Corner sensor mounting structure and mining wide-body dump truck

Abstract

The utility model discloses a corner sensor mounting structure and mining wide body dump truck, include: sensor fixed bolster, for frame structure, be used for supporting corner sensor body, corner sensor body, its input is equipped with the rotary connection axle for torque transmission, fixed base, be located axle housing inside and with axle kingpin keep coaxial, the upper end of fixed base is equipped with the base connecting axle of cylindrical, shaft coupling, including hollow opening's cylindrical elastic structure, and the shaft coupling whole is located in sensor fixed bolster, and the upper end of shaft coupling is inserted with rotary connection axle, and the lower end is inserted with base connecting axle, and both ends of shaft coupling all realize the axial clamping through fastener, the protective cover, cover is located the outside of sensor fixed bolster, and covers the connecting part of shaft coupling and each component. The utility model can eliminate radial stress, protect sensor body, zero clearance fit, improve data acquisition accuracy, and the protection performance is excellent, and adapts the severe working condition.

Description

Technical Field

[0001] This utility model relates to an angle sensor mounting structure and a wide-body dump truck for mining, belonging to the field of dump truck technology. Background Technology

[0002] With the development of electrification and intelligentization, unmanned off-highway wide-body dump trucks have been applied in mining, infrastructure and other scenarios. The core of their drive-by-wire chassis—the intelligent steering system—relies on real-time and accurate steering angle data for safe operation, which places high demands on data acquisition components. The steering angle sensor is the only core component in the intelligent steering system that collects the kingpin steering angle of the axle, and the data directly drives the steering actuator. Because unmanned driving requires autonomous obstacle avoidance and path planning in complex environments, high steering angle accuracy is required. Therefore, the installation accuracy of the steering angle sensor becomes crucial in determining the overall unmanned driving performance of the vehicle.

[0003] The current corner sensor mounting structure has the following technical bottlenecks: (1) Stress damage from rigid connection: The sensor shaft is rigidly connected to the axle kingpin. Assembly errors or component wear can easily generate radial stress, leading to sensor bearing damage and data drift. (2) Insufficient stability and accuracy: The lack of positioning reference and anti-loosening design makes it easy to loosen and there is eccentric error, resulting in data distortion. (3) Complex structure and difficult maintenance: The low integration of components requires disassembly of multiple components, which is cumbersome and costly.

[0004] Mining wide-body dump trucks are subjected to high-frequency vibration, high load, and dust and mud conditions for a long time: vibration aggravates hard connection damage and eccentricity error, and reduces rotational synchronization; dust intrusion causes component jamming, affects data acquisition and even causes steering failure, which seriously restricts the large-scale application of unmanned vehicles. Summary of the Invention

[0005] To address the problems existing in the prior art, this utility model provides a corner sensor mounting structure and a wide-body dump truck for mining, which features a stable structure, accurate positioning, and convenient installation.

[0006] To achieve the above objectives, this utility model employs a rotation sensor mounting structure, comprising:

[0007] The sensor mounting bracket is a frame structure, which is fixedly connected to the axle housing to support the angle sensor body;

[0008] An angle sensor body is mounted on top of the sensor mounting bracket. The input end of the angle sensor body is provided with a rotary connecting shaft for torque transmission, which extends downward into the sensor mounting bracket.

[0009] A fixed base is located inside the axle housing and is coaxial with the axle kingpin. The upper end of the fixed base is provided with a cylindrical base connecting shaft, which extends upward into the sensor fixing bracket.

[0010] The coupling includes a hollow, open cylindrical elastic structure. The entire coupling is located inside the sensor fixing bracket. The upper end of the coupling is inserted into the rotary connecting shaft, and the lower end is inserted into the base connecting shaft. Both ends of the coupling are axially clamped by fasteners.

[0011] The protective cover is installed on the outside of the sensor mounting bracket and covers the coupling and the connection parts of each component.

