is preset by the operator based on the actual operating rate of the crusher and the frequency of impact events.

[0020] After the statistics are completed, the working face of the liner is divided into multiple impact energy level zones based on the total number of impacts and the cumulative impact amplitude.

[0021] Multiple impact energy level zones include at least a high impact energy zone, a medium impact energy zone, and a low impact energy zone.

[0022] When dividing the data, the total number of impacts and the cumulative impact amplitude at each detection point can be normalized and then weighted and summed to obtain the comprehensive impact energy index for each detection point.

[0023] The comprehensive impact energy index is arranged in descending order. The area covered by the first 25% to 35% of the detection points is taken as the high impact energy area, the area covered by the middle 40% to 50% of the detection points is taken as the medium impact energy area, and the area covered by the last 20% to 30% of the detection points is taken as the low impact energy area.

[0024] The values ​​of the above percentage examples can be obtained and preset by the operator based on extensive experience, experiments, or statistics.

[0025] The results of dividing the impact energy level regions are used as a priori models for the spatial distribution of impact energy.

[0026] Using the above methods, a spatial distribution prior model reflecting the long-term statistical law of impact energy on the working face of the liner plate was constructed using historical operating data, providing a basis for subsequent sensor layout.

[0027] In one feasible implementation scheme, based on the prior model of impact energy spatial distribution, the specific process of implementing a non-uniform variable density sensor array layout on the working surface of the liner is as follows.

[0028] Based on the prior model of impact energy spatial distribution, the location ranges of high impact energy region, medium impact energy region and low impact energy region on the working surface of the liner are determined.

[0029] Sensors are deployed at a first spacing in the high impact energy region, at a second spacing in the medium impact energy region, and at a third spacing in the low impact energy region.

[0030] The first spacing is smaller than the second spacing, and the second spacing is smaller than the third spacing.

[0031] The value of the first spacing can be between 20 mm and 40 mm, for example, 30 mm.

[0032] The second spacing can be between 50 and 80 millimeters, for example, 65 millimeters.

[0033] The value of the third spacing can be between 100 mm and 150 mm, for example, 120 mm.

[0034] The specific values ​​of the aforementioned spacing are pre-set by the operator after comprehensive calculation based on the total area of ​​the working surface of the liner, the total number of sensors, and the area ratio of each impact energy zone.

[0035] The general principle is that the sensor deployment density in high-impact energy areas per unit area should be higher than that in medium-impact energy areas, and the sensor deployment density in medium-impact energy areas should be higher than that in low-impact energy areas.

[0036] By employing the aforementioned non-uniform variable density layout, the spatial sampling resolution of high-impact energy regions is improved under the condition of a limited total number of sensors, avoiding the problem of insufficient sampling in high-gradient regions and redundant sampling in low-gradient regions under the uniform array method.

[0037] In another feasible implementation scheme, the first spacing can be 25 mm to 35 mm, the second spacing can be 60 mm to 75 mm, and the third spacing can be 110 mm to 140 mm.

[0038] In another feasible implementation scheme, the sensor array can adopt a rectangular grid layout or a honeycomb hexagonal grid layout.

[0039] When a rectangular grid layout is used, the row spacing and column spacing in each impact energy region can be equal or unequal.

[0040] When a honeycomb hexagonal grid layout is used, each sensor is arranged in a regular hexagonal vertices on the working surface of the liner, and the center distance between adjacent sensors is the spacing value corresponding to that area.

[0041] Rectangular grid layouts are suitable for regularly shaped liner working surfaces, while honeycomb hexagonal grid layouts can provide higher spatial coverage uniformity with the same number of sensors.

[0042] Regardless of which layout method is adopted, transition sensors should be installed at the boundaries between each impact energy zone.

[0043] The spacing between transition sensors is between the spacing values ​​of two adjacent areas to avoid sampling blind spots at the boundary of areas.

[0044] In the embodiments of this application, any of the above methods can achieve a non-uniform variable density sensor array layout based on a prior model of impact energy spatial distribution, so that sensor resources are tilted towards high impact energy areas, thereby maximizing the impact force signal acquisition resolution of key areas under the condition of limited number of channels.

[0045] S2: It adopts a fully parallel synchronous acquisition architecture to acquire the impact force response signal of the non-uniform variable density sensor array layout in real time; In this embodiment of the invention, during the acquisition of multi-channel impact force signals, the synchronization accuracy of the sampling time between each sensor channel directly determines the accuracy of the subsequent construction of the impact force spatial distribution matrix.

[0046] If there is a time deviation in the sampling time of each channel, the impact force amplitude of each measuring point under the same physical transient will be recorded on different time coordinates. As a result, the reconstructed spatial distribution matrix will not be able to reflect the true stress state of the working surface of the liner at the same time.

[0047] Therefore, this invention adopts a fully parallel synchronous acquisition architecture to achieve synchronous sampling of each channel.

[0048] In a feasible implementation scheme, the specific implementation process of the fully parallel synchronous acquisition architecture is as follows.

[0049] Set a unified clock source, and generate a synchronous sampling trigger signal from the unified clock source.

[0050] A unified clock source can be a high-precision temperature-compensated crystal oscillator with a frequency stability better than ±1 / 1 million, or it can be a rubidium atomic clock or a GPS timing module as an external reference clock source.

[0051] Regardless of which clock source is used, the output reference clock frequency should meet the sampling clock requirements of each channel's analog-to-digital converter.

[0052] The typical value for the reference clock frequency is 10 MHz, but it can also be selected as 5 MHz, 20 MHz or 50 MHz depending on the maximum sampling rate of the analog-to-digital converter. The specific value is determined in advance by the operator based on the highest frequency component of the sensor output signal and the Nyquist sampling theorem.

[0053] The synchronous sampling trigger signal is sent simultaneously to each preamplifier circuit through a signal transmission path of equal length.

