A multi-component on-line thickness detection device for slurry pump of dredger and mine

Abstract

The utility model relates to a kind of online thickness detection device of multiple components of slurry pump for silt ship and mine, including multiple components micropore pre-embedded structure, pre-embedded probe assembly, high-speed rotating signal transmission unit and data acquisition processing center and early warning terminal;The multiple components micropore pre-embedded structure includes laser micropore on the impeller of slurry pump, metal inner runner sheath, inner lining and main shaft, hole inner wall is made hard anodic oxidation treatment, aperture is made rounding treatment;The pre-embedded probe assembly includes probe with micropore interference fit, sealing ring between probe and micropore gap, probe tail connects double-layer shielded wire;The high-speed rotating signal transmission unit includes multi-channel conductive slip ring installed on the main shaft end of slurry pump pump body, signal conditioning module fixed in main shaft, slip ring rotor end connects probe shielded wire, stator end connects signal conditioning module.Pre-embedded structure does not need to disassemble pump, can detect the thickness of impeller, sheath, inner lining in the slurry pump operation synchronously, and detection efficiency is improved.

Description

Technical Field

[0001] This utility model relates to the field of slurry pump operation and maintenance testing technology, specifically to an online testing device suitable for slurry pump impeller, metal inner flow channel sheath and inner lining thickness detection scenarios. Background Technology

[0002] The core flow-through components of slurry pumps used in sludge ships and mines include the impeller, metal inner flow channel sleeve, and lining. These components are subjected to long-term erosion and wear from hard particles, and changes in their thickness directly determine the operational safety of the equipment. Existing detection technologies have the following structural defects:

[0003] For example, ultrasonic thickness gauges require disassembling the pump to expose components, and endoscopes can only observe the surface. Neither has a pre-embedded detection structure suitable for complex curved surfaces, such as impeller blades and flow channel bends, making it impossible to perform non-stop testing. A single stop test takes 2-3 hours, interrupting the continuity of operations.

[0004] Similar technologies, such as rotary shaft thickness measuring devices, use fixed probes and liquid coupling agents, lack signal conduction structures for high-speed impeller rotation, have a signal interruption rate exceeding 60% when the speed is >1000 r / min, and lack anti-electromagnetic interference structures, resulting in a data error rate >20%.

[0005] Existing devices can only detect single components such as the main shaft, and lack an integrated detection structure that covers the impeller, sheath, and inner liner. They cannot provide early warning of chain damage risks, such as impeller wear-through leading to sheath scratches.

[0006] The aforementioned structural defects prevent existing technologies from meeting the real-time and preventative maintenance requirements of slurry pumps, necessitating the development of an online thickness detection device for multiple components of slurry pumps used in slurry ships and mines. Utility Model Content

[0007] To address the problems mentioned above in the background technology, this utility model proposes an online thickness detection device for multiple components of slurry pumps used in sludge ships and mines, in order to overcome the aforementioned technical problems existing in the relevant prior art.

[0008] Therefore, the specific technical solution adopted by this utility model is as follows:

[0009] An online thickness detection device for multiple components of a slurry pump used in sludge ships and mines includes a multi-component micro-hole pre-embedded structure, a pre-embedded probe assembly, a high-speed rotating signal transmission unit, a data acquisition and processing center, and an early warning terminal.

[0010] The multi-component micro-hole pre-embedded structure includes laser micro-holes installed on the slurry pump impeller, metal inner flow channel sleeve, liner and main shaft. The inner wall of the hole is hard anodized and the hole opening is rounded.

[0011] The pre-embedded probe assembly includes a probe that is interference-fitted with a micropore, a sealing ring disposed in the gap between the probe and the micropore, and a double-layer shielded wire connected to the tail of the probe.

[0012] The high-speed rotating signal transmission unit includes a multi-channel conductive slip ring installed at the end of the main shaft of the slurry pump body, a signal conditioning module fixed inside the main shaft, a probe shielding wire connected to the rotor end of the slip ring, and a signal conditioning module connected to the stator end.

[0013] The data processing center and early warning terminal include an industrial-grade acquisition module and a three-level early warning structure. The terminal is connected to the signal conditioning module via RS485 or Ethernet.