[0012] As an improvement, the sensor fixing bracket is a U-shaped frame structure, which is formed by welding together a top plate, a bottom plate and two vertical plates;

[0013] The two upright plates are symmetrically welded to both sides of the base plate, and the tops of the two upright plates are welded to the top plate. Limiting grooves are correspondingly provided on the top plate and the upright plates.

[0014] As an improvement, fastening holes are symmetrically provided on the two upright plates, and welding nuts are provided on the inner side of the upright plates corresponding to the positions of the fastening holes;

[0015] The protective cover includes two U-shaped plates, each with an elongated hole on its side that mates with a fastening hole. The protective cover is fastened to the sensor mounting bracket by passing fastening bolts through the elongated holes and the fastening holes, thus forming a closed protection for the coupling and the connection parts of each component.

[0016] As an improvement, the top plate is provided with four adjustment holes arranged symmetrically in a cross shape, and the angle sensor body is connected to the corresponding two adjustment holes by two connecting bolts.

[0017] As an improvement, the fasteners at both ends of the coupling are hexagon socket head cap screws, and the openings at both ends of the coupling are provided with threaded holes that are compatible with the hexagon socket head cap screws; by tightening the hexagon socket head cap screws, the two ends of the coupling are contracted and clamp the rotating connecting shaft and the base connecting shaft.

[0018] As an improvement, the protective cover is made of Q235 steel.

[0019] As an improvement, the rotating connecting shaft of the angle sensor body has a D-shaped cross section, which is used to cooperate with the coupling to achieve synchronous rotation.

[0020] A second aspect of this utility model also provides a mining wide-body dump truck, wherein the aforementioned angle sensor mounting structure is installed on the mining wide-body dump truck.

[0021] Compared with the prior art, the angle sensor mounting structure of this utility model has the following advantages:

[0022] (1) Eliminate radial stress and protect the sensor body. In view of the problem of easy wear of the axle kingpin bushing under the high load conditions of vehicles, this utility model adopts a coupling with a hollow open cylindrical elastic structure to connect the fixed base and the angle sensor body, replacing the traditional hard connection. It can effectively eliminate the fit clearance caused by wear, avoid radial stress caused by hard contact between the rotating connecting shaft of the angle sensor body and the axle kingpin, prevent internal damage to the sensor, and ensure the continuous and stable operation of the equipment.

[0023] (2) Zero clearance fit improves data acquisition accuracy. The coupling is axially clamped by fasteners at both ends to form a clamping structure, so that one end is tightly connected to the rotating connecting shaft of the angle sensor body and the other end is tightly inserted into the base connecting shaft of the fixed base, completely eliminating the fit gap, ensuring that the angle sensor body can accurately collect the kingpin rotation data of the axle, significantly improving the data output accuracy and further ensuring the stability of equipment operation.

[0024] (3) Excellent protective performance and suitable for harsh working conditions. The protective cover installed on the outside of the coupling can prevent mud and sand from entering the gap of the coupling in harsh working conditions such as mining and infrastructure construction. It can prevent mud and sand from getting stuck and causing the coupling to lose its elasticity and flexibility, ensuring that its functions of buffering vibration and absorbing installation errors are properly performed, and improving the overall structure's ability to resist harsh environments.

[0025] (4) Easy installation and maintenance, and strong compatibility. This utility model is installed on the upper section of the axle end cover. Combined with the welded support design of the sensor fixing bracket and modular components (couplings, fixing bases), it is not only easy to install and operate, but also easy to observe whether each component is loose or damaged, reducing the difficulty of maintenance. At the same time, the modular design can be adapted to various specifications of angle sensor bodies and rotating connecting shafts and base connecting shafts of different diameters, greatly improving the structural versatility. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a schematic diagram of the structure of this utility model;

[0028] Figure 2 This is a schematic diagram of the exploded structure of this utility model;

[0029] Figure 3This is a schematic diagram of the coupling of this utility model; (A) is the front view and (B) is the left view.