[0054] Equal-length signal transmission paths refer to physical traces of equal length from the output of a unified clock source to the trigger signal input of each preamplifier circuit, with trace length errors controlled within ±5 millimeters.

[0055] By using equal-length trace design, the time deviation of the synchronous sampling trigger signal reaching each preamplifier circuit is ensured to be less than one nanosecond.

[0056] At the same moment that each preamplifier circuit receives the synchronous sampling trigger signal, it samples and holds the analog signal output by the sensor to obtain the holding voltage signal of each channel.

[0057] The sampling and holding process is performed by the sampling and holding circuits built into each preamplifier circuit. The aperture time of the sampling and holding circuit is less than ten nanoseconds to capture the instantaneous amplitude of the impact force analog signal.

[0058] After receiving the synchronous sampling trigger signal, each preamplifier circuit amplifies and filters the analog signal output by the sensor.

[0059] The gain of the preamplifier circuit can be set according to the amplitude range of the sensor output signal. Typical gain factors are 10, 50 or 100 times.

[0060] The cutoff frequency of the filtering process is set according to the effective frequency bandwidth of the impulse signal, with typical cutoff frequencies being 1 kHz, 5 kHz, or 10 kHz.

[0061] The holding voltage signals of each channel are converted from analog to digital to obtain the digital impact amplitude of each channel.

[0062] The analog-to-digital conversion is performed by an independently configured analog-to-digital converter for each channel, with a resolution of at least twelve bits, typically sixteen or twenty-four bits.

[0063] The sampling rate of the analog-to-digital converter is set according to the time domain width and frequency domain characteristics of the impulse signal, with typical sampling rates ranging from 100,000 times per channel per second to 1 million times per channel per second.

[0064] The digital impact amplitude values ​​of all channels obtained at the same sampling time are associated with the sensor position identifiers corresponding to each channel to obtain synchronously acquired data frames.

[0065] The synchronously acquired data frame contains a timestamp of the sampling time, sensor location identifiers for each channel, and the corresponding digital impact force amplitude.

[0066] Through the above-mentioned fully parallel synchronous acquisition architecture, each channel completes sampling and holding and analog-to-digital conversion at the same time, achieving complete synchronization at the hardware level. This eliminates the time misalignment caused by sequential sampling between channels under the traditional polling acquisition method, providing original data with a consistent time reference for subsequently constructing the impact force spatial distribution matrix of the liner working surface at the same time.

[0067] In another feasible implementation scheme, the synchronous sampling trigger signal generated by the unified clock source is fan-out distributed through the clock distribution chip, and the output of the clock distribution chip is connected to the trigger signal input of each preamplifier circuit through equal-length microstrip lines.

[0068] The clock distribution chip can use a low-jitter clock buffer with an additional jitter of less than one picosecond.

[0069] In another feasible implementation, the sample-and-hold circuits in each preamplifier circuit can be analog-to-digital converter chips with integrated sample-and-hold functions. These chips contain sample-and-hold capacitors and sampling switches, and perform sample-and-hold and analog-to-digital conversion simultaneously upon receiving a trigger signal.

[0070] When using an integrated solution, the analog-to-digital converter chips of each channel share the same external reference voltage source to eliminate amplitude measurement deviations caused by differences in reference voltage between channels.

[0071] In another feasible implementation scheme, for scenarios with a large number of sensors and a wide physical distribution range, each preamplifier circuit can be deployed in a distributed manner, and each distributed acquisition node can be connected through a synchronous clock cable.

[0072] The length of the synchronization clock cable is kept consistent across all nodes to ensure that the synchronization trigger signal arrives at each distributed node at the same time.

[0073] In a distributed deployment, the synchronization accuracy of each acquisition node can be controlled within five clock cycles.

[0074] Regardless of which method is used, it is possible to achieve synchronous acquisition of multi-channel impact force response signals under a fully parallel synchronous acquisition architecture, so that all channels complete the sampling, holding and analog-to-digital conversion of their respective sensor output signals at the same sampling time, providing time-aligned raw data for the subsequent construction of the synchronous impact force spatial distribution matrix.

[0075] S3: Construct the synchronous impact force spatial distribution matrix of the working surface of the liner plate based on the position coordinates and impact force amplitude in the impact force response signal; In this embodiment of the invention, after the impact force amplitude data at the same sampling time are acquired synchronously from each channel, the amplitude data of these discrete measurement points need to be organized into a matrix according to their spatial positional relationship so that subsequent spatiotemporal mapping calculations can be performed.

[0076] If the data from each channel are simply arranged in order of channel number, the spatial adjacency and relative position information between the measuring points are lost, and the continuous distribution characteristics of the impact force on the two-dimensional working surface of the liner cannot be characterized.

[0077] Therefore, this invention establishes a planar coordinate system with the working surface of the liner as the reference surface, and determines the spatial coordinate values ​​of each sensor in the planar coordinate system according to the installation position of each sensor on the working surface of the liner.

[0078] In one feasible implementation scheme, the planar coordinate system is established as follows.

[0079] A rectangular coordinate system is established with the geometric center of the working surface of the liner plate as the origin, the length direction of the working surface of the liner plate as the horizontal axis, and the width direction of the working surface of the liner plate as the vertical axis.

[0080] The spatial coordinates of each sensor are uniquely determined by its x-coordinate and y-coordinate values ​​in the Cartesian coordinate system.

[0081] In another feasible implementation scheme, a rectangular coordinate system can be established with the lower left corner vertex of the working surface of the liner as the origin, the bottom edge direction as the horizontal axis direction, and the left side direction as the vertical axis direction.

[0082] Regardless of which coordinate system establishment method is used, the spatial coordinate values ​​of each sensor in the coordinate system maintain a one-to-one correspondence with their actual installation position on the working surface of the liner.

[0083] Obtain the impact force amplitude corresponding to each sensor unit at the same sampling time.

[0084] The impact force amplitude is the digital impact force amplitude after analog-to-digital conversion. Its physical unit is consistent with the sensor calibration result, and the typical unit is Newton or kilonewton.