[0014] As a further embodiment of this utility model, the micropore diameter is 2-6mm, the depth is 5-40mm, the thickness is based on the thickness of the silicon carbide material, the thickness of the hard anodized layer is 8-12μm, the micropore opening rounding is R0.5mm, the interference between the probe and the micropore is 0.02-0.03mm, and the fluororubber sealing ring is an O-ring made of FKM material.

[0015] As a further embodiment of this utility model, a pre-embedded probe assembly is provided:

[0016] Probe body: Selects an ultrasonic pre-embedded probe with a diameter matching the micro-hole and a frequency of 5-10MHz. The probe shell is made of silicon carbide with a hardness of HV≥2200, suitable for high wear conditions.

[0017] Fixing structure: The probe and the micropore adopt an interference fit with an interference amount of 0.02-0.03m. A fluororubber O-ring made of FKM is installed at the gap to achieve a seal and prevent slurry from seeping in.

[0018] Signal extraction structure: The probe tail is connected to a double-layer shielded wire, with an inner copper mesh and an outer aluminum foil. The shielded wire is laid along a pre-reserved groove on the inner wall of the component to avoid contact and wear with flowing particles.

[0019] As a further embodiment of this invention, a high-speed rotating signal transmission unit is provided:

[0020] Conductive slip ring: A multi-channel miniature slip ring is selected, with ≥10 channels, rated speed ≥3000r / min, and contact resistance ≤50mΩ. It is installed on the end of the slurry pump main shaft through the slip ring mounting base. The rotor end of the slip ring is connected to the shielded wire of the impeller probe, and the stator end is connected to the signal conditioning module.

[0021] Signal conditioning module: It adopts a waterproof and dustproof shell with IP65 protection rating, is fixed to the side wall of the pump body, and integrates a signal amplification circuit with a gain of 20-40dB and a filter circuit with a cutoff frequency of 1kHz to achieve interference signal filtering. The module output end is reserved with RS485 or Ethernet interface.

[0022] As a further embodiment of this utility model, a data acquisition and early warning terminal is provided;

[0023] Data Acquisition and Processing Center: Uses industrial-grade data acquisition units with a sampling rate of 100Hz, a resolution of 16-bit, and supports 8-12 channels of probe signal input. It is connected to the signal conditioning module via shielded cables.

[0024] Early warning structure: The terminal panel is equipped with three levels of early warning indicator lights: green - normal, yellow - reminder, and red - emergency. It has a built-in buzzer with an alarm sound pressure level of ≥85dB and a reserved APP or SMS communication interface to realize remote push of early warning information.

[0025] Installation structure: The terminal is fixed to the operating platform next to the pump body by a wall-mounted bracket. The outer shell is made of cold-rolled steel plate with powder coating for rust prevention.

[0026] Beneficial effects

[0027] The pre-embedded structure eliminates the need to disassemble the pump, allowing for simultaneous detection of the impeller, jacket, and lining thickness during slurry pump operation, thus improving detection efficiency.

[0028] The conductive slip ring and double-layer shielded wire structure achieves signal transmission delay <100ms, attenuation rate <5%, EMI suppression rate ≥85%, and data accuracy ≥95% at a speed of 3000r / min.

[0029] Multi-position micro-hole detection achieves a detection coverage rate of ≥90%, reduces the missed detection rate and data error rate, provides early warning of component wear, reduces the rate of cascading damage caused by impeller wear, and increases the reduction in single maintenance costs;

[0030] The silicon carbide probe and fluororubber sealing structure are resistant to corrosion and high temperatures, ensuring long-term continuous and stable operation and reducing the failure rate. Attached Figure Description

[0031] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 This is an overall assembly drawing of a multi-component online thickness detection device for slurry pumps used in mud and sand ships and mines, according to an embodiment of the present utility model.

[0033] Figure 2 This is a cross-sectional view of the micropores and probe of a multi-component online thickness detection device for slurry pumps used in mud and sand ships and mines, according to an embodiment of the present utility model.

[0034] Figure 3 This is a data processing flowchart of a multi-component online thickness detection device for slurry pumps used in mud and sand ships and mines, according to an embodiment of the present utility model.

