An online detection device for the balance rope rotator of a hoist

Abstract

This invention relates to the field of detection technology, specifically to an online detection device for a hoist balance rope rotator. The device includes a hoisting container, a rotator, a tail rope, a magnet, a sensor, a mounting frame, a support plate, a detection controller, and a hoist safety circuit. A magnet is installed on the side of the rotator. The sensor detects the interval time of the magnet's rotation to achieve online detection of the rotator's working status. The sensor is fixed to the mounting frame using a positioning nut. The distance between the sensor and the magnet can be adjusted by changing the position of the positioning nut on the sensor. The mounting frame and the support plate are connected by bolts and nuts. An elongated hole is drilled in the support plate to allow for vertical adjustment of the sensor's fixed position. This device enables online detection during the hoist's operation.

Description

Technical Field

[0001] This invention relates to the field of detection technology, specifically to an online detection device for a hoist balance rope rotator, and more particularly to a device for real-time online detection of the working status of the balance rope rotator and fault alarm during hoist operation. Background Technology

[0002] In a mine hoist, the balance rope's function is to adjust the balance of the wire rope, reducing static tension differences and achieving overall hoisting system balance. Because the balance rope has a specific twist, it rotates around its central axis during hoist operation. Therefore, both ends of the balance rope must be connected to the bottom of the hoisting container via a rotator. The rotator's function is to relieve the twist of the balance rope. The round tail rope rotates continuously during the hoist system's lifting and lowering operation. If the rotator malfunctions (such as bearing damage or jamming), the balance rope is prone to kinking, twisting, or even breakage, jeopardizing equipment and personnel safety.

[0003] Currently, the rotator is mainly inspected manually by rotating it to check its flexibility. This method is inconvenient, has a high risk factor, and cannot perform online real-time monitoring during equipment operation. Therefore, there is an urgent need for a device and method that can achieve online monitoring of the rotator during hoist operation. Summary of the Invention

[0004] The technical problem to be solved by this invention is that, in view of the shortcomings of existing technologies where the detection of rotators relies on manual labor and cannot be monitored online in real time, this invention provides an online detection device and method for the rotator of the hoist balance rope, which aims to realize online real-time detection and fault alarm of the rotator's working status.

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0006] In a first aspect, the present invention provides an online detection device for the balance rope rotator of a hoist, characterized in that the detection device includes: a hoisting container, a rotator, a tail rope, a magnet, a sensor, a fixing frame, a support plate, a detection controller, and a hoist safety circuit;

[0007] The magnet is fixedly installed on the side of the rotator;

[0008] The sensor is mounted on the lifting container via a fixing frame and a support plate, and corresponds to the position of the magnet, and is used to detect the signal generated by the magnet during the rotation of the rotator.

[0009] The mounting bracket is connected to the sensor via a positioning nut. By adjusting the position of the positioning nut on the sensor, the distance between the sensor and the magnet can be adjusted.

[0010] The support plate has an elongated hole, and the fixing bracket is connected to the support plate by bolts and nuts passing through the elongated hole. By adjusting the position of the bolts in the elongated hole, the vertical height of the sensor fixing position can be adjusted.

[0011] The detection controller is connected to the sensor signal and is used to receive and process the sensor signal;

[0012] The detection controller is connected to the safety circuit of the hoist.

[0013] Secondly, the present invention provides an online detection method for a hoist balance rope rotator based on the above-mentioned detection device, characterized in that the method includes the following steps:

[0014] (a) During the operation of the hoist, the sensor is used to detect in real time the periodic pulse signal generated when the magnet installed on the side of the rotator rotates;

[0015] (b) The detection controller receives the pulse signal sent by the sensor and calculates the time interval between two consecutive pulse signals;

[0016] (c) The detection controller compares the calculated time interval with a preset normal operating threshold range;

[0017] (d) If the time interval exceeds the preset normal operating threshold range, or if no pulse signal is detected for more than a preset duration, the detection controller determines that the rotator is malfunctioning.