[0085] The sensitivity coefficient of each sensor unit is determined by the factory calibration. During the acquisition process, the digital quantity after analog-to-digital conversion is converted into the impact force amplitude with physical units based on the sensitivity coefficient.

[0086] Arrange the impact force amplitudes according to the order of their corresponding spatial coordinates in the plane coordinate system to form the impact force spatial distribution vector at that sampling moment.

[0087] The arrangement order is determined as follows: the sensors are arranged in ascending order of their horizontal coordinate values. For sensors with the same horizontal coordinate value, they are then arranged in ascending order of their vertical coordinate values, thus forming a one-dimensional ordered sequence.

[0088] Each element in this one-dimensional ordered sequence contains the spatial coordinates of the corresponding sensor and the magnitude of the impact force, thus forming the spatial distribution vector of the impact force at that sampling moment.

[0089] The spatial distribution vector of impact force is used as a column element of the spatial distribution matrix of synchronous impact force, and the arrangement position of each column in the spatial distribution matrix of synchronous impact force is determined by the order of sampling time.

[0090] Specifically, the spatial distribution vector of the impact force corresponding to the earliest sampling time is taken as the first column of the matrix, the spatial distribution vector of the impact force corresponding to the second earliest sampling time is taken as the second column of the matrix, and so on, until the spatial distribution vector of the impact force at all sampling times is included in the matrix.

[0091] Let M be the spatial distribution matrix of synchronous impact force. The number of rows in matrix M is the total number of sensors, and the number of columns is the total number of sampling times. The element in the i-th row and j-th column of matrix M represents the impact force amplitude collected at the i-th sensor position at the j-th sampling time.

[0092] With the above arrangement, each column of the synchronous impact force spatial distribution matrix represents the spatial distribution of impact force amplitude at all measuring points on the working surface of the liner at a sampling time. The columns are arranged in chronological order of sampling time, forming structured data containing two-dimensional information of time and space.

[0093] In another feasible implementation scheme, after obtaining the spatial coordinate values ​​of each sensor, they can be arranged according to the preset arrangement order of the position markers of each sensor on the working surface of the liner.

[0094] The preset arrangement order specifically refers to arranging the sensors row by row from the top left to the bottom right according to their physical positions on the working surface of the liner, or arranging them one by one according to the sequence of sensor installation numbers mapped to spatial coordinates.

[0095] Once the above arrangement order is determined, the same arrangement order is used at all sampling times to ensure that the impact force amplitude of the same sensor at different times appears in the same row of the matrix.

[0096] In another feasible implementation scheme, the spatial distribution matrix of synchronous impact force can also be constructed in blocks according to the grouping of sensor location identifiers.

[0097] Specifically, sensors in the high impact energy region are grouped into the first group, sensors in the medium impact energy region are grouped into the second group, and sensors in the low impact energy region are grouped into the third group. Sensors within the same group are arranged in spatial coordinate order, and the groups are arranged sequentially from high to low impact energy level.

[0098] The block-based construction method facilitates subsequent calculations of impact energy spatiotemporal mapping for different impact energy regions, thereby improving computational efficiency.

[0099] Regardless of the construction method used, the constructed synchronous impact force spatial distribution matrix uses the rows of the matrix to correspond to the sensor positions and the columns of the matrix to correspond to the sampling times. This achieves synchronous correlation between the impact force amplitude and spatial position of each measuring point at the same time and temporal alignment between different times, providing a well-structured and complete data foundation for subsequent impact energy spatiotemporal mapping calculations.

[0100] S4: Perform spatiotemporal mapping calculation of impact energy on the spatial distribution matrix of synchronous impact force to obtain the impact energy density distribution map; In this embodiment of the invention, after obtaining the spatial distribution matrix of synchronous impact force, it is necessary to convert the impact force amplitude information carried by the time and space dimensions in the matrix into a physical quantity that can characterize the driving force of material wear, namely impact energy density.

[0101] The magnitude of the impact force itself only reflects the intensity of the impact at a certain moment, but the cumulative amount of wear on the material under impact depends not only on the magnitude of the impact force, but also on the duration of the impact and the area covered by the impact.

[0102] If only the impact amplitude is used as the basis for wear assessment, it is impossible to distinguish the difference in the contribution of short-duration high-amplitude impacts and long-duration medium-amplitude impacts to material wear, and it is also difficult to classify the impact data of discrete measurement points into the surface density index of each local area of ​​the working surface of the liner.

[0103] Therefore, this invention extracts the time series of impact force amplitude at each sensor location from the synchronous impact force spatial distribution matrix.

[0104] The impact force amplitude time series refers to the set of all impact force amplitude data arranged in chronological order at the same sensor location.

[0105] The length of this time series is equal to the number of columns in the spatial distribution matrix of the synchronous impact force, that is, the total number of sampling times.

[0106] After extracting the time series of impact force amplitude at each sensor location, the start and end times of the impact at each sensor location are determined based on the series.

[0107] The method for determining the start time of the impact is as follows: compare each amplitude in the time series of impact force amplitude with a preset impact trigger threshold. When the impact force amplitude of multiple consecutive sampling points exceeds the impact trigger threshold, the sampling time corresponding to the first sampling point that exceeds the threshold is taken as the start time of the impact.

[0108] The impact trigger threshold can be set according to the sensor's noise level and the level of environmental vibration interference. A typical value is five to ten percent of the sensor's full-scale amplitude.

[0109] The method for determining the termination time of the impact is as follows: After the start time of the impact, when the impact force amplitude of multiple consecutive sampling points is lower than the impact trigger threshold, the sampling time corresponding to the last sampling point before the first sampling point that is lower than the threshold is taken as the termination time of the impact.

[0110] The number of consecutive sampling points can be set to three to five to avoid misjudgment caused by single-point noise.

[0111] The duration of each impact is determined based on the start and end times of the impact.

