Elastic coupling wear state detection device

Abstract

The utility model discloses a kind of elastic coupling wear state detection devices, including brushless power generation module, rectifier voltage stabilizing module, magnetic induction detection module and wireless communication module;The brushless power generation module includes permanent magnet generator;The rectifier voltage stabilizing module includes filter rectifier circuit and overvoltage protection circuit;The magnetic induction detection module includes hall sensor array, array interface circuit and infrared temperature sensor.The utility model realizes self-power supply by permanent magnet generator, carries out multi-parameter fusion real-time monitoring by adopting four-quadrant hall sensor array and infrared temperature sensor, and the data of monitoring is wirelessly transmitted to PLC control system, and it is convenient for remote monitoring personnel to know coupling wear state in time, compared with the detection mode in prior art, its detection efficiency is obviously improved, to realize the efficient, accurate, automated monitoring of industrial transmission system wear state.

Description

Technical Field

[0001] This utility model relates to the field of coupling technology, and in particular to a device for detecting the wear condition of flexible couplings. Background Technology

[0002] As a key component of industrial transmission systems, the wear condition of flexible couplings directly affects the operational safety and transmission efficiency of equipment. Traditional inspection methods are usually manual inspections, which have the following technical drawbacks: the couplings need to be disassembled periodically for visual inspection or micrometer measurement, resulting in low inspection efficiency and the inability to achieve real-time monitoring. Therefore, this application proposes a wear condition detection device for flexible couplings. Utility Model Content

[0003] The purpose of this invention is to address the shortcomings of existing technologies by proposing a wear condition detection device for flexible couplings.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A wear condition detection device for flexible couplings includes a brushless power generation module, a rectifier and voltage regulator module, a magnetic sensing module, and a wireless communication module;

[0006] The brushless power generation module includes a permanent magnet generator;

[0007] The rectifier and voltage regulator module includes a filter rectifier circuit and an overvoltage protection circuit;

[0008] The magnetic sensing module includes a Hall sensor array, an array interface circuit, and an infrared temperature sensor.

[0009] Preferably, the filter rectifier circuit includes a transformer T, diodes D1, D2, D3, and D4. Diodes D1, D2, D3, and D4 are connected in series to form a rectifier bridge. One end of capacitor C1 is electrically connected to pin 1 of transformer T. The other end of capacitor C1 is electrically connected to the negative terminal of diode D1 and the positive terminal of diode D4. Pin 2 of transformer T is electrically connected to the negative terminal of diode D2 and the positive terminal of diode D3. The positive terminals of diodes D1 and D2 are electrically connected to one end of the same capacitor C2. The other end of capacitor C2 is electrically connected to one end of resistor R1. The negative terminals of diodes D4 and D3 are electrically connected to one end of the same resistor R2. The other ends of resistors R2 and R1 are output terminals. Pins 3 and 4 of transformer T are both input terminals and are electrically connected to the generating terminal of the permanent magnet generator.

[0010] Preferably, the overvoltage protection circuit includes a resistor R3. One end of the resistor R3 is electrically connected to the cathode of diode D5 and one end of resistor R4. The other end of the resistor R4 is electrically connected to the base of transistor Q1. The emitter of transistor Q1 is electrically connected to the other end of resistor R3. The collector of transistor Q1 is electrically connected to one end of resistor R5. The other end of the resistor R3 is also electrically connected to the cathode of diode D6. The anode of diode D6 is electrically connected to the anode of diode D5. Resistor R5 is connected in parallel with resistor R6 and indicator LED. One end of resistor R6 is electrically connected to one end of indicator LED. The other end of resistor R6 is electrically connected to one end of resistor R5. The other end of indicator LED, the other end of resistor R5, the anode of diode D6, and the anode of diode D5 are all grounded. The other end of resistor R3 is the input terminal and is electrically connected to the other ends of resistor R2 and resistor R1.

