Rigid cage guide fault detection device
By designing a rigid tank channel fault detection device including eddy current sensors and data acquisition cards, the problem of difficult to detect and quantify tank channel faults in the prior art is solved, and accurate detection and diagnosis of misalignment and excessive gaps are achieved, and the safety and stability of tank cage operation are improved.
Patent Information
- Application Number
- CN202421057672.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-05-15
- Publication Date
- 2025-03-25
- Estimated Expiration
- 2034-05-15
AI Technical Summary
The prior art is difficult to effectively detect and quantify the faults of rigid tank passages, especially the problems of misalignment and excessive gaps, which lead to abnormal operation of the tank cage and affect safety.
A fault detection device including a test bench, a tank cage, a rigid tank passage, a drive motor, a chain, a control box, a frequency converter, a roller, a limit switch, an eddy current sensor bracket, an eddy current sensor, a data acquisition card and a host computer are designed to collect the tank passage failure signal through an eddy current sensor, and real-time analysis and diagnosis are carried out through a data acquisition card and a host computer.
Accurate detection and quantification of rigid tank passage faults is achieved, and faults of different types and degrees can be identified, which improves the safety and stability of tank cage operation and reduces the impact on the normal production of coal mines.
Smart Images
Figure CN222671741U_ABST
Abstract
Description
Technical Field
[0001] The utility model belongs to the technical field of rigid tank channel detection, in particular to a rigid tank channel fault detection device. Background Art
[0002] Vertical shafts are used to transport personnel, equipment and materials, and are an important part of underground mines. Rigid tankways are the infrastructure of the vertical shaft hoisting system, and always play a guiding and stable operation role in the hoisting process. Due to shaft deformation, steel corrosion and other reasons, tankways are prone to defects, which can lead to abnormal operation of the cage and then to accidents. Therefore, it is necessary to detect defects in tankways. Common tankway defects include local bulges, tilts, misalignments, and excessive gaps. Different defect types have different impacts on the operation of the cage. The main causes of impact vibration on the cage operation are misalignment and excessive gaps in the tankway.
[0003] Common methods
[0004] 1. Hanging wire method
[0005] This method is not only time-consuming and labor-intensive, but also affects the normal production of coal mines.
[0006] 2. Vibration method
[0007] When a tank channel has defects, the cage cannot maintain stable operation and will produce severe impact and vibration. By establishing a dynamic model between the cage and the tank channel, the mechanism of rigid tank channel defects is analyzed from the perspective of cage vibration. Commonly used detection methods include traditional fault diagnosis methods such as SVM and wavelet transform.
[0008] The existing vibration method is an indirect measurement method, which is easily affected by external factors such as the cage running speed and load. In addition, the above method only classifies common tankway defects, but does not quantify the tankway defects.
[0009] To this end, a rigid tank fault detection device is provided to solve the above problems. Utility Model Content
[0010] In view of the above situation, in order to overcome the defects of the prior art, the utility model provides a rigid tank fault detection device to at least partially solve the above technical problems.
[0011] The technical solution adopted by the utility model is as follows:
[0012] The utility model proposes a rigid tankway fault detection device, comprising a test bench, a tank cage, a rigid tankway, a drive motor, a chain, a control box, a frequency converter, a roller, a limit switch, an eddy current sensor bracket, an eddy current sensor, a data acquisition card and a host computer;
[0013] The rigid tankway is horizontally arranged on both sides of the test bench, the tank cage is parked on the rigid tankway by means of the rollers, the driving motor is arranged above the test bench, the eddy current sensor bracket is arranged inside the tank cage, the limit switch is arranged on both sides of the top of the test bench, and the chain is arranged above the test bench.
[0014] As a further solution of the utility model: the rigid tank channel is provided with two, each of which is divided into three sections, and is arranged on the columns on both sides of the test bench using a cross hole structure. The relative position of two adjacent sections of the rigid tank channel is adjusted by adjusting the position of the cross hole to simulate tank channel failures of different types and degrees.
[0015] As a further solution of the utility model: the rollers are provided in groups, which are respectively arranged around the tank cage, each group includes rollers, which are located on the upper side, inner side and lower side of the rigid tank way. The upper rollers support the tank cage, and the inner and lower rollers guide. The rollers are connected to the rigid tank way through a cylinder.
[0016] As a further solution of the utility model: a fixing hole is provided above the cage, the chain is connected to the cage through the fixing hole, and the drive motor drives the cage to move by being connected to the chain.