[0112] The duration is calculated by subtracting the start time of the impact from the end time of the impact, and the difference is the duration of the impact.

[0113] The physical unit for this difference is seconds or milliseconds.

[0114] Based on the amplitude changes of each impact in the time series of each impact force amplitude, the representative value of the amplitude of each impact is determined.

[0115] The amplitude representative value can be the peak value of the impact force amplitude during the duration of the impact.

[0116] The amplitude representative value can also be the average value of the impact force amplitude during the duration of the impact, that is, the value obtained by arithmetically averaging the amplitudes of all sampling points during the duration of the impact.

[0117] The amplitude representative value can also be the root mean square value of the impact force amplitude during the duration of the impact, which is the value obtained by first squaring the amplitude of all sampling points during the duration of the impact, then averaging and finally taking the square root.

[0118] The cumulative impact at the same sensor location is obtained by summing the products of the representative amplitude values ​​of each impact at that location and their durations.

[0119] Mathematically, this can be expressed as: the cumulative impact force is equal to the sum of the products of the magnitude and the duration.

[0120] Specifically, for a certain sensor location, suppose that N impact events occurred at that location within a unit time window. ; in, This represents the cumulative impact force at the sensor location, and its physical unit is Newtons multiplied by seconds; This indicates the total number of impact events occurring at the sensor location within a unit time window; Indicates the first The magnitude of the impact is represented by the physical unit Newton. Indicates the first The duration of an impact is measured in seconds.

[0121] The physical unit of the cumulative impact force is Newton multiplied by a second, which is the dimension of impulse.

[0122] Through the above cumulative calculation, the time series of impact force amplitude at each sensor location is transformed into the cumulative impact force at that location within a certain time window. This force includes comprehensive information on both impact intensity and impact duration, and can more comprehensively reflect the driving force contribution of impact load to material wear.

[0123] The cumulative impact force at each sensor location is correlated with the corresponding spatial coordinates to form a set of cumulative impact forces with spatial coordinates.

[0124] Each element in this set contains the spatial x-coordinate value, spatial y-coordinate value of the sensor location, and the corresponding cumulative impact force at that location.

[0125] After obtaining the cumulative impact at each sensor location, it is necessary to attribute this cumulative impact to the detection area represented by each sensor in order to eliminate the influence of sensor density differences on impact energy evaluation.

[0126] Therefore, based on the spatial coordinates of each sensor's location, the detection area represented by each sensor on the working surface of the liner is determined, and the area value of each detection area is obtained.

[0127] The detection area is divided as follows: with each sensor position as the center point, the working surface of the liner is divided into areas according to the Thiessen polygon method, and each Thiessen polygon is the detection area represented by the corresponding sensor.

[0128] In another feasible implementation scheme, for sensor arrays with a rectangular grid layout, the detection area represented by each sensor can also be divided into rectangular areas, that is, each detection area is a rectangular area centered on the sensor position and with the distance between adjacent sensors as the side length.

[0129] When the spacing between sensors in all directions is equal, the detection area is a square area, the area of ​​which is equal to the square of the spacing.

[0130] When the row spacing and column spacing are not equal, the detection area is a rectangular area, the area of ​​which is equal to the row spacing multiplied by the column spacing.

[0131] For a sensor array that uses a honeycomb hexagonal grid layout, the detection area represented by each sensor is a regular hexagonal region, the area of ​​which is equal to three-half a square root of three times the square of the side length of the hexagon.

[0132] After obtaining the area value of each detection area, the cumulative impact at each sensor location is divided by the area value of the corresponding detection area to obtain the impact energy density value of each detection area.

[0133] Mathematically, the impact energy density value is equal to the cumulative impact force divided by the area of ​​the detection zone.

[0134] The physical unit of impact energy density is Newton multiplied by a second and divided by a square meter, which is the impulse per unit area.

[0135] The impact energy density values ​​of each detection area are arranged according to the spatial adjacency of each detection area on the working surface of the liner, generating an impact energy density distribution map of the working surface of the liner with the area location as the index and the impact energy density value as the content.

[0136] Specifically, using the plane coordinate system of the working surface of the liner as a reference, the impact energy density value of each detection area is filled into the corresponding spatial location of that area to form a two-dimensional distribution map.

[0137] Impact energy density distribution maps can be presented in the form of contour maps or pseudo-color maps.

[0138] In a contour map, adjacent regions with the same impact energy density are connected by contour lines, and the spacing between the contour lines reflects the spatial gradient of the impact energy density.

[0139] In a pseudo-color image, different impact energy density values ​​correspond to different color levels, and the transition from cool to warm colors indicates a change in impact energy density values ​​from low to high.

[0140] Through the above-mentioned spatiotemporal mapping calculation of impact energy, the discrete amplitude data in the spatial distribution matrix of synchronous impact force are transformed into an impact energy density distribution map with clear physical dimensions. This distribution map continuously reflects the impact load intensity borne by each area of ​​the working surface of the liner in space, providing input parameters with clear physical meaning and matching spatial resolution for subsequent wear state assessment in combination with material wear rate curves.

[0141] S5: Based on the impact energy density distribution map and the pre-stored liner material wear rate-impact energy density mapping curve, evaluate the wear status and remaining life of each area of ​​the liner.

[0142] In this embodiment of the invention, after obtaining the impact energy density values ​​of each detection area on the working surface of the liner, it is necessary to convert this physical quantity into a quantitative assessment result of wear state and remaining working time.

[0143] Impact energy density reflects the cumulative intensity of impact load per unit area on the surface of the liner, but this physical quantity is not directly equivalent to the amount of material wear.

[0144] The wear rate of a material under impact load depends not only on the magnitude of the impact energy density, but also on the physical properties, microstructure, and wear failure mechanism of the liner material.

[0145] Different liner materials exhibit significant differences in wear response to the same impact energy density. Therefore, it is necessary to establish a correlation between impact energy density and material wear rate in order to achieve a complete closed loop from impact force detection to wear state assessment.