[0035] In the picture:

[0036] 1. Slurry pump body; 2. Liner; 3. Slurry pump impeller; 4. Probe; 5. Micro-hole; 6. Main shaft; 7. Conductive slip ring; 8. Data acquisition and processing center; 9. Sealing ring; 10. Substrate; 11. Shielding wire. Detailed Implementation

[0037] To further illustrate the various embodiments, the present invention provides accompanying drawings, which are part of the disclosure of the present invention. These drawings are mainly used to illustrate the embodiments and can be used in conjunction with the relevant descriptions in the specification to explain the operating principles of the embodiments. With reference to these contents, those skilled in the art should be able to understand other possible implementation methods and the advantages of the present invention. The components in the figures are not drawn to scale, and similar component symbols are usually used to represent similar components.

[0038] Please refer to the instruction manual appendix. Figure 1-3 According to an embodiment of the present invention, a multi-component online thickness detection device for slurry pumps used in sludge ships and mines includes a multi-component micro-hole pre-embedded structure, a pre-embedded probe assembly, a high-speed rotating signal transmission unit, a data acquisition and processing center, and an early warning terminal.

[0039] The multi-component microporous pre-embedded structure includes micropores 5 provided on the slurry pump impeller 3, the metal inner flow channel sleeve, the inner liner 2, and the main shaft 6. The inner wall of the hole is hard anodized, and the hole opening is rounded.

[0040] The probe 4 assembly includes a probe that is interference-fitted with the micro-hole 5, a sealing ring 9 disposed in the gap between the probe 4 and the micro-hole 5, and a double-layer shielded wire 10 connected to the tail of the probe 4.

[0041] The high-speed rotating signal transmission unit includes a multi-channel conductive slip ring 7 installed at the end of the main shaft 6 of the slurry pump body 1, a signal conditioning module fixed inside the main shaft 6, a probe double-layer shielded wire 10 connected to the rotor end of the slip ring, and a signal conditioning module connected to the stator end.

[0042] The data processing center 8 and the early warning terminal include an industrial-grade acquisition module and a three-level early warning structure. The terminal is connected to the signal conditioning module via RS485 or Ethernet.

[0043] The micropore 5 has a diameter of 2-6mm, a depth of 5-40mm, and a thickness based on the thickness of the silicon carbide material. The thickness of the hard anodized layer is 8-12μm. The rounded edge of the micropore 5 is R0.5mm. The interference fit between the probe 4 and the micropore 5 is 0.02-0.03mm. The fluororubber sealing ring is an O-ring made of FKM material.

[0044] Pre-embedded probe assembly:

[0045] Probe body: Selected ultrasonic pre-embedded probe, with diameter matching micro-hole 5, frequency 5-10MHz, probe shell is made of silicon carbide material, hardness HV≥2200, suitable for high wear conditions.

[0046] Fixing structure: The probe 4 and the micropore 5 are interference fit with an interference amount of 0.02-0.03m. Fluororubber O-rings made of FKM are installed at the gap to achieve a seal and prevent slurry from seeping in.

[0047] Signal extraction structure: The probe tail is connected to a double-layer shielded wire 10, with an inner copper mesh and an outer aluminum foil. The shielded wire is laid along a pre-reserved groove on the inner wall of the component to avoid contact and wear with flowing particles.

[0048] High-speed rotating signal transmission unit:

[0049] Conductive slip ring 7: Select a multi-channel miniature slip ring with ≥10 channels, rated speed ≥3000r / min, and contact resistance ≤50mΩ. It is installed on the end of the slurry pump main shaft through the slip ring mounting base. The rotor end of the slip ring is connected to the shielded wire of the impeller probe, and the stator end is connected to the signal conditioning module.

[0050] Signal conditioning module: It adopts a waterproof and dustproof shell with IP65 protection rating, is fixed to the side wall of the pump body, and integrates a signal amplification circuit with a gain of 20-40dB and a filter circuit with a cutoff frequency of 1kHz to achieve interference signal filtering. The module output end is reserved with RS485 or Ethernet interface.

[0051] Data acquisition and early warning terminal;

[0052] The data processing center 8 uses an industrial-grade data acquisition device with a sampling rate of 100Hz, a resolution of 16 bits, and supports 8-12 channels of probe signal input. It is connected to the signal conditioning module via a shielded cable.

[0053] Early warning structure: The terminal panel is equipped with three levels of early warning indicator lights: green - normal, yellow - reminder, and red - emergency. It has a built-in buzzer with an alarm sound pressure level of ≥85dB and a reserved APP or SMS communication interface to realize remote push of early warning information.