[0018] (e) When the rotator is found to be malfunctioning, the detection controller sends a fault signal to the hoist safety circuit to trigger a fault alarm.

[0019] Compared with the prior art, the present invention has the following advantages:

[0020] 1. Enable online detection:

[0021] At the device level: By installing magnets on the rotator and using sensors to detect its rotation signal, the working status of the rotator can be monitored in real time during the operation of the hoist.

[0022] Methodologically: By detecting the pulse interval time generated by the rotation of the magnet and determining whether it is abnormal, an automated and quantitative online evaluation of the rotator's operating status is achieved.

[0023] 2. Adjustable position (device advantage): The sensor's front and rear positions can be adjusted by using the positioning nut (adjusting the distance from the magnet), and the sensor's up and down positions can be adjusted by moving the fixing frame within the long hole of the support plate, ensuring that the sensor can accurately detect the magnet signal at the hoist's stopping position.

[0024] 3. Security linkage:

[0025] At the device level: the device connects the detection controller to the hoist safety circuit.

[0026] At the methodological level: The method realizes the automatic judgment of the rotator's fault state and triggers the safety circuit alarm (and possible protective actions), effectively preventing serious accidents such as balance rope kinking and rope breakage caused by rotator failure.

[0027] 4. High degree of automation and reduced risk: It replaces dangerous manual inspection methods and achieves fully automatic, non-contact online monitoring and alarm through the combination of devices and methods, which significantly improves detection efficiency and operational safety.

[0028] 5. Method universality: The detection method has a clear logic and is based on time interval judgment. It can effectively identify various abnormal states such as rotator stopping, excessive speed or slow speed. Attached Figure Description

[0029] Figure 1 A front view of the hoist balance rope rotator detection device;

[0030] Figure 2 This is a side view of the hoist balance rope rotator detection device.

[0031] In the diagram: 1-lifting container, 2-rotator, 3-tail rope, 4-magnet, 5-sensor, 6-positioning nut, 7-fixed frame, 8-support plate, 9, 10-fixing bolts, 11-detection controller, 12-lifting machine safety circuit. Detailed Implementation

[0032] Example 1: Online detection device and method for hoist balance rope rotator.

[0033] See Figure 1 and Figure 2 This embodiment provides an online detection device and method for the balance rope rotator of a hoist.

[0034] I. Device Composition and Installation

[0035] The detection device mainly includes a hoisting container 1, a rotator 2, a tail rope 3, a magnet 4, a sensor 5, a positioning nut 6, a fixing frame 7, a support plate 8, fixing bolts 9 and nuts 10, a detection controller 11, and a hoist safety circuit 12. The specific installation is as follows:

[0036] 1. Magnet installation: A magnet 4 is fixedly installed on the side of the rotator 2.

[0037] 2. Sensor installation and adjustment:

[0038] The sensor 5 is fixed to the mounting bracket 7 using the positioning nut 6. By tightening the positioning nut 6, it can be moved back and forth on the threaded rod portion of the sensor 5, thereby finely adjusting the distance between the end of the sensor 5 and the magnet 4 on the side of the rotator 2. Figure 2 (Adjustment in the middle horizontal direction).

[0039] The mounting bracket 7 is connected to the support plate 8 using fixing bolts 9 and nuts 10. The support plate 8 is fixed to the bottom of the lifting container 1 and has two pre-machined vertical oblong holes. By loosening the bolts 9 and nuts 10, the position of the mounting bracket 7 (along with the sensor 5) on the support plate 8 can be moved up and down. After adjusting it appropriately, the bolts and nuts are tightened. Figure 1 (Vertical adjustment). This bidirectional adjustment mechanism ensures that sensor 5 can be accurately aligned with and detect magnet 4 when the hoist is stopped.

[0040] 3. Electrical Connection: The output signal line of sensor 5 is connected to the input port of detection controller 11. The output port (alarm signal output terminal) of detection controller 11 is connected to the corresponding input terminal of hoist safety circuit 12.