[0146] To this end, the present invention retrieves a pre-stored liner material wear rate-impact energy density mapping curve, which characterizes the wear amount per unit time of the liner material under different impact energy density conditions.

[0147] In one feasible implementation scheme, the method for obtaining the liner material wear rate-impact energy density mapping curve is as follows.

[0148] A series of impact and wear tests were conducted under laboratory conditions using material specimens of the same material and heat treatment state as the liner to be evaluated.

[0149] During the test, the impact energy density is controlled to change according to a preset gradient, and the wear amount of the material specimen per unit time under each gradient condition is measured, that is, the wear volume or wear thickness.

[0150] By fitting the impact energy density under each gradient condition with the corresponding wear rate per unit time, a mapping curve of wear rate as a function of impact energy density is obtained.

[0151] In another feasible implementation scheme, the liner material wear rate-impact energy density mapping curve can also be obtained based on the crusher's on-site calibration test.

[0152] Specifically, when replacing the liner, multiple calibration areas are selected, and impact force sensors and wear measurement devices are simultaneously arranged in each calibration area. Under actual operating conditions, impact energy density data and actual wear data within the corresponding time period are collected for each calibration area.

[0153] Regression analysis was performed on the data collected on site to obtain the wear rate-impact energy density mapping curve applicable to this actual working condition.

[0154] Regardless of which acquisition method is used, the horizontal axis of the mapping curve represents the impact energy density value, and the vertical axis represents the wear amount per unit time. The correspondence between the two can be stored in the form of a data table or in the form of a function expression.

[0155] After retrieving the pre-stored liner material wear rate-impact energy density mapping curve, the impact energy density value of each detection area is substituted into the mapping curve to obtain the current wear amount per unit time of each detection area under the current impact energy density.

[0156] Specifically, for the i-th detection area in the impact energy density distribution map, the impact energy density value of the area is used as the input parameter to input the mapping curve, and the corresponding output wear amount per unit time is the current wear amount per unit time of the area.

[0157] The physical unit for wear per unit time is millimeters per hour or micrometers per hour.

[0158] Obtain the initial thickness value and scrap thickness threshold of each detection area of ​​the liner.

[0159] The initial thickness value refers to the actual thickness of each inspection area when the liner is installed. This value is determined by the factory dimensions of the liner and the measurement data before installation.

[0160] The scrap thickness threshold refers to the minimum allowable thickness of the liner when it must be replaced. This value is determined by the structural strength requirements of the liner and the safe operation requirements of the equipment. A typical value is 20% to 40% of the initial thickness.

[0161] Based on the current wear rate per unit time, initial thickness value, and scrap thickness threshold of each detection area, determine the remaining working time required for each detection area to wear down from the current thickness to the scrap thickness threshold.

[0162] Mathematically, this can be expressed as: the remaining working time equals the difference between the current thickness and the scrap thickness threshold, divided by the wear amount per unit time.

[0163] The current thickness is equal to the initial thickness value minus the amount of wear that has occurred during the service period.

[0164] The amount of wear that has occurred can be obtained by accumulating the wear per unit time at each sampling moment and multiplying it by the corresponding time interval.

[0165] In another feasible implementation scheme, when the measured current thickness value of each detection area cannot be obtained, the estimated current thickness value can be obtained by subtracting the amount of wear estimated based on the cumulative running time and average wear rate from the initial thickness value.

[0166] The physical unit for remaining working time is hours or days.

[0167] The remaining working time of each testing area is arranged according to the spatial adjacency of each testing area on the working surface of the liner to generate a distribution map of the remaining life of the liner.

[0168] The remaining life distribution map uses the plane coordinate system of the working surface of the liner as a reference, and fills the remaining working time of each detection area into the corresponding spatial position.

[0169] The remaining working time distribution map can be presented in the form of a pseudo-color map, with different remaining working times corresponding to different color levels. The transition from cool to warm colors indicates the trend of the remaining working time from long to short, intuitively showing the life distribution status of each area of ​​the liner working surface.

[0170] After generating the remaining life distribution map of the liner, the detection areas in the remaining working time of the liner remaining life distribution map that are lower than the preset safe time threshold are marked as high-risk wear areas.

[0171] The preset safe time threshold is set by the operator based on the equipment maintenance cycle and production scheduling plan, with a typical range of 24 to 168 hours.

[0172] When the remaining working time of a certain inspection area is lower than the preset safe time threshold, it indicates that the area is at risk of wear and tear to the point of being scrapped in the next maintenance cycle, and needs to be given special attention or maintenance should be arranged in advance.

[0173] Output the location information and remaining working time of each high-risk wear area.

[0174] Location information includes the spatial coordinate range or area number of the detection area in the plane coordinate system of the liner working surface, and the remaining working time is the specific value of the remaining working time of the area.

[0175] The output location information and remaining working time can be presented as a data list or overlaid on the remaining life distribution map as a highlighted mark, providing operators with clear risk area location and replacement time reference.

[0176] Through the above evaluation process, the impact energy density distribution map is combined with the pre-stored material wear rate-impact energy density mapping curve to achieve a complete quantitative calculation of the remaining working time of each area of ​​the liner from the synchronous acquisition of impact force. This enables operators to formulate accurate maintenance and replacement plans based on the spatially distributed remaining life information, avoiding material waste caused by overall replacement or equipment safety accidents caused by excessive local wear.

[0177] In another feasible implementation, the impact energy spatiotemporal mapping calculation in S4 of the present invention can also be to extract the impact force amplitude time sequence at each sensor location from the synchronous impact force spatial distribution matrix.

[0178] The rows of the synchronous impact force spatial distribution matrix correspond to the sensor positions, and the columns correspond to the sampling times. Therefore, extracting the impact force amplitude time series at a certain sensor position means extracting all elements of that row in all columns.

