A dynamic load monitoring instrument for mining trucks

Abstract

This utility model relates to the field of mining truck technology, and in particular to a dynamic load monitoring device for mining trucks, comprising three main modules: data acquisition, data processing, and display / alarm, which are electrically connected in sequence. The data acquisition module collects real-time vehicle loading and driving data through sensors on the mining truck; the data processing module receives and processes the data to derive the average dynamic load for one operating cycle; the display and alarm module displays the collected data and average dynamic load in real time, and alarms when the value exceeds a preset calibration limit. It can accurately monitor changes in the dynamic load of mining trucks, solving the problem of traditional methods failing to obtain dynamic load data in real time, avoiding the aggravation of equipment wear due to unknown dynamic load, and helping personnel to promptly detect equipment anomalies, avoiding cumulative downtime due to faults, meeting the requirements for safe, stable, and long-term full-load operation of vehicles. It also changes the traditional manual periodic shutdown maintenance mode, reducing maintenance costs and improving the timeliness and accuracy of maintenance.

Description

Technical Field

[0001] This utility model relates to the field of mining truck technology, and in particular to a dynamic load monitoring device for mining trucks. Background Technology

[0002] Mining trucks are transport vehicles that operate under off-road conditions. In particular, large-capacity mining trucks work under heavy loads on harsh roads. Factors such as the suspension and shock absorption system, road surface smoothness, average load, and tire inflation pressure cause huge impact dynamic loads on the structural components of mining trucks. The increased vibration reduces the reliability of electrical components. Under normal circumstances, the maximum dynamic load can reach more than three times the static load. Therefore, the relatively short service life of mining trucks is largely due to this.

[0003] The requirements of mine management and operators for safe, stable, long-term, and full-load operation of mining truck equipment are becoming increasingly urgent. To avoid accumulated failures leading to downtime and huge economic losses to the entire production system, the traditional manual periodic shutdown maintenance and visual inspection can no longer meet the requirements of modern production. Therefore, the development of condition monitoring instruments for mining truck operation is of great significance. Utility Model Content

[0004] The purpose of this utility model is to provide a dynamic load monitoring instrument for mining trucks, so as to solve the technical problem that the existing technology cannot detect changes in the operating conditions of the vehicle in a timely and accurate manner, which leads to an increase in dynamic load.

[0005] This utility model provides a dynamic load monitoring device for mining trucks, including a data acquisition module, a data processing module, and a display and alarm module; the data acquisition module is electrically connected to the data processing module, and the data processing module is electrically connected to the display and alarm module;

[0006] The data acquisition module is used to collect data in real time during the loading and driving process of the mining truck through sensors installed on the mining truck; the data includes at least the pressure of the oil-pneumatic suspension cylinder, the change in the height of the oil-pneumatic suspension cylinder, the vehicle speed, and the tire pressure.

[0007] The data processing module is used to receive data transmitted by the data acquisition module, analyze and process the data based on a preset algorithm and model, and calculate the average dynamic load of a mining truck in one operating cycle.

[0008] The display and alarm module is used to display the data collected by the data acquisition module and the average dynamic load calculated by the data processing module in real time, and to issue an alarm signal when the average dynamic load exceeds the preset calibration limit value.

[0009] Furthermore, the sensors in the data acquisition module include a hydraulic suspension cylinder pressure sensor, a hydraulic suspension cylinder height sensor, a vehicle speed sensor, and a tire pressure sensor; the hydraulic suspension cylinder pressure sensor is used to collect the inflation working pressure of the hydraulic suspension cylinder, the hydraulic suspension cylinder height sensor is used to collect the stroke change of the hydraulic suspension cylinder to obtain height change data, the vehicle speed sensor is used to collect the driving speed of the mining truck, and the tire pressure sensor is used to collect tire pressure.

[0010] Furthermore, it also includes a vehicle tilt sensor for detecting load deviations.

[0011] Furthermore, the pressure sensor of the hydropneumatic suspension cylinder is installed next to the inflation valve of the hydropneumatic suspension cylinder.