[0030] Figure 4 This is a schematic diagram of the connection structure of the angle sensor body, coupling and fixed base of this utility model;

[0031] Figure 5 This is a schematic diagram showing the sensor mounting bracket and the axle installation position of this utility model;

[0032] Figure 6 This is a schematic diagram of the installation structure of the protective cover and sensor fixing bracket of this utility model;

[0033] In the diagram: 1. Angle sensor body; 11. Rotary connecting shaft; 2. Coupling; 21. Socket head bolt; 3. Protective cover; 31. U-shaped plate; 32. Oblong hole; 4. Sensor mounting bracket; 41. Top plate; 42. Vertical plate; 43. Base plate; 44. Limiting groove; 45. Adjustment hole; 46. Fastening hole; 5. Fixed base; 51. Base connecting shaft; 6. Connecting bolt; 7. Fastening bolt. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this application will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the embodiments and specific features in the embodiments are detailed descriptions of the technical solutions of this application, rather than limitations thereof. In the absence of conflict, the embodiments and technical features in the embodiments can be combined with each other.

[0035] like Figures 1-6 As shown, an angle sensor mounting structure includes an angle sensor body 1, a coupling 2, a sensor fixing bracket 4, a fixing base 5, and a protective cover 3.

[0036] The sensor mounting bracket 4 is a frame structure. The sensor mounting bracket 4 is fixedly connected to the axle housing and is used to support the corner sensor body 1. The frame structure can provide a stable support reference, avoid sensor installation offset due to vehicle vibration, and ensure the stability of corner data acquisition.

[0037] The angle sensor body 1 is mounted on the sensor fixing bracket 4. The input end of the angle sensor body 1 is provided with a rotary connecting shaft 11 for torque transmission. The rotary connecting shaft 11 extends downward into the sensor fixing bracket 4. The extension design of the rotary connecting shaft 11 can shorten the docking distance with the coupling 2, reduce torque transmission loss, and at the same time avoid external impurities from directly contacting the connection part, thereby improving transmission reliability.

[0038] The fixed base 5 is located inside the axle housing and is coaxial with the axle kingpin. The fixed base 5 is fixed by bolts. Its upper end is provided with a cylindrical base connecting shaft 51. The base connecting shaft 51 extends upward into the sensor fixing bracket 4. The design of being coaxial with the axle kingpin can ensure that the base connecting shaft 51 rotates synchronously with the kingpin, avoiding deviation of the reference for corner data acquisition. The bolt fixing method improves the installation firmness of the base and is suitable for high load conditions.

[0039] The coupling 2 is a flexible coupling with an elastic element (e.g., an elastic rubber coupling of model 19*28-D06). Its elastic element adopts a hollow open cylindrical elastic structure. The entire coupling 2 is located inside the sensor fixing bracket 4. The upper end of the coupling 2 is inserted into the rotating connecting shaft 11, and the lower end is inserted into the base connecting shaft 51. Both ends of the coupling 2 are axially clamped by fasteners. The hollow open cylindrical elastic structure can absorb high-frequency vibration of the vehicle and installation errors, and avoid the radial stress generated by the hard connection from damaging the internal components of the sensor. The axial clamping design can eliminate the fit gap and improve the accuracy of corner data acquisition.

[0040] The protective cover 3 is installed on the outside of the sensor fixing bracket 4 and covers the coupling 2 and the connection parts of each component. It can isolate impurities such as mud and dust from entering, prevent the connection parts from rusting or jamming, extend the service life of the overall structure, and is suitable for harsh working environments such as mines.

[0041] In some embodiments, such as Figure 6 As shown, the sensor fixing bracket 4 is a U-shaped frame structure, which is formed by welding together a top plate 41, a bottom plate 43 and two upright plates 42. Compared with ordinary frames, the U-shaped structure has better rigidity and can withstand greater vibration and impact, thus avoiding bracket deformation that affects sensor positioning.

[0042] The two upright plates 42 are symmetrically welded to both sides of the base plate 43, and the top of the two upright plates 42 is welded to the top plate 41. Limiting grooves 44 are correspondingly opened on the top plate 41 and the upright plates 42. The symmetrical welding design ensures that the support is subjected to uniform force. The limiting grooves 44 can form a circumferential limit on the coupling 2 to prevent it from shifting laterally during operation, and further ensure the stability of torque transmission.