[0054] Installation structure: The terminal is fixed to the operating platform next to the pump body by a wall-mounted bracket. The outer shell is made of cold-rolled steel plate with powder coating for rust prevention.

[0055] This utility model's pre-embedded structure eliminates the need for pump disassembly, enabling simultaneous detection of impeller, sleeve, and liner thickness during slurry pump operation, thus improving detection efficiency. The conductive slip ring and double-layer shielded wire structure achieve signal transmission delay <100ms, attenuation rate <5%, EMI suppression rate ≥85%, and data accuracy ≥95% at 3000r / min. Multi-position micro-hole detection achieves a detection coverage rate ≥90%, reducing missed detection rates and data error rates, providing early warning of component wear, decreasing the rate of cascading damage caused by impeller wear, and increasing the cost per repair. The silicon carbide probe and fluororubber sealing structure are resistant to corrosion and high temperatures, ensuring long-term continuous and stable operation and reducing the failure rate.

[0056] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model shall be included within the protection scope of the present utility model.

Claims

1. A multi-component on-line thickness detection device for slurry pumps for dredging and mining, characterized in that, It includes a multi-component micro-hole pre-embedded structure, a pre-embedded probe assembly, a high-speed rotating signal transmission unit, and a data acquisition and processing center and early warning terminal; The multi-component micro-hole pre-embedded structure includes micro-holes (5) provided on the slurry pump impeller (3), metal inner flow channel sleeve, inner liner (2) and main shaft (6), with the inner wall of the hole being hard anodized and the orifice being rounded. The pre-embedded probe assembly includes a probe (4) that is interference-fitted with the microhole (5), a sealing ring (9) located in the gap between the probe (4) and the microhole (5), and a double-layer shielded wire (10) connected to the tail of the probe (4). The high-speed rotating signal transmission unit includes a multi-channel conductive slip ring (7) installed at the end of the main shaft (6) of the slurry pump body (1), a signal conditioning module fixed inside the main shaft (6), a probe shielding wire (10) connected to the rotor end of the slip ring, and a signal conditioning module connected to the stator end; The data acquisition and processing center (8) and the early warning terminal include an industrial-grade acquisition module and a three-level early warning structure. The terminal is connected to the signal conditioning module via RS485 or Ethernet.

2. The on-line thickness detection device of claim 1, wherein The micropore (5) has a diameter of 2-6 mm, a depth of 5-40 mm, a thickness based on the thickness of silicon carbide material, a hard anodized layer thickness of 8-12 μm, a rounded opening of the micropore (5) with a radius of R0.5 mm, an interference fit between the probe (4) and the micropore (5) of 0.02-0.03 mm, and a sealing ring (9) of type O-ring made of FKM material.

3. The on-line thickness detection device of claim 1, wherein The micropores of the impeller are located on the working surface of the blade, the outlet edge of the impeller, and the root of the hub. Each blade has at least two micropores, avoiding the area within 5mm of the blade edge.

4. The on-line thickness detection device of claim 1, wherein The micropores at the corners of the flow channels of the metal inner flow channel sheath are inclined at 15°, and the depth of the micropores is less than 90% of the thickness of the sheath.

5. The on-line thickness detection device of claim 1, wherein The contact resistance of the conductive slip ring (7) is ≤50mΩ. The signal conditioning module has a built-in amplifier circuit with a gain of 20-40dB and a filter circuit with a cutoff frequency of 1kHz. The protection level is IP65.

6. The on-line thickness detection device of claim 1, wherein The outer shell of the probe (4) is made of silicon carbide with a hardness of HV≥2200 and a working frequency of 5-10MHz.

7. The on-line thickness detection device of claim 1, wherein The data processing center (8) and the three-level early warning structure of the early warning terminal include a green normal light, a yellow reminder light, and a red emergency light. The built-in buzzer alarm sound pressure is ≥85dB, and an APP or SMS communication interface is reserved.

8. The on-line thickness detection device of claim 1, wherein The micropores of the liner are uniformly distributed along the circumference of the liner, with a spacing of 100-150mm, and the detection coverage is ≥90%.

9. The on-line thickness detection device of claim 1, wherein, The inner layer of the double-shielded wire is a copper mesh, and the outer layer is an aluminum foil. It is laid along the reserved wire groove on the inner wall of the component, and the wire groove is filled with epoxy resin for fixation.

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