[0012] Furthermore, the pressure sensor of the oil-gas suspension cylinder is installed next to the inflation valve of the oil-gas suspension cylinder via an auxiliary valve block.

[0013] Furthermore, the data acquisition module also includes a sensor signal acquisition and amplification circuit, which includes at least four operational amplifiers. Each operational amplifier is connected to a hydraulic suspension cylinder pressure sensor and is used to amplify and process the signals acquired by the hydraulic suspension cylinder pressure sensor before transmitting them to the data processing module.

[0014] Furthermore, the data processing module employs a microprocessor and also includes a power supply circuit, an A / D conversion circuit, and a CPU interface circuit.

[0015] The power supply circuit includes a sensor and amplifier power supply and a CPU power supply. The sensor and amplifier power supply converts the +24V voltage of the mining truck battery to +18V and +12V voltages to power the sensors and operational amplifiers. The CPU power supply converts the +12V voltage to +5V and -5V voltages to power the microprocessor.

[0016] The A / D conversion circuit is used to convert the analog signal transmitted by the data acquisition module into a digital signal, and the CPU interface circuit is used to realize data transmission between the A / D conversion circuit and the microprocessor.

[0017] Furthermore, the data processing module also has a data storage unit that can save the statistically processed data, and is equipped with a data output interface.

[0018] Furthermore, the monitor also includes an operation control component, which is electrically connected to the data processing module. The operation control component includes a power switch, a start switch, a calibration button, and a display button.

[0019] The power switch is used to control the monitoring instrument to turn on and off, the start switch is used to control the start and stop of the monitoring function, the calibration button is used to start the calibration program, and the display button is used to control the display screen to display or not display data.

[0020] Furthermore, the monitoring device is embedded in the dashboard of the mining truck's cab.

[0021] Beneficial effects:

[0022] This invention uses a data acquisition module to collect real-time loading and driving data of mining trucks, and a data processing module to calculate the average dynamic load of the operating cycle. This allows for precise monitoring of dynamic load changes in mining trucks, solving the problem of traditional methods failing to obtain dynamic load data in real time. It avoids increased equipment wear due to unknown dynamic loads and effectively handles harsh operating conditions where dynamic loads exceed three times the static load. Real-time display of monitoring data and average dynamic load, along with alarms when exceeding calibrated limits, helps mine management and operators promptly detect equipment anomalies, preventing accumulated faults and downtime. This meets the urgent requirements for safe, stable, long-term, and full-load operation of mining trucks, reducing the impact on the production system. It changes the traditional maintenance model of periodic manual shutdowns and visual inspections, achieving effective monitoring without frequent shutdowns, reducing maintenance costs, improving the timeliness and accuracy of mining truck maintenance, extending equipment lifespan, and reducing economic losses. This is of great significance for ensuring continuous mine production. Attached Figure Description

[0023] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0024] Figure 1 This paper shows a circuit structure block diagram of a mining truck dynamic load monitoring instrument according to an embodiment of the present application;

[0025] Figure 2 This illustration shows a schematic diagram of a pressure sensor being added to a dynamic load monitoring instrument for a mining truck, according to an embodiment of this application.

[0026] Figure 3 This illustration shows a schematic diagram of a pressure sensor being added to a dynamic load monitoring instrument for a mining truck, according to an embodiment of this application.

[0027] Figure 4 A schematic diagram of the appearance of a mining truck dynamic load monitoring device according to an embodiment of this application is shown;

[0028] Figure 5 The sensor signal acquisition and amplification circuit is shown;

[0029] Figure 6 The power supply circuit for the sensor and microprocessor is shown;

[0030] Figure 7 The A / D conversion and CPU interface circuits are shown.