[0043] In some embodiments, such as Figure 6 As shown, fastening holes 46 are symmetrically provided on the two upright plates 42, and welding nuts are welded to the inner side of each upright plate 42 at the position coaxial with the fastening holes 46. This welding nut design can directly eliminate the on-site tapping process, shorten the installation time of the protective cover 3, and greatly improve the assembly efficiency. At the same time, compared with the on-site tapped threads, the connection strength between the welding nut and the upright plate 42 is higher, which can effectively avoid the risk of thread loosening caused by vehicle vibration and ensure long-term stability.

[0044] The protective cover 3 consists of two symmetrical U-shaped plates 31. Each U-shaped plate 31 has elongated holes 32 on both sides that match the fastening holes 46 on the upright plate 42. During installation, the two U-shaped plates 31 are respectively attached to the outer sides of the two upright plates 42, aligning the elongated holes 32 with the fastening holes 46. Then, fastening bolts 7 are passed through the elongated holes 32 and the fastening holes 46 in sequence and tightened with the welded nuts. This securely mounts the protective cover 3 onto the sensor mounting bracket 4, forming a full-circumferential enclosure for the coupling 2 and the connecting parts of each component. The elongated holes 32 provide installation error compensation and facilitate fine-tuning of the mating position of the U-shaped plates 31, ensuring that the two U-shaped plates 31 effectively block the intrusion of mud, sand, and dust in mining conditions after being spliced ​​together, further enhancing the protective effect.

[0045] In some embodiments, such as Figure 6 As shown, the top plate 41 of the sensor mounting bracket 4 is provided with four adjustment holes 45 arranged symmetrically in a cross shape. The angle sensor body 1 is detachably connected to two corresponding holes in the four adjustment holes 45 by two connecting bolts 6. The cross-shaped symmetrical arrangement of the adjustment holes 45 can form a two-way adjustment space in the horizontal and vertical directions. During installation, there is no need to disassemble the entire bracket. By simply adjusting the fixed position of the connecting bolts 6 in the adjustment holes 45, the installation angle deviation of the angle sensor body 1 can be accurately corrected, ensuring that the coaxiality of the bottom rotating connecting shaft 11 and the lower coupling 3 meets the requirements, avoiding the angle data acquisition error caused by the angle offset, and improving the installation adaptability and operation convenience.

[0046] In some embodiments, such as Figure 4 As shown, the fasteners at both ends of the coupling 2 are hexagon socket head cap screws 21, and the openings at both ends of the coupling 2 are respectively provided with threaded holes adapted to the hexagon socket head cap screws 21. During installation, tightening the hexagon socket head cap screws 21 with a tool can drive the opening structure at both ends of the coupling 2 to retract inward, thereby making the inner wall of the coupling 2 tightly fit and clamp with the rotating connecting shaft 11 and the base connecting shaft 51. Compared with ordinary bolts, the hexagon socket head cap screws 21 not only have a higher tightening torque, but also ensure that the clamping force between the coupling 2 and the two shafts is uniform and stable, completely eliminating the fit clearance and avoiding slippage during torque transmission; at the same time, combined with the elastic structural characteristics of the coupling 2, the clamping force can be adaptively adjusted during the retraction process, effectively avoiding excessive clamping and damage to the connecting shaft, ensuring the flexibility during the transmission process, and adapting to the working conditions of high-frequency steering.

[0047] In some embodiments, the protective cover 3 is made of Q235 steel, which has a wear resistance of 180HB and significantly better impact resistance than ordinary plastic or thin steel plate protective covers. In mining operations, it can withstand direct impacts from gravel and silt without deformation or damage. Furthermore, Q235 steel has stronger corrosion resistance and structural stability, extending its service life by 3-5 times compared to ordinary protective covers. This reduces maintenance frequency in harsh environments, lowers replacement costs, and ensures long-term reliable operation of the overall installation structure from a protective perspective.