[0017] As a further solution of the utility model: the frequency converter is control-connected to the control box, and the control box is connected to the drive motor. By adjusting the frequency of the frequency converter, the moving speed of the drive motor can be controlled. The control box can have four buttons of start, pause, forward and reverse, which can control the operation, stop, forward movement and reverse movement of the cage. The limit switch is arranged above the test bench, one on each side of the test bench, and is connected to the control box. When the cage reaches the limit switch position, the limit switch sends a signal to the control box to control the cage to stop running or turn.
[0018] As a further solution of the utility model: the eddy current sensor is arranged on the eddy current sensor bracket through a mounting hole, the eddy current sensor has threads all around, and the distance between the eddy current sensor and the rigid tank channel can be adjusted by an adjusting nut.
[0019] As a further solution of the utility model: the eddy current sensor is connected to the data acquisition card through a signal line, the eddy current sensor moves with the tank cage to obtain the rigid tankway fault signal, the data acquisition card uploads the collected eddy current signal to the host computer, and the host computer analyzes the tankway fault type through software.
[0020] Implementing the embodiments of the present utility model will have the following beneficial effects:
[0021] In this embodiment, the frequency converter frequency is set, the driving motor speed is set, and the control box controls the start and stop of the motor and the rotation direction of the motor. The motor drives the tank cage to reciprocate at a certain speed through the chain. The limit switch stops the motor rotation when the tank cage reaches the boundary. The roller guides and supports the tank cage. The eddy current sensor bracket is used to fix the eddy current sensor. The rigid tankway can be set with faults of different types and severity. The eddy current sensor collects tankway fault signals. The acquisition card collects eddy current sensor signals in real time and uploads them to the host computer. The host computer is responsible for processing eddy current signals and diagnosing tankway faults.
[0022] The above summary is for the purpose of description only and is not intended to be limiting in any way. In addition to the illustrative aspects, embodiments and features described above, further aspects, embodiments and features of the utility model will be readily apparent by reference to the accompanying drawings and the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS
[0023] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments or technical descriptions will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.
[0024] Figure 1 The present invention is a schematic structural diagram of a rigid tank fault detection device proposed in an embodiment of the present invention.
[0025] In the figure: 1. test bench; 2. cage; 3. rigid tankway; 4. drive motor; 5. chain; 6. control box; 7. frequency converter; 8. roller; 9. limit switch; 10. eddy current sensor bracket; 11. eddy current sensor; 12. data acquisition card; 13. host computer.
[0026] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. They are used together with the embodiments of the present invention to explain the present invention and do not constitute a limitation to the present invention. DETAILED DESCRIPTION
[0027] In the following, only some exemplary embodiments are briefly described. As those skilled in the art will appreciate, the described embodiments may be modified in various ways without departing from the spirit or scope of the present invention. Therefore, the drawings and descriptions are considered to be exemplary and non-restrictive in nature.
[0028] It should be noted that the terms "first", "second", etc. are only used to distinguish between description and position description, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the feature defined as "first" etc. may explicitly or implicitly include one or more of the features; similarly, when the quantity of certain features is not limited in the form of words such as "two" or "three", it should be noted that the feature also explicitly or implicitly includes one or more feature quantities;
[0029] In the embodiments of the present invention, unless otherwise clearly specified and limited, the terms such as "installation", "connection", "fixation" and the like should be understood in a broad sense; for example, it can be a fixed connection, a detachable connection, or an integral molding; it can be a mechanical connection, a direct connection, welding, or an indirect connection through an intermediate medium, or it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to the drawings in the specification and the specific circumstances.
[0030] In the description of the embodiments of the present invention, it should be understood that terms such as "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inside" and "outside" indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as a limitation on the embodiments of the present invention.
[0031] like Figure 1 As shown, a rigid tankway fault detection device includes a test bench 1, a cage 2, a rigid tankway 3, a drive motor 4, a chain 5, a control box 6, a frequency converter 7, a roller 8, a limit switch 9, an eddy current sensor bracket 10, an eddy current sensor 11, a data acquisition card 12 and a host computer 13; the rigid tankway 3 is horizontally arranged on both sides of the test bench 1, the cage 2 is parked on the rigid tankway 3 by the roller 8, the drive motor 4 is arranged above the test bench 1, the eddy current sensor bracket 10 is arranged inside the cage 2, the limit switch 9 is arranged on both sides of the top of the test bench 1, and the chain 5 is arranged above the test bench 1.