[0031] Explanation of reference numerals in the attached diagram: 1-sensor connector, 2-sensor signal acquisition and amplification circuit, 3-microprocessor, 4-inflation valve, 5-pressure sensor, 6-auxiliary valve block. Detailed Implementation

[0032] The technical solution of this utility model will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0033] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0034] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified. Furthermore, the terms "installed," "connected," and "linked" should be interpreted broadly; for example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0035] Example 1

[0036] A dynamic load monitoring device for mining trucks includes a data acquisition module, a data processing module, and a display and alarm module. The data acquisition module is electrically connected to the data processing module and is used to collect vehicle loading and driving data in real time through sensors installed on the mining truck. This data includes at least the pressure of the hydraulic suspension cylinder, the change in the hydraulic suspension cylinder height, the vehicle speed, and the tire pressure. The collected data is transmitted to the data processing module in real time; specifically, the signals from multiple sensors are aggregated and transmitted to the sensor connector 1.

[0037] The data processing module employs a high-performance microprocessor 3, possessing anti-interference and anti-vibration capabilities, and a wide operating temperature range. It is compatible with the 24V DC regulated power supply system of mining trucks and can save critical information during power outages. After receiving data transmitted from the data acquisition module, this module analyzes and processes the data based on preset algorithms and models to calculate the average dynamic load of the mining truck for one operating cycle.

[0038] The display and alarm module is electrically connected to the data processing module. On the one hand, it can display the raw data collected by the data acquisition module (such as hydraulic suspension cylinder pressure, vehicle speed, tire pressure, etc.) and the average dynamic load calculated by the data processing module in real time. On the other hand, when the average dynamic load exceeds the limit value calibrated according to the standard condition, or the dynamic load coefficient exceeds the preset driving dynamic load evaluation calibration value, it will issue an audible and visual alarm signal to remind the driver or management personnel to take appropriate measures in a timely manner.

[0039] Furthermore, the sensors in the data acquisition module include a hydraulic suspension cylinder pressure sensor, a hydraulic suspension cylinder height sensor, a vehicle speed sensor, and a tire pressure sensor. The vehicle speed sensor and tire pressure sensor can preferably be the original sensors provided with the mining truck to reduce costs; if the original vehicle does not have them, they will be added separately. There are two installation methods for the hydraulic suspension cylinder pressure sensor: one is to drill a hole next to the cylinder head inflation valve for connection; the other is to install an auxiliary valve at the original inflation valve installation location and then connect. Both installation methods can effectively collect hydraulic suspension cylinder pressure data.

[0040] The data acquisition module also includes a sensor signal acquisition and amplification circuit 2. This circuit has at least four operational amplifiers (such as LM358), each of which is connected to a hydraulic suspension cylinder pressure sensor. It can amplify the weak pressure signal acquired by the sensor to ensure the accuracy and stability of the signal transmission, and then transmit the amplified signal to the data processing module.

[0041] The power supply circuit of the data processing module is divided into power supplies for the sensors and amplifiers, and a CPU power supply. The sensor and amplifier power supplies use W7818 and W7812 voltage regulator chips to convert the +24V voltage from the mining truck battery to +18V and +12V respectively, powering the sensors and operational amplifiers. The CPU power supply uses W7805 and W7905 voltage regulator chips to convert the +12V voltage to +5V and -5V, providing a stable power supply to the microprocessor. Furthermore, the A / D conversion circuit of the data processing module uses the ICL7135 chip, responsible for converting the analog signals transmitted by the data acquisition module into digital signals, while the CPU interface circuit enables data interaction between the A / D conversion circuit and the microprocessor.

[0042] The preset algorithm of the data processing module is as follows: During the operation of the mining truck, the dynamic load pressure value of the oil-gas suspension is continuously sampled according to the set sampling frequency (which can be adjusted according to actual needs). The sampling process continues until a lifting signal of the truck bed is received (indicating that the mining truck has completed unloading). Using the loading weight measured in this loading as the basic evaluation standard, all sampled values ​​are compared with this basic evaluation standard and divided into four categories: Category 1 sampled values ​​are lower than the basic evaluation standard; Category 2 sampled values ​​are higher than the basic evaluation standard but not exceeding 1-2 times; Category 3 sampled values ​​are higher than the basic evaluation standard but not exceeding 2-3 times; and Category 4 sampled values ​​are higher than 3 times the basic evaluation standard.