[0048] In some embodiments, the rotary connecting shaft 11 of the angle sensor body 1 has a D-shaped cross-section, which is adapted to the inner side of the coupling 2 to achieve synchronous rotational transmission between the two. Compared with a circular cross-section, the D-shaped cross-section, through a planar positioning structure, can prevent relative slippage between the rotary connecting shaft 11 and the coupling 2: when torque is transmitted, the planar portion of the D-shaped cross-section forms a rigid fit with the corresponding plane on the inner side of the coupling 2, avoiding circumferential displacement caused by vibration or load fluctuations, thereby eliminating the problem of angle data lag caused by slippage and ensuring the real-time performance and accuracy of angle signal transmission. This design is particularly suitable for the high-frequency steering requirements of mining vehicles. In mining scenarios, vehicles turn frequently and experience large load variations. The synchronous transmission structure of the D-shaped cross-section can stably guarantee data accuracy over a long period of time, providing reliable signal support for intelligent steering or autonomous driving systems.

[0049] Installation process of the above-mentioned angle sensor mounting structure:

[0050] (1) Installation of fixed base: Install the fixed base 5 to the end of the axle with bolts, and use tools to ensure that it is coaxial with the kingpin;

[0051] (2) Sensor mounting bracket installation: Initially fix the sensor mounting bracket 4 to the axle housing with bolts;

[0052] (3) Installation of the angle sensor: Place the angle sensor body 1 on the top plate 41, and extend the rotating connecting shaft 11 into the sensor fixing bracket 4; use two connecting bolts 6 to pass through the sensor mounting hole and connect to the two adjustment holes 45 on the top plate 41; after fine-tuning the position, tighten the bolts to ensure that the rotating connecting shaft 11 is vertically downward.

[0053] (4) Coupling fixing: Insert the coupling 2 into the inside of the sensor fixing bracket 4, and connect the fixing base connecting shaft 51 and the sensor connecting shaft 11 to both ends respectively; tighten with hex bolts 21 to make the two ends of the coupling 2 shrink and clamp the two shafts, and check that there is no looseness or skewness.

[0054] (5) Installation of protective cover: Take the protective cover 3 composed of two U-shaped plates 31, fit it against the outside of the support plate 42, and align the elongated hole 32 with the fastening hole 46 on the plate 42; use fastening bolts 7 to connect the welding nut through the hole and tighten it (to avoid deformation of the U-shaped plate 31) to form a closed protection.

[0055] (6) Power-on test: Connect the power supply and signal lines of the sensor, and use an oscilloscope or vehicle controller to test the corner signal to ensure that the signal is stable (error ≤ ±0.2°) and without vibration fluctuations. After confirmation, the installation is complete.

[0056] Finally, this utility model also provides a wide-body mining dump truck, on which the aforementioned angle sensor mounting structure is installed. This angle sensor mounting structure is specifically adapted to the harsh working conditions of the wide-body mining dump truck, which involves high-frequency vibration, high load, and abundant mud and sand. Through the elastic buffer of the coupling 2, the dustproof and wear-resistant design of the protective cover 3, and the coaxial positioning design of the fixed base 5, the accuracy of the steering system's angle data acquisition is ensured to be stable within ±0.2°, fully meeting the core requirements of the vehicle's unmanned driving or intelligent steering function for angle data accuracy. At the same time, the modular design and convenient maintenance characteristics of this mounting structure can simplify the later disassembly and maintenance process, reduce vehicle downtime for maintenance, and effectively improve mining operation efficiency.

[0057] Taking a fully autonomous, electric-driven off-highway wide-body dump truck (a common model in mining scenarios) as an example, its steering control system uses a non-contact magnetically encoded angle sensor. The input shaft of this sensor (i.e., the rotating connecting shaft 11 of the angle sensor body 1) has a diameter of 6mm. After applying the angle sensor installation structure of this utility model, even under conditions where there is slight wear on the kingpin shaft of the axle, the sensor can still accurately read the angle data with the help of the clamping and elastic compensation function of the coupling 2. The error is strictly controlled within ±0.2°. This not only avoids the damage to the sensor caused by radial stress due to wear in traditional hard connections, but also effectively improves the operational safety and response accuracy of the vehicle's intelligent steering, adapting to the long-term use needs of complex mining operating environments.