[0011] Preferably, the array interface circuit includes an electromagnetic coil L, one end of which is electrically connected to one end of a capacitor C3, the other end of which is electrically connected to one end of a resistor R9, the other end of which is grounded, the other end of which is electrically connected to the emitter of a transistor Q2, the emitter of which is electrically connected to the emitter of a transistor Q3, the base of which and the base of which are electrically connected to pin 3 of the same comparator U1, pins 1 and 2 of which are electrically connected to one end of a resistor R8 and one end of a resistor R7, respectively, and the other ends of which are electrically connected to the Hall sensor array.

[0012] Preferably, the infrared temperature sensor is installed on the coupling to measure the surface temperature of the coupling in real time and detect abnormal temperature rise caused by increased friction.

[0013] Preferably, the wireless communication module adopts industrial-grade LoRa wireless transmission, supports the Modbus-RTU protocol, and is matched with an external PLC control system.

[0014] Preferably, the Hall sensor array is a four-quadrant layout, consisting of four sensors evenly distributed at 90° intervals, and is embedded in the coupling cover, maintaining a 1-3mm air gap with the solenoid valve L.

[0015] Compared with existing technologies, the beneficial effects of this utility model are:

[0016] This invention achieves self-powered operation through a permanent magnet generator and uses a four-quadrant Hall sensor array and an infrared temperature sensor for multi-parameter fusion and real-time monitoring. The monitored data is wirelessly transmitted to the PLC control system, allowing remote monitoring personnel to promptly obtain information on the wear status of the coupling. Compared with existing detection methods, its detection efficiency is significantly improved, thus achieving efficient, accurate, and automated monitoring of the wear status of industrial transmission systems. Attached Figure Description

[0017] Figure 1 This is a connection block diagram of a wear condition detection device for an elastic coupling proposed in this utility model;

[0018] Figure 2 The circuit diagram is shown in the filter and rectifier circuit of the wear condition detection device for flexible coupling proposed in this utility model.

[0019] Figure 3 The circuit diagram is shown in the overvoltage protection circuit of the wear condition detection device for flexible coupling proposed in this utility model.

[0020] Figure 4 This is a circuit diagram of the array interface circuit in a wear condition detection device for an elastic coupling proposed in this utility model. Detailed Implementation

[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0022] Reference Figures 1-4 A wear condition detection device for flexible coupling includes a brushless power generation module, a rectifier and voltage regulator module, a magnetic sensing module and a wireless communication module. The wireless communication module adopts industrial-grade LoRa wireless transmission, supports the Modbus-RTU protocol, and is matched with an external PLC control system.

[0023] Brushless power generation modules include permanent magnet generators;

[0024] The rotor of the permanent magnet generator is equipped with high-performance permanent magnets, forming a constant strong magnetic field. The magnetic poles typically employ a multi-pole pair design, and the magnetic field distribution is optimized using a Halbach array to make the air gap magnetic flux density waveform approach a sine wave. When the coupling drives the rotor to rotate, the permanent magnet magnetic field moves relative to the stator windings. The stator core uses laminated silicon steel to reduce eddy current losses, and the windings are connected in a three-phase star configuration. The number of effective conductors per phase is precisely designed based on the speed-voltage characteristics. The rotating magnetic field induces an electromotive force in the stator windings, following Faraday's law. Where N is the number of turns in the winding, B is the magnetic flux density, and A is the effective cross-sectional area;

[0025] The rectifier and voltage regulator module includes a filter and rectifier circuit and an overvoltage protection circuit;

[0026] The filter and rectifier circuit includes a transformer T, diodes D1, D2, D3, and D4. Diodes D1, D2, D3, and D4 are connected in series to form a rectifier bridge. One end of capacitor C1 is electrically connected to pin 1 of transformer T. The other end of capacitor C1 is electrically connected to the cathode of diode D1 and the anode of diode D4. Pin 2 of transformer T is electrically connected to the cathode of diode D2 and the anode of diode D3. The anodes of diodes D1 and D2 are electrically connected to one end of the same capacitor C2. The other end of capacitor C2 is electrically connected to one end of resistor R1. The cathodes of diodes D4 and D3 are electrically connected to one end of the same resistor R2. The other ends of resistors R2 and R1 are the output terminals. Pins 3 and 4 of transformer T are both input terminals and are electrically connected to the generating end of the permanent magnet generator.