[0043] Calculate the average value for each type of sampled data, then count the proportion of each of the four data types to the total sampled data. Finally, calculate the weighted average using the following formula to obtain the average dynamic load for one operating cycle:

[0044]

[0045] in, For the average dynamic load, t1, t2, t3, and t4 represent the frequencies of occurrence of the four data types. , , , These are the averages of the four types of data. This represents the total sampling frequency.

[0046] At the same time, the data processing module will also calculate the dynamic load factor K. d The calculation formula is as follows:

[0047]

[0048] Where W is the measured value of this loading, and the calculated dynamic load coefficient K d When the preset dynamic load rating value for the vehicle is exceeded, the display and alarm modules will issue an alarm signal.

[0049] In addition, the data processing module also has data storage and transmission functions, which can save the statistically processed average dynamic load, dynamic load coefficient, and various raw collected data. It also has a data output interface, through which managers can download data for subsequent trend analysis, troubleshooting, and other tasks.

[0050] The monitor is also equipped with an operation control component, which is electrically connected to the data processing module. This component includes a power switch, a start switch, a calibration button, and a display button. The power switch controls the overall operation of the monitor; the start switch controls the start and stop of the monitoring function, allowing the driver to turn it off when not in use, saving energy; the calibration button initiates the calibration program, allowing administrators to reset parameters such as basic evaluation standards, dynamic load limits, and driving dynamic load evaluation calibration values ​​based on the specific model, service life, and loading standards of the mining truck, ensuring the accuracy and compatibility of the monitoring; the display button controls whether the display shows data or not, allowing the display to be turned off to avoid distractions when the driver is focused on driving.

[0051] The monitoring device is integrated into the dashboard of the mining truck's cab, featuring a compact structure that doesn't occupy excessive driving space and allows the driver easy access to displayed data and control components. In practical applications, if conditions permit, the data acquisition module can also collect vehicle tilt data. Based on the vehicle's tilt, the data processing module can calculate the mining truck's load deviation, providing a reference for adjusting the vehicle's load balance.

[0052] Data acquisition module deployment:

[0053] Sensor selection and installation: High-speed, high-stability, and anti-interference sensors are selected. Among them, the hydraulic suspension cylinder pressure sensor adopts a product with an accuracy class of 0.5 and a range adapted to the working pressure range of the hydraulic suspension cylinder of the mining truck; the hydraulic suspension cylinder height sensor adopts a laser displacement sensor with a measurement accuracy of ±0.1mm; the vehicle speed sensor and tire pressure sensor should preferably be the sensors originally equipped on the mining truck. If the original vehicle does not have them, products adapted to the mining truck model should be selected.

[0054] According to the oil-gas suspension cylinder pressure sensor Figure 2 or Figure 3 Install as shown: Figure 2 The method is to connect the pressure sensor 5 directly next to the air filling valve 4 of the oil-gas suspension cylinder; Figure 3The pressure sensor 5 is connected to the inflation valve 4 via the auxiliary valve block 6. Both installation methods must ensure sealing performance to prevent pressure leakage from affecting data acquisition. The hydraulic suspension cylinder height sensor is installed on the cylinder head at the piston extension end to ensure accurate acquisition of hydraulic suspension cylinder stroke changes; the vehicle speed sensor and tire pressure sensor are connected according to the original vehicle interface or standard interface to ensure normal signal transmission.

[0055] Signal amplification and processing: according to Figure 5 The sensor signal acquisition and amplification circuit shown is constructed using four LM358 operational amplifiers (U1-U4). Each operational amplifier is connected to a hydraulic suspension cylinder pressure sensor. The circuit input voltage is +12V. The pressure signal acquired by the sensor is amplified and processed, and the amplified signal is transmitted to the A / D conversion circuit of the data processing module.

[0056] Data processing module setup

[0057] Hardware configuration: A high-performance microprocessor (such as the 8051 microprocessor) with anti-interference and vibration resistance, and an operating temperature range of -40℃ to 85℃, is selected to suit the harsh working environment of mining trucks. According to... Figure 1 The circuit structure block diagram is shown.