[0032] In the specific application of the embodiment of the utility model, the device is mainly composed of a test bench 1, a tank cage 2, a rigid tank channel 3, a drive motor 4, a chain 5, a control box 6, a frequency converter 7, a roller 8, a limit switch 9, an eddy current sensor bracket 10, an eddy current sensor 11, a data acquisition card 12 and a host computer 13. The tank cage moves on the plane of the rigid tank channel 3 through the roller 8. The tank cage 2 is connected to the control box 6 and the drive motor 4, and is driven by the drive motor to move up and down along the rigid tank channel 3. When the tank cage is docked, the roller 8 ensures stability. The eddy current sensor bracket 10 is installed inside the tank cage 2, and the eddy current sensor 11 is used to monitor the surface state of the tank channel, such as potential faults such as cracks or wear. This sensor is based on the principle of electromagnetic induction and can sensitively capture changes in the tank channel material.
[0033] Limit switches 9 are set on both sides of the top of the test bench 1 to monitor the upper and lower limit positions of the cage to prevent exceeding the range and ensure safe operation. When the eddy current sensor detects an abnormal signal, the data is transmitted to the data acquisition card 12 for preliminary processing and then further analyzed and stored by the host computer 13. The host computer usually converts this data into user-friendly reports or alarms.
[0034] In a possible implementation, two rigid tank tunnels 3 are provided, each of which is divided into three sections and is arranged on the columns on both sides of the test bench 1 using a cross hole structure. The relative position of two adjacent sections of the rigid tank tunnel 3 is adjusted by adjusting the position of the cross hole to simulate tank tunnel failures of different types and degrees.
[0035] In the specific application of the embodiment of the utility model, each rigid tank channel is fixed to the columns on both sides of the test bench 1 through a cross hole, and the cross hole allows the distance between adjacent sections to be changed by accurately adjusting the position. Through the adjustment of the cross hole, the device can simulate various types of faults that the tank channel may encounter in actual operation, such as local bulges, excessive gaps, and misalignment.
[0036] In a possible embodiment, four groups of rollers 8 are arranged around the tank cage 2, each group includes three rollers, which are located on the upper side, inner side and lower side of the rigid tank channel 3. The upper rollers support the tank cage 2, and the inner and lower rollers guide. The rollers 8 are connected to the rigid tank channel 3 through a cylinder.
[0037] In the specific application of the embodiment of the utility model, the rollers 8 in the device are designed as 4 groups, each group contains 3 rollers, which are evenly distributed around the cage 2, ensuring all-round contact and enhancing the stability and guidance of the cage on the tank track. The upper rollers are mainly used to support the weight of the cage 2 and provide a stable bearing platform. Ensure the vertical stability of the cage during operation to prevent vibration or deformation caused by gravity. The inner and lower rollers play a guiding role, helping to guide the cage to move along the preset track path and prevent the cage from deviating from the predetermined route. Ensure the linear motion of the cage and reduce the wear caused by friction and impact.
[0038] The roller 8 is tightly connected to the rigid tank channel 3 through the cylinder, so that the roller can be accurately positioned and moved according to the control of the cylinder. When the cylinder contracts or expands, the relative position of the roller and the tank channel can be accurately adjusted to adapt to the slight deformation of the tank channel.
[0039] The rollers may be worn or damaged during operation, and by monitoring the status of the rollers, the condition of the tankway can be indirectly detected. For example, if the rollers wear too fast in a certain area, it may mean that there are abnormalities on the surface of the tankway in that area, such as unevenness or cracks.
[0040] In a possible implementation manner, two fixing holes are provided above the cage 2, the chain 5 is connected to the cage 2 through the fixing holes, and the driving motor 4 is connected to the chain 5 to drive the cage 2 to move.
[0041] In the specific application of the embodiment of the utility model, the cage 2 is used to install the interface of the drive mechanism to ensure a compact and safe structure. The chain 5 connects the drive motor 4 and the cage 2, and passes through the fixing hole above the cage 2 to form a firm mechanical connection. The strength and wear resistance of the chain ensure that it can bear the weight of the cage and effectively transmit power.
[0042] The driving motor 4 is responsible for generating power, usually an electric motor, which converts electrical energy into mechanical energy through the chain 5. The motor transmits power to the chain through a transmission method such as gears or belts, thereby driving the cage 2 to move along the rigid tank track. By accurately adjusting the working state of the motor, the speed and direction of the cage 2 can be controlled to ensure the stability of the lifting process.
[0043] The movement state of the cage 2 can be monitored by chain tension, wear, motor current and other parameters. If the chain is loose or abnormally worn, or the motor is not working properly, it may indicate that the tankway or cage may have a fault. At this time, the device will trigger an alarm or stop running to prevent further damage and accidents.