[0041] II. Detection Methods and Procedures

[0042] The following testing methods shall be performed during the operation of the hoist:

[0043] 1. Signal Detection: When the rotator 2 rotates normally with the balance rope (tail rope 3), the magnet 4 on its side will periodically pass through the sensing area of ​​the sensor 5. Whenever the magnet 4 approaches the sensor 5, the sensor 5 generates a pulse signal.

[0044] 2. Signal transmission: Sensor 5 sends the generated pulse signal to the detection controller 11 in real time.

[0045] 3. Interval Calculation: After receiving continuous pulse signals, the detection controller 11 calculates the time interval between two adjacent pulse signals. This time interval reflects the time required for the magnet 4 (i.e., the rotator 2) to rotate one revolution.

[0046] 4. Status judgment:

[0047] 1) The detection controller 11 has a preset time interval threshold range [Tmin-Tmax] for the rotator under normal operating conditions. This range is set based on the rotator's design speed and allowable fluctuation range.

[0048] 2) The detection controller 11 compares the calculated real-time time interval Δt with the preset threshold range:

[0049] If Δt remains within the range of [Tmin, Tmax], then the rotator is considered to be working normally.

[0050] If Δt > Tmax (rotating too slowly) or Δt < Tmin (rotating too fast), it is determined that the rotational speed of the rotator is abnormal.

[0051] If the next pulse signal is not detected after exceeding the preset timeout, it is determined that the rotator may be jammed and stopped rotating.

[0052] 5. Fault alarm:

[0053] When the detection controller 11 determines that the rotator is operating abnormally according to Step 4, a fault alarm signal is immediately generated, and this fault alarm signal is sent to the hoist safety circuit 12 through an electrical connection.

[0054] After receiving this fault signal, the hoist safety circuit 12 immediately triggers a preset alarm action:

[0055] 1) Start the audible and visual alarm (such as a warning bell, flashing light) to notify the operator.

[0056] 2) Display the rotator fault information on the operating console or monitoring screen.

[0057] In summary, the present invention effectively captures the physical quantity of the rotation of the rotator through a specific device structure (magnet, adjustable sensor bracket), and realizes the intelligent judgment and fault alarm of the working state of the rotator through the described detection method (pulse interval calculation, threshold comparison). The device and method are closely combined to jointly solve the problem that the balance rope rotator of the hoist cannot be detected online in real time, significantly improving the safety and reliability of the equipment operation.

[0058] It should be noted that the above embodiments are not used to limit the protection scope of the present invention. Equivalent transformations or substitutions made on the basis of the above technical solutions all fall within the protection scope of the claims of the present invention.

Claims

1. An online detection device for a hoist balance rope spinner, characterized in that The detection device includes a hoisting container, a rotator, a tail rope, a magnet, a sensor, a fixing frame, a support plate, a detection controller, and a hoist safety circuit. The magnet is fixedly installed on the side of the rotator. The sensor is mounted on the hoisting container via the fixing frame and the support plate, corresponding to the position of the magnet, and is used to detect the signal generated by the magnet during the rotation of the rotator. The sensor detects the interval time of the magnet's rotation to achieve online detection of the rotator's working status. The sensor is fixed to the fixing frame by a positioning nut. The distance between the sensor and the magnet can be adjusted by adjusting the position of the positioning nut on the sensor. The fixing frame and the support plate are connected by bolts and nuts. The detection controller is connected to the sensor signal and is used to receive and process the sensor signal. The detection controller is connected to the hoist safety circuit.

2. An online detection device for a hoist balance rope rotator according to claim 1, characterized in that An elongated hole is made in the support plate, and the fixing bracket is connected to the support plate by bolts and nuts passing through the elongated hole. By adjusting the position of the bolt in the elongated hole, the vertical height of the sensor fixing position can be adjusted, thereby realizing the vertical adjustment of the sensor fixing position.

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