[0058] Power supply circuit according to Figure 6 The setup shown is as follows: For the power supply section for the sensors and amplifiers, the +24V voltage from the car battery is converted to +18V using a W7818 voltage regulator chip, and then converted to +12V using a W7812 voltage regulator chip, to power the sensors and operational amplifiers respectively; For the CPU power supply section, the +12V voltage is converted to +5V using a W7805 voltage regulator chip, and then converted to -5V using a W7905 voltage regulator chip, to power the microprocessor, ensuring stable power supply for each hardware module.

[0059] A / D conversion and CPU interface circuit according to Figure 7 The setup shown uses the ICL7135 chip as the A / D conversion chip to convert the analog signal transmitted by the data acquisition module into a digital signal, and then realizes the A / D conversion through the CPU interface circuit composed of the 74LS157 chip, etc.

[0060] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A dynamic load monitoring instrument for mining trucks, characterized in that, It includes a data acquisition module, a data processing module, and a display and alarm module; the data acquisition module is electrically connected to the data processing module, and the data processing module is electrically connected to the display and alarm module. The data acquisition module is used to collect data in real time during the loading and driving process of the mining truck through sensors installed on the mining truck; The data processing module is used to receive the data transmitted by the data acquisition module, process it, and obtain the average dynamic load of the mining truck in one operating cycle. The display and alarm module is used to display the data collected by the data acquisition module and the average dynamic load calculated by the data processing module in real time, and to issue an alarm signal when the average dynamic load exceeds the preset calibration limit value.

2. The mining truck dynamic load monitoring instrument according to claim 1, characterized in that, The sensors in the data acquisition module include a hydraulic suspension cylinder pressure sensor, a hydraulic suspension cylinder height sensor, a vehicle speed sensor, and a tire pressure sensor.

3. The mining truck dynamic load monitoring instrument according to claim 2, characterized in that, It also includes a vehicle tilt sensor to detect load deviations.

4. The mining truck dynamic load monitoring instrument according to claim 2, characterized in that, The pressure sensor for the hydropneumatic suspension cylinder is installed next to the inflation valve of the hydropneumatic suspension cylinder.

5. The mining truck dynamic load monitoring instrument according to claim 2, characterized in that, The pressure sensor of the oil-gas suspension cylinder is installed next to the inflation valve of the oil-gas suspension cylinder via an auxiliary valve block.

6. The dynamic load monitoring instrument for mining trucks according to claim 1, characterized in that, The data acquisition module further includes a sensor signal acquisition and amplification circuit, which includes at least four operational amplifiers. Each operational amplifier is connected to a hydraulic suspension cylinder pressure sensor and is used to amplify and process the signals acquired by the hydraulic suspension cylinder pressure sensor before transmitting them to the data processing module.

7. The mining truck dynamic load monitoring instrument according to claim 1, characterized in that, The data processing module employs a microprocessor and further includes a power supply circuit, an A / D conversion circuit, and a CPU interface circuit. The power supply circuit includes power supplies for the sensor and amplifier, as well as a CPU power supply. The A / D conversion circuit is used to convert the analog signals transmitted by the data acquisition module into digital signals. The CPU interface circuit is used to realize data transmission between the A / D conversion circuit and the microprocessor.

8. The dynamic load monitoring instrument for mining trucks according to claim 1, characterized in that, The data processing module also has a data storage unit, which can save the statistically processed data, and is equipped with a data output interface.

9. The dynamic load monitoring instrument for mining trucks according to claim 1, characterized in that, The monitor also includes an operation control component, which is electrically connected to the data processing module. The operation control component includes a power switch, a start switch, a calibration button, and a display button. The power switch is used to control the monitoring instrument to turn on and off, the start switch is used to control the start and stop of the monitoring function, the calibration button is used to start the calibration program, and the display button is used to control the display screen to display or not display data.

10. The dynamic load monitoring instrument for mining trucks according to claim 1, characterized in that, The monitoring device is embedded in the dashboard of the mining truck's cab.

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