[0179] The time series is arranged in chronological order of sampling times and includes the impact force amplitude data of the sensor location at all sampling times.

[0180] Based on the time series of each impact force amplitude, the start time and end time of the impact at each sensor location are determined.

[0181] In another feasible implementation scheme, the start and end times of the impact are determined using a fixed threshold comparison method.

[0182] Specifically, an impact trigger threshold is preset, and each amplitude in the time series of impact force amplitude is compared with the impact trigger threshold one by one.

[0183] When the impact force amplitude of three consecutive sampling points exceeds the impact trigger threshold, the sampling time corresponding to the first sampling point that exceeds the threshold is taken as the start time of the impact.

[0184] After the start of the impact, when the impact force amplitude of three consecutive sampling points is lower than the impact trigger threshold, the sampling time corresponding to the last sampling point before the first sampling point that is lower than the threshold is taken as the end of the impact.

[0185] The impact trigger threshold can be set according to the sensor's measurement noise level and the level of environmental vibration interference. A typical value is five to ten percent of the sensor's full-scale amplitude.

[0186] In another feasible implementation scheme, the start and end times of the impact are determined using an adaptive threshold method.

[0187] Specifically, the mean and standard deviation of the impact force amplitude time series during the non-impact period are calculated, and the impact trigger threshold is set to the mean plus three to five times the standard deviation.

[0188] Periods without impact can be identified by using a sliding window to detect periods where the rate of change of amplitude is consistently lower than a preset rate of change threshold.

[0189] The advantage of the adaptive threshold method is that it can dynamically adjust the trigger threshold according to the actual background noise level of each sensor location, and is suitable for scenarios where there are large differences in noise levels between different sensors or where environmental vibration interference changes over time.

[0190] In one feasible implementation scheme, the start and end times of the impact are determined using the slope change detection method.

[0191] Specifically, the rate of change of amplitude between adjacent sampling points in the time series of impact force amplitude is calculated. When the rate of change suddenly increases from a state close to zero and exceeds a preset rate of change threshold, the sampling point corresponding to the rate of change exceeding the threshold is taken as the starting time of the impact.

[0192] When the rate of change falls back to near zero after experiencing a high value and continues to exceed a preset number of sampling points, the sampling point corresponding to the fall back is taken as the termination time of the impact.

[0193] The slope change detection method does not rely on the absolute amplitude threshold and can accurately identify the start and end times of an impact event when the impact amplitude itself is small but the rate of change is obvious.

[0194] After determining the start and end times of the impact, the duration of each impact is determined based on the difference between the two.

[0195] The duration of an impact is the difference between the time it ends and the time it begins. The physical unit of this duration is seconds or milliseconds.

[0196] Based on the amplitude changes of each impact in the time series of each impact force amplitude, the representative value of the amplitude of each impact is determined.

[0197] In one feasible implementation scheme, the amplitude representative value is taken as the peak value of the impact force amplitude during the duration of the impact.

[0198] When the peak value is used as the representative value of the amplitude, the maximum load intensity during the impact process can be highlighted. It is suitable for working conditions where the peak impact stress is the main wear driving factor, such as the impact wear scenario of high hardness materials on the liner.

[0199] In another feasible implementation scheme, the amplitude representative value is taken as the average value of the impact force amplitude over the duration of the impact.

[0200] The average value is calculated by summing the amplitudes of all sampling points during the duration of the impact and dividing by the number of sampling points.

[0201] When the average value is used as the representative value of the amplitude, it can comprehensively reflect the average load level throughout the entire impact process and is suitable for working conditions where the impact waveform is relatively flat and the difference between the peak value and the average value is not large.

[0202] In another feasible implementation scheme, the amplitude representative value is taken as the root mean square value of the impact force amplitude during the duration of the impact.

[0203] The root mean square value is calculated by first squaring the amplitude of all sampling points during the duration of the impact, then summing the values, dividing by the number of sampling points, and finally taking the square root of the quotient.

[0204] When the root mean square value is used as the representative value of the amplitude, it takes into account both the fluctuation range of the amplitude and the contribution of the amplitude at each moment during the duration. It is suitable for scenarios where the impact waveform fluctuates greatly and it is necessary to characterize the effective intensity of the impact.

[0205] After determining the representative amplitude value and duration, the product of the representative amplitude value and duration of each impact at the same sensor location is accumulated to obtain the cumulative impact force at that sensor location.

[0206] In another feasible implementation, the obtained impact energy density distribution map in S4 of the present invention can also be obtained by dividing the detection area using the Thiessen polygon method.

[0207] The specific division method of the Thiessen polygon method is as follows: using the position of each sensor as the generation point, the plane on which the working surface of the liner plate is located is divided into regions, so that any point on the plane belongs to the detection area where the nearest sensor is located.

[0208] For any given sensor location, the corresponding Thiessen polygon is a convex polygonal region bounded by the perpendicular bisectors between that sensor location and the adjacent sensor locations.

[0209] The Thiessen polygon method is suitable for scenarios where sensors are non-uniformly and discretely distributed on the working surface of the liner. Regardless of the spacing and arrangement direction of the sensors, this method can generate a seamless area division covering the entire working surface.

[0210] In other embodiments, for sensor arrays employing a rectangular grid layout, each detection area is divided into rectangular sections.

[0211] The specific rules for the rectangular division method are as follows: taking the position of each sensor as the center, half of the difference in the horizontal coordinate between adjacent sensors is used as the horizontal radius of the detection area, and half of the difference in the vertical coordinate between adjacent sensors is used as the vertical radius of the detection area. The rectangular detection area represented by each sensor is determined by the horizontal radius and the vertical radius.

[0212] When the row spacing is equal to the column spacing, the rectangular detection area is a square, and its area is equal to the square of the sensor spacing.

[0213] When the row spacing and column spacing are not equal, the rectangular detection area is a rectangle, and its area is equal to the row spacing multiplied by the column spacing.