[0044] In a possible implementation, the frequency converter 7 is controlled and connected to the control box 6, and the control box 6 is connected to the drive motor 4. By adjusting the frequency of the frequency converter 7, the moving speed of the drive motor 4 can be controlled. The control box 6 can have four buttons of start, pause, forward, and reverse, which can control the cage 2 to run, stop, move forward, and move reversely. The limit switch 9 is arranged above the test bench 1, one on each side of the test bench, and is connected to the control box 6. When the cage 2 reaches the limit switch position, the limit switch 9 sends a signal to the control box 6 to control the cage 2 to stop running or turn.
[0045] In the specific application of the embodiment of the utility model, the frequency converter 7 is used to control the speed of the motor (drive motor 4), which is connected to the control box 6 and realizes precise control of the motor speed through digital signal transmission. The frequency converter allows the motor speed to be adjusted as needed, thereby realizing precise speed adjustment of the cage 2. The control box 6 integrates multiple operation modes, including start, pause, forward and reverse control. The user can instruct the operation state of the cage 2 through buttons, such as starting, stopping, moving above (forward) or below (reverse) the cage 2.
[0046] The limit switches 9 are installed on the top and both sides of the test bench 1 to detect the travel boundaries of the cage 2 to ensure safety. When the cage 2 approaches or reaches the preset limit position, these switches will be activated and send an electrical signal to the control box 6. After receiving the signal from the limit switch, the control box 6 will receive the information that the cage 2 is approaching the limit position. Based on this signal, the control box will immediately interrupt or change the working state of the motor, such as slowing down, stopping or changing the driving direction, to prevent the cage 2 from rushing out of the predetermined range, thereby avoiding potential safety risks.
[0047] At the same time, the device may also have a fault detection function. Through real-time monitoring of parameters such as motor current, temperature, vibration, etc., if any abnormality is found, an alarm signal will be sent through the control box 6 to ensure the stable operation of the system and the safety of personnel.
[0048] In a possible implementation, the eddy current sensor 11 is disposed on the eddy current sensor bracket 10 through a mounting hole. The eddy current sensor 11 has threads all around it, and the distance between the eddy current sensor 11 and the rigid tank channel 3 can be adjusted by adjusting a nut.
[0049] In the specific application of the embodiment of the utility model, the eddy current sensor 11 usually includes an excitation coil and a receiving coil, which are designed to be installed on the eddy current sensor bracket 10. The bracket 10 provides a stable mounting platform for the sensor. The eddy current sensor 11 works on the principle of electromagnetic induction. When the excitation coil of the sensor generates a changing electromagnetic field, if there is metal material on the tank channel 3, such as a rail, it will interfere with the magnetic field. According to the law of electromagnetic induction, this interference will generate eddy currents and form a feedback signal.
[0050] Since the eddy current sensor 11 allows the user to adjust the distance between the sensor and the tank channel 3 by adjusting the nut, it is ensured that the sensor and the target surface (tank channel) maintain an optimal sensing distance to obtain the most accurate signal, which is not affected by factors such as the thickness and deformation of the tank channel surface material. By adjusting the sensor position, the eddy current sensor can detect any slight deformation or wear of the tank channel 3, such as cracks, corrosion or other forms of defects.
[0051] After being processed, the collected data can reflect the actual status of the tank channel. If any abnormal eddy current changes are detected, the system will trigger the corresponding alarm or automatic shutdown procedure to prevent the fault from worsening and ensure equipment safety.
[0052] In a possible implementation, the eddy current sensor 11 is connected to the data acquisition card 12 via a signal line. The eddy current sensor 11 moves with the cage 2 to obtain a fault signal of the rigid tankway 3. The data acquisition card 12 uploads the collected eddy current signal to the host computer 13. The host computer 13 analyzes the tankway fault type through software.
[0053] In the specific application of the embodiment of the utility model, the eddy current sensor 11 is connected to the data acquisition card 12 through a signal line. When the tank cage 2 is in operation, it moves up and down with the tank cage, and continuously sweeps across the rigid tank channel 3. Any deformation or fault of the tank channel (such as cracks, wear, local protrusions, excessive gaps and misalignment, etc.) will change the response of the electromagnetic field around the sensor and form a specific eddy current signal. The eddy current signal generated by the eddy current sensor 11 is variable and has characteristic information reflecting the state of the tank channel. These signals are transmitted to the data acquisition card 12 through the signal line. The data acquisition card is responsible for real-time acquisition and amplification of these weak electrical signals to ensure that the signal quality is not lost during the transmission process.