[0058] The above descriptions are merely embodiments of this utility model, and common technical solutions and / or characteristics known in the scheme are not described in detail here. It should be noted that those skilled in the art can make various modifications, improvements, or equivalent substitutions without departing from the technical solution of this utility model, and all such modifications, improvements, or equivalent substitutions should be covered within the scope of the claims of this utility model. The scope of protection claimed in this application should be determined by the content of its claims, and the detailed descriptions of the embodiments can be used to interpret the content of the claims.

Claims

1. A mounting structure for an angle sensor, characterized in that, include: The sensor mounting bracket (4) is a frame structure. The sensor mounting bracket (4) is fixedly connected to the axle housing and is used to support the angle sensor body (1). An angle sensor body (1) is mounted above the sensor fixing bracket (4). The input end of the angle sensor body (1) is provided with a rotary connecting shaft (11) for torque transmission. The rotary connecting shaft (11) extends downward into the sensor fixing bracket (4). The fixed base (5) is located inside the axle housing and is coaxial with the axle kingpin. The upper end of the fixed base (5) is provided with a cylindrical base connecting shaft (51), which extends upward into the sensor fixing bracket (4). The coupling (2) includes a hollow cylindrical elastic structure. The coupling (2) is located inside the sensor fixing bracket (4). The upper end of the coupling (2) is inserted into the rotating connecting shaft (11), and the lower end is inserted into the base connecting shaft (51). Both ends of the coupling (2) are axially clamped by fasteners. The protective cover (3) is placed on the outside of the sensor fixing bracket (4) and covers the coupling (2) and the connection parts of each component.

2. The angle sensor mounting structure according to claim 1, characterized in that, The sensor mounting bracket (4) is a U-shaped frame structure, which is formed by welding together a top plate (41), a bottom plate (43) and two upright plates (42); The two upright plates (42) are symmetrically welded to both sides of the base plate (43), and the top of the two upright plates (42) is welded to the top plate (41). Limiting grooves (44) are respectively opened on the top plate (41) and the upright plates (42).

3. The angle sensor mounting structure according to claim 2, characterized in that, Two vertical plates (42) are symmetrically provided with fastening holes (46), and welding nuts are provided on the inner side of the vertical plates (42) corresponding to the positions of the fastening holes (46); The protective cover (3) includes two U-shaped plates (31). Each U-shaped plate (31) has an elongated hole (32) on its side that matches the fastening hole (46). The protective cover (3) is fastened to the sensor mounting bracket (4) by passing a fastening bolt (7) through the elongated hole (32) and the fastening hole (46), thus forming a closed protection for the coupling (2) and the connection parts of each component.

4. The angle sensor mounting structure according to claim 2, characterized in that, The top plate (41) is provided with four adjustment holes (45) arranged symmetrically in a cross shape. The angle sensor body (1) is connected to the corresponding two adjustment holes (45) by two connecting bolts (6).

5. The angle sensor mounting structure according to claim 1, characterized in that, The fasteners at both ends of the coupling (2) are hexagon socket head cap screws (21), and the openings at both ends of the coupling (2) are provided with threaded holes that are compatible with the hexagon socket head cap screws (21); by tightening the hexagon socket head cap screws (21), the two ends of the coupling (2) are contracted and clamp the rotating connecting shaft (11) and the base connecting shaft (51).

6. The angle sensor mounting structure according to claim 1, characterized in that, The protective cover (3) is made of Q235 steel.

7. The angle sensor mounting structure according to claim 1, characterized in that, The rotating connecting shaft (11) of the angle sensor body (1) has a D-shaped cross section, which is used to cooperate with the coupling (2) to achieve synchronous rotation.

8. A wide-body dump truck for mining, characterized in that, The mining wide-body dump truck is equipped with the angle sensor mounting structure as described in any one of claims 1-7.

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