[0214] The rectangular partitioning method is suitable for grid layouts where sensors are arranged at equal or non-equal intervals along orthogonal directions. The area shape is regular and the calculation is simple.

[0215] In another feasible implementation scheme, for sensor arrays with a honeycomb hexagonal grid layout, each detection area is divided into regular hexagons.

[0216] The specific rules for dividing a regular hexagon are as follows: each sensor is located at the center of the regular hexagon, and the center distance between adjacent sensors is equal to the side length of the regular hexagon multiplied by the square root of three.

[0217] The area of ​​the hexagonal detection region is equal to three-half the square root of three times the square of the side length of the hexagon.

[0218] The hexagonal partitioning method is superior to the rectangular partitioning method in terms of spatial coverage uniformity. Under the same sensor density, the total length of the boundary of each detection area is the shortest, making it suitable for scenarios where it is necessary to minimize the boundary effect between areas.

[0219] After determining the division method of the detection area and obtaining the area value of each detection area, the cumulative impact of each sensor position is divided by the area value of the corresponding detection area to obtain the impact energy density value of each detection area.

[0220] like Figure 2 The diagram shown is a functional block diagram of a crusher liner impact force distribution detection system with integrated pressure sensor provided in an embodiment of the present invention.

[0221] The crusher liner impact force distribution detection system 100 with integrated pressure sensor described in this invention can be installed in an electronic device. Depending on the functions implemented, the crusher liner impact force distribution detection system 100 with integrated pressure sensor may include a layout module 101, an impact acquisition module 102, a spatial distribution analysis module 103, an energy density calculation module 104, and a state assessment module 105. The module described in this invention can also be called a unit, which refers to a series of computer program segments that can be executed by the processor of an electronic device and can perform a fixed function, and is stored in the memory of the electronic device.

[0222] In this embodiment, the functions of each module / unit are as follows: The arrangement module 101 is used to implement a non-uniform variable density sensor array layout on the working surface of the liner plate based on a prior model of the spatial distribution of impact energy. The impact acquisition module 102 is used to acquire impact force response signals in real time using a fully parallel synchronous acquisition architecture with a non-uniform variable density sensor array layout. The spatial distribution analysis module 103 is used to construct a synchronous impact force spatial distribution matrix of the working surface of the liner plate based on the position coordinates and impact force amplitude in the impact force response signal. The energy density calculation module 104 is used to perform impact energy spatiotemporal mapping calculation on the synchronous impact force spatial distribution matrix to obtain an impact energy density distribution map. The condition assessment module 105 is used to assess the wear state and remaining life of each region of the liner based on the impact energy density distribution map and the pre-stored liner material wear rate-impact energy density mapping curve. In the several embodiments provided by this invention, it should be understood that the disclosed methods and systems can be implemented in other ways. For example, the system embodiments described above are merely illustrative; for instance, the division of modules is only a logical functional division, and other division methods may be used in actual implementation.

[0223] The modules described as separate components may or may not be physically separate. The components shown as modules may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0224] Furthermore, the functional modules in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or in the form of hardware plus software functional modules.

[0225] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention.

[0226] This application embodiment can acquire and process relevant data based on artificial intelligence technology. Artificial intelligence is the theory, method, technology, and application system that uses digital computers or machines controlled by digital computers to simulate, extend, and expand human intelligence, perceive the environment, acquire knowledge, and use that knowledge to obtain optimal results.

[0227] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A method for detecting impact force distribution in crusher liners using an integrated pressure sensor, characterized in that, The method includes: S1: Based on the prior model of spatial distribution of impact energy, a non-uniform variable density sensor array layout is implemented on the working surface of the liner. S2: It adopts a fully parallel synchronous acquisition architecture to acquire the impact force response signal of the non-uniform variable density sensor array layout in real time; S3: Construct the synchronous impact force spatial distribution matrix of the working surface of the liner plate based on the position coordinates and impact force amplitude in the impact force response signal; S4: Perform spatiotemporal mapping calculation of impact energy on the spatial distribution matrix of synchronous impact force to obtain the impact energy density distribution map; S5: Based on the impact energy density distribution map and the pre-stored liner material wear rate-impact energy density mapping curve, evaluate the wear status and remaining life of each area of ​​the liner.

2. The method for detecting the impact force distribution of a crusher liner with an integrated pressure sensor as described in claim 1, characterized in that, Prior models for the spatial distribution of impact energy include: Acquire impact event records at each detection point of the crusher during its historical operating cycle. The impact event records include the time of impact occurrence and the impact amplitude. Based on the impact event record data, the total number of impacts and the cumulative impact amplitude at each detection point within a unit time window were statistically analyzed. Based on the total number of impacts and the cumulative impact amplitude, the working surface of the liner is divided into multiple impact energy level zones, which include at least a high impact energy zone, a medium impact energy zone, and a low impact energy zone. The results of dividing the impact energy level regions are used as a priori models for the spatial distribution of impact energy.

3. The method for detecting the impact force distribution of a crusher liner with an integrated pressure sensor as described in claim 1, characterized in that, Based on a priori model of impact energy spatial distribution, a non-uniform variable density sensor array layout is implemented on the working surface of the liner, including: Based on the prior model of impact energy spatial distribution, the location range of high impact energy region, medium impact energy region and low impact energy region on the working surface of the liner plate is determined; Sensors are deployed at a first spacing in the high impact energy region, at a second spacing in the medium impact energy region, and at a third spacing in the low impact energy region. The first spacing is smaller than the second spacing, and the second spacing is smaller than the third spacing.