[0054] The data acquisition card 12 digitizes the received eddy current signal and processes it according to the preset sampling rate and format. The data is organized into a form that can be recognized by the computer and then stored in the internal memory for further processing. The host computer 13 receives the data from the data acquisition card, analyzes the eddy current signal, and uses advanced signal processing algorithms (such as frequency domain analysis, filtering and pattern recognition, etc.) to parse the signal and identify the possible fault types of the tank channel, such as local wear, crack expansion or overall structural problems.
[0055] Based on the analysis results, the host computer will generate a detailed fault report and may trigger an alarm mechanism. This helps operators to promptly discover and deal with tank channel problems and avoid accidents, and is also beneficial to the maintenance and management of equipment. Through network connection, the host computer 13 can also send real-time fault information of the tank channel to the remote monitoring center to achieve remote maintenance and early warning, thereby improving the operating efficiency and safety of the entire system.
[0056] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.
[0057] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.
[0058] The above description of the utility model and its implementation methods is not restrictive. The drawings show only one implementation method of the utility model, and the actual structure is not limited thereto. In short, if ordinary technicians in this field are inspired by it and design structural methods and embodiments similar to the technical solution without creativity without departing from the purpose of the invention of the utility model, they should all fall within the protection scope of the utility model.
Claims
1. A rigid tank fault detection device, characterized in that: It includes a test bench (1), a cage (2), a rigid tank channel (3), a drive motor (4), a chain (5), a control box (6), a frequency converter (7), a roller (8), a limit switch (9), an eddy current sensor bracket (10), an eddy current sensor (11), a data acquisition card (12) and a host computer (13); The rigid tank track (3) is horizontally arranged on both sides of the test bench (1), the tank cage (2) is parked on the rigid tank track (3) by means of the rollers (8), the drive motor (4) is arranged above the test bench (1), the eddy current sensor bracket (10) is arranged inside the tank cage (2), the limit switch (9) is arranged on both sides of the top of the test bench (1), and the chain (5) is arranged above the test bench (1).
2. A rigid tank fault detection device according to claim 1, characterized in that: The rigid tank channel (3) is provided with two, each of which is divided into three sections and is arranged on the columns on both sides of the test bench (1) using a cross hole structure. The relative position of two adjacent sections of the rigid tank channel (3) is adjusted by adjusting the position of the cross hole to simulate tank channel failures of different types and degrees.
3. A rigid tank fault detection device according to claim 1, characterized in that: The rollers (8) are provided in four groups, which are respectively arranged around the tank cage (2), each group comprising three rollers, which are located on the upper side, inner side and lower side of the rigid tank path (3), the upper rollers play a role of supporting the tank cage (2), and the inner side and lower side rollers play a guiding role. The rollers (8) are connected to the rigid tank path (3) through a cylinder.
4. A rigid tank fault detection device according to claim 1, characterized in that: Two fixing holes are arranged above the tank cage (2), the chain (5) is connected to the tank cage (2) through the fixing holes, and the driving motor (4) is connected to the chain (5) to drive the tank cage (2) to move.
5. A rigid tank fault detection device according to claim 1, characterized in that: The frequency converter (7) is control-connected to the control box (6), and the control box (6) is connected to the drive motor (4). By adjusting the frequency of the frequency converter (7), the moving speed of the drive motor (4) can be controlled. The control box (6) can have four buttons, namely, start, pause, forward and reverse, which can control the cage (2) to run, stop, move forward and move reversely. The limit switch (9) is arranged above the test bench (1), one on each side of the test bench, and is connected to the control box (6). When the cage (2) reaches the limit switch position, the limit switch (9) sends a signal to the control box (6) to control the cage (2) to stop running or turn.
6. A rigid tank fault detection device according to claim 1, characterized in that: The eddy current sensor (11) is arranged on the eddy current sensor bracket (10) through a mounting hole. The eddy current sensor (11) has threads all around it, and the distance between the eddy current sensor (11) and the rigid tank channel (3) can be adjusted by an adjusting nut.
7. A rigid tank fault detection device according to claim 1, characterized in that: The eddy current sensor (11) is connected to the data acquisition card (12) via a signal line; the eddy current sensor (11) moves with the cage (2) to acquire a fault signal of the rigid tankway (3); the data acquisition card (12) uploads the acquired eddy current signal to the host computer (13); and the host computer (13) analyzes the type of tankway fault through software.