[0027] The overvoltage protection circuit includes resistor R3. One end of resistor R3 is electrically connected to the cathode of diode D5 and one end of resistor R4. The other end of resistor R4 is electrically connected to the base of transistor Q1. The emitter of transistor Q1 is electrically connected to the other end of resistor R3. The collector of transistor Q1 is electrically connected to one end of resistor R5. The other end of resistor R3 is also electrically connected to the cathode of diode D6. The anode of diode D6 is electrically connected to the anode of diode D5. Resistor R5 is connected in parallel with resistor R6 and indicator LED. One end of resistor R6 is electrically connected to one end of indicator LED. The other end of resistor R6 is electrically connected to one end of resistor R5. The other end of indicator LED, the other end of resistor R5, the anode of diode D6, and the anode of diode D5 are all grounded. The other end of resistor R3 is the input terminal and is electrically connected to the other ends of resistor R2 and resistor R1.

[0028] The magnetic sensing module includes a Hall sensor array, an array interface circuit, and an infrared temperature sensor;

[0029] The array interface circuit includes an electromagnetic coil L, one end of which is electrically connected to one end of a capacitor C3, the other end of which is electrically connected to one end of a resistor R9, the other end of which is grounded, the other end of which is electrically connected to the emitter of a transistor Q2, the emitter of which is electrically connected to the emitter of a transistor Q3, the base of which and the base of which are electrically connected to pin 3 of the same comparator U1, pins 1 and 2 of which are electrically connected to one end of a resistor R8 and one end of a resistor R7, respectively, and the other ends of which are electrically connected to the Hall sensor array.

[0030] The Hall sensor array has a four-quadrant layout, consisting of four sensors evenly distributed at 90° intervals. They are embedded in the coupling cover and maintain a 1-3mm air gap with the solenoid valve L. Each Hall sensor measures the tangential magnetic field component of the coupling magnetic ring to achieve radial detection.

[0031] An infrared temperature sensor is installed on the coupling to measure the surface temperature of the coupling in real time and detect abnormal temperature rise caused by increased friction.

[0032] Among them, the preferred infrared temperature sensor is the industrial-grade infrared temperature sensor with model number MLX90614ESF-DCI-000-TU, which detects temperature based on the blackbody radiation law and photoelectric detection technology; its specific detection principle is existing technology and will not be elaborated here.

[0033] This invention achieves self-powered operation through a permanent magnet generator and uses a four-quadrant Hall sensor array and an infrared temperature sensor for multi-parameter fusion and real-time monitoring. The monitored data is wirelessly transmitted to the PLC control system, allowing remote monitoring personnel to promptly obtain information on the wear status of the coupling. Compared with existing detection methods, its detection efficiency is significantly improved, thus achieving efficient, accurate, and automated monitoring of the wear status of industrial transmission systems.

[0034] Working principle: When the coupling rotates, it drives the permanent magnet generator rotor to rotate, generating three-phase alternating current through electromagnetic induction. This three-phase alternating current is input to a full-bridge rectifier circuit composed of diodes D1, D2, D3, and D4. After harmonic suppression by a π-type LC filter composed of capacitors C1 and C2, a pulsating direct current is output. The rectified direct current voltage is sampled by a voltage divider network composed of resistors R3 and R4, and the voltage division ratio is calculated. When the sampled voltage exceeds the reference value, diodes D5 and D6 form a 5.8V reference, and transistor Q1 enters the saturation conduction state. After transistor Q1 conducts, the following linkage effect occurs: the collector current of transistor Q1 forms a voltage drop through resistor R5, triggering the parallel diode D6 to conduct, thereby achieving the overvoltage protection effect.

[0035] Simultaneously, the output pulsating DC power supplies the Hall sensor array and the infrared temperature sensor. The Hall sensor array, distributed in four quadrants, monitors the radial clearance change of the coupling in real time through electromagnetic coupling, while the infrared temperature sensor detects the surface temperature rise. The signal is processed by comparator U1 and array interface circuit, and then transmitted to the PLC control system via wireless communication module, so that remote monitoring personnel can know the wear status of the coupling in a timely manner. When the clearance exceeds the threshold or the temperature is abnormal, the base bias voltage of transistor Q1 cuts off the collector-emitter path, and at the same time triggers the parallel diode D6 to conduct and discharge energy, realizing self-powered closed-loop monitoring of the wear status.