4. The method for detecting the impact force distribution of a crusher liner with an integrated pressure sensor as described in claim 1, characterized in that, Employing a fully parallel synchronous acquisition architecture, the system acquires impact response signals in real time from a non-uniform variable density sensor array layout, including: Set a unified clock source, and generate a synchronous sampling trigger signal from the unified clock source; The synchronous sampling trigger signal is sent to each preamplifier circuit simultaneously through a signal transmission path of equal length; At the same moment that the preamplifier circuits receive the synchronous sampling trigger signal, they sample and hold the analog signal output by the sensor to obtain the holding voltage signal of each channel. The holding voltage signals of each channel are converted from analog to digital to obtain the digital impact amplitude of each channel; The digital impact amplitude values ​​of all channels obtained at the same sampling time are associated with the sensor position identifiers corresponding to each channel to obtain synchronously acquired data frames.

5. The method for detecting the impact force distribution of a crusher liner with an integrated pressure sensor as described in claim 1, characterized in that, Based on the position coordinates and impact amplitude in the impact response signal, a synchronous impact force spatial distribution matrix is ​​constructed on the working surface of the liner, including: A plane coordinate system is established with the working surface of the liner as the reference surface. Based on the installation position of each sensor on the working surface of the liner, the spatial coordinate values ​​of each sensor in the plane coordinate system are determined. Obtain the impact force amplitude corresponding to each sensor unit at the same sampling time; Arrange the impact force amplitudes according to the order of their corresponding spatial coordinates in the plane coordinate system to form the impact force spatial distribution vector at the sampling time; The spatial distribution vector of impact force is used as a column element of the spatial distribution matrix of synchronous impact force, and the arrangement position of each column in the spatial distribution matrix of synchronous impact force is determined by the order of sampling time.

6. The method for detecting the impact force distribution of a crusher liner with an integrated pressure sensor as described in claim 5, characterized in that, Based on the position coordinates and impact amplitude in the impact response signal, a synchronous impact force spatial distribution matrix is ​​constructed on the working surface of the liner, which also includes: The digital impact force amplitude corresponding to each sensor is extracted from each synchronously acquired data frame, and each digital impact force amplitude is bound to the corresponding sensor position identifier to form an impact force amplitude data set with position identifier; According to the preset arrangement order of the position markers of each sensor unit on the working surface of the liner, the impact force amplitude data set with position markers at the same time is arranged into a row vector; The row vectors corresponding to each sampling time are stacked vertically in chronological order of sampling time to obtain the spatial distribution matrix of synchronous impact force with sampling time as the row and sensor position as the column.

7. The method for detecting the impact force distribution of a crusher liner with an integrated pressure sensor as described in claim 1, characterized in that, The calculation of the spatiotemporal mapping of impact energy on the spatial distribution matrix of synchronous impact force includes: Extract the time series of impact force amplitude at each sensor location from the spatial distribution matrix of synchronous impact force; Based on the time series of each impact force amplitude, the start time and end time of the impact at each sensor location are determined, and the duration of each impact is determined based on the start time and end time of the impact. Based on the amplitude changes of each impact in the time series of each impact force amplitude, the representative value of the amplitude of each impact is determined; The cumulative impact at the sensor location is obtained by summing the products of the representative amplitude values ​​of each impact at the same sensor location and the duration. The cumulative impact force at each sensor location is correlated with the corresponding spatial coordinates to form a set of cumulative impact forces with spatial coordinates.

8. The method for detecting the impact force distribution of a crusher liner with an integrated pressure sensor as described in claim 7, characterized in that, The impact energy density distribution map is obtained, including: Based on the spatial coordinates of each sensor's location, determine the detection area represented by each sensor on the working surface of the liner, and obtain the area value of each detection area. The impact energy density of each detection area is obtained by dividing the cumulative impact at each sensor location by the area of ​​the corresponding detection area. The impact energy density values ​​of each detection area are arranged according to the spatial adjacency of each detection area on the working surface of the liner, generating an impact energy density distribution map of the working surface of the liner with the area location as the index and the impact energy density value as the content.

9. The method for detecting the impact force distribution of a crusher liner with an integrated pressure sensor as described in claim 1, characterized in that, Based on the impact energy density distribution map and the pre-stored liner material wear rate-impact energy density mapping curve, the wear state and remaining life of each region of the liner are evaluated, including: Obtain the impact energy density values ​​of each detection area in the impact energy density distribution map; Retrieve the pre-stored liner material wear rate-impact energy density mapping curve, where the liner material wear rate-impact energy density mapping curve characterizes the wear amount of the liner material per unit time under different impact energy density conditions. Substitute the impact energy density value of each detection area into the liner material wear rate-impact energy density mapping curve to obtain the current wear amount per unit time of each detection area under the current impact energy density. Obtain the initial thickness value and scrap thickness threshold of each detection area of ​​the liner. Based on the current wear rate per unit time, initial thickness value and scrap thickness threshold of each detection area, determine the remaining working time required for each detection area to wear down from the current thickness to the scrap thickness threshold. The remaining working time of each detection area is arranged according to the spatial adjacency of each detection area on the working surface of the liner to generate a distribution map of the remaining life of the liner. The detection areas in the remaining working time of the liner plate remaining life distribution map that are lower than the preset safe time threshold are marked as high-risk wear areas, and the location information and remaining working time of each high-risk wear area are output.

10. A crusher liner impact force distribution detection system integrating a pressure sensor, characterized in that, The system for implementing the crusher liner impact force distribution detection method with integrated pressure sensor as described in claim 1 includes: The arrangement module is used to implement a non-uniform variable density sensor array layout on the working surface of the liner plate based on a prior model of the spatial distribution of impact energy. The impact acquisition module is used to acquire impact force response signals in real time using a fully parallel synchronous acquisition architecture with a non-uniform variable density sensor array layout. The spatial distribution analysis module is used to construct the synchronous impact force spatial distribution matrix of the liner working surface based on the position coordinates and impact force amplitude in the impact force response signal. The energy density calculation module is used to perform spatiotemporal mapping calculations of impact energy on the spatial distribution matrix of synchronous impact force to obtain an impact energy density distribution map. The condition assessment module is used to assess the wear status and remaining life of each region of the liner based on the impact energy density distribution map and the pre-stored liner material wear rate-impact energy density mapping curve.

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