[0036] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A device for detecting the wear condition of a flexible coupling, characterized in that, It includes a brushless power generation module, a rectifier and voltage regulator module, a magnetic sensing module, and a wireless communication module; The brushless power generation module includes a permanent magnet generator; The rectifier and voltage regulator module includes a filter rectifier circuit and an overvoltage protection circuit; The magnetic sensing module includes a Hall sensor array, an array interface circuit, and an infrared temperature sensor.

2. The wear condition detection device for a flexible coupling according to claim 1, characterized in that, The filtering and rectifier circuit includes a transformer T, diodes D1, D2, D3, and D4. Diodes D1, D2, D3, and D4 are connected in series to form a rectifier bridge. One end of capacitor C1 is electrically connected to pin 1 of transformer T. The other end of capacitor C1 is electrically connected to the cathode of diode D1 and the anode of diode D4. Pin 2 of transformer T is electrically connected to the cathode of diode D2 and the anode of diode D3. The anodes of diodes D1 and D2 are electrically connected to one end of the same capacitor C2. The other end of capacitor C2 is electrically connected to one end of resistor R1. The cathodes of diodes D4 and D3 are electrically connected to one end of the same resistor R2. The other ends of resistors R2 and R1 are the output terminals. Pins 3 and 4 of transformer T are both input terminals and are electrically connected to the generating terminal of the permanent magnet generator.

3. The wear condition detection device for a flexible coupling according to claim 2, characterized in that, The overvoltage protection circuit includes a resistor R3. One end of resistor R3 is electrically connected to the cathode of diode D5 and one end of resistor R4. The other end of resistor R4 is electrically connected to the base of transistor Q1. The emitter of transistor Q1 is electrically connected to the other end of resistor R3. The collector of transistor Q1 is electrically connected to one end of resistor R5. The other end of resistor R3 is also electrically connected to the cathode of diode D6. The anode of diode D6 is electrically connected to the anode of diode D5. Resistor R5 is connected in parallel with resistor R6 and an indicator LED. One end of resistor R6 is electrically connected to one end of indicator LED. The other end of resistor R6 is electrically connected to one end of resistor R5. The other end of indicator LED, the other end of resistor R5, the anodes of diode D6 and D5 are all grounded. The other end of resistor R3 is the input terminal and is electrically connected to the other ends of resistor R2 and resistor R1.

4. The wear condition detection device for a flexible coupling according to claim 1, characterized in that, The array interface circuit includes an electromagnetic coil L. One end of the electromagnetic coil L is electrically connected to one end of a capacitor C3. The other end of the capacitor C3 is electrically connected to one end of a resistor R9. The other end of the resistor R9 is grounded. The other end of the electromagnetic coil L is electrically connected to the emitter of a transistor Q2. The emitter of transistor Q2 is electrically connected to the emitter of a transistor Q3. The base of transistor Q3 and the base of diode Q2 are electrically connected to pin 3 of the same comparator U1. Pins 1 and 2 of comparator U1 are electrically connected to one end of a resistor R8 and one end of a resistor R7, respectively. The other ends of resistors R8 and R7 are both electrically connected to the Hall sensor array.

5. The wear condition detection device for a flexible coupling according to claim 1, characterized in that, The infrared temperature sensor is installed on the coupling to measure the surface temperature of the coupling in real time and detect abnormal temperature rise caused by increased friction.

6. The wear condition detection device for a flexible coupling according to claim 1, characterized in that, The wireless communication module adopts industrial-grade LoRa wireless transmission, supports the Modbus-RTU protocol, and is matched with an external PLC control system.

7. The wear condition detection device for a flexible coupling according to claim 4, characterized in that, The Hall sensor array has a four-quadrant layout, consisting of four sensors evenly distributed at 90° intervals. It is embedded in the coupling cover and maintains a 1-3mm air gap with the solenoid